Deutz Fahr AGROPLUS-60-70-80-Repair-manual PDF [PDF]

Zitiervorschau

WORKSHOP MANUAL

introduction This publication is intended for the trained technician who must operate on our tractors. It contains all general information relating to our tractor range, and in particular it highlights the inspection, overhauling and adjustment procedures as well as the main instructions for dismantling and reassembling operations. The workshop manual is a natural summary for the mechanic who has attended the vocational training and specialization courses, which are held every year at our Service School, to permit him to perform a precise and qualified work on tractor. Its contents are therefore an exhaustive reference book for the experienced mechanic who desires to refresh his memory on the sequence of the operations to be done. It is then good practice for every authorized dealer mechanic to have at his disposal this publication, so that it may be consulted quickly when necessary. We wish to thank in advance for the cooperation all thos people, who will let us have their suggestions in order to make this publication more complete.

1

List of contents Tractor configurations AGROPLUS 60 - 70 - 80 ......................................................................................................6 Dimensions and weights...........................................................................................................................................7 Prescribed lubricants and capacities ........................................................................................................................8 Conversion tables .....................................................................................................................................................9 Parts .......................................................................................................................................................................10

1 - ENGINE ................................................................................................................................................................................11

2 - CLUTCH Gearshift clutch.......................................................................................................................................................12 General specifications ............................................................................................................................................12 Cecking clutch ........................................................................................................................................................16 Adjusting clutch control pedal .................................................................................................................................16 Bleeding air from the hydraulic circuit.....................................................................................................................16 Stripping the slave cylinder.....................................................................................................................................17 Stripping the master cylinder ..................................................................................................................................18 Diagnosing malfunctions ........................................................................................................................................20 POWERSHIFT unit, general specifications ............................................................................................................21 POWERSHIFT unit detach from the gear box ........................................................................................................24 Assembly of POWERSHIFT unit ...........................................................................................................................35 Re-assembly of the POWERSHIFT unit. ...............................................................................................................37 Fitting the oil manifolds of the POWERSHIFT unit ................................................................................................39 Diagnosing malfunctions ........................................................................................................................................44

3 - TRANSMISSION General specifications ............................................................................................................................................45 Technical specifications ..........................................................................................................................................45 Speed change configurations .................................................................................................................................47 Section through transmission .................................................................................................................................51 Section through transmission with POWERSHIFT unit ..........................................................................................52 Separating the front gearbox from the engine ........................................................................................................61 Dismantling the gearbox .........................................................................................................................................62 Removal of the gearbox input and P.T.O. shafts ....................................................................................................62 Separating the POWERSHIFT unit from the gearbox ...........................................................................................62 Removal of the gear train positioned in the front gearbox ......................................................................................63 Disassembly of the inversor control rods and forks ................................................................................................64 Dismantling of the gearchange rod and fork assembly ..........................................................................................65 Dismantling of the gearchange selector rods and forks assembly .........................................................................66 Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive ..........................67 Removal of the range gear shaft ........................................................................................................................... 67 Examining parts removed .......................................................................................................................................68 Adjusting play of the gearbox shafts by means of the thrust plates on the mini/inversor shaft and the secondary shaft ...............................................................................................................................69 Warnigns related to assembly of the gears of the P.T.O. unit, the range reduction unit and synchronised P.T.O. shaft ............................................................................................................................................................73 Assembly of the P.T.O. ..........................................................................................................................................73 Installation of the range reduction unit, the gear for the front-wheel drive shaft and the parking brake discs...................................................................................................................................73 Points where sealant is to be used .........................................................................................................................75 Tightening torques ..................................................................................................................................................78 Bevel drive adjustment ...........................................................................................................................................81 Servicing operations ...............................................................................................................................................82 Rear power take-off ................................................................................................................................................83 P.T.O. clutch ...........................................................................................................................................................88 Technical specifications ..........................................................................................................................................89 Correct positions of P.T.O. sensors and cables .....................................................................................................89 Clutch inspection ....................................................................................................................................................91 Checking clutch hydraulic pressures ......................................................................................................................92 Checking the end-play of the front shaft of the P.T.O. clutch .................................................................................93 Renewal of the rear P.T.O. clutch ..........................................................................................................................94 Main operations for removal of the rear P.T.O. unit ...............................................................................................95 Diagnosing malfunctions ......................................................................................................................................100

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4 - AXLES Rear axle ..............................................................................................................................................................101 Installing the rear half-shafts ...............................................................................................................................102 Removal and disassembly of the epicyclic reduction unit.........................................................................................104 Fitting lateral stub axles of the wheel ...................................................................................................................105 2WD extendible axle.............................................................................................................................................106 Removing the axle from the front support ............................................................................................................108 Centre steering lever ............................................................................................................................................111 Wheel hub ............................................................................................................................................................112 End float adjustment .............................................................................................................................................114 Front-wheel drive..................................................................................................................................................115 Specifications .......................................................................................................................................................115 Epicyclic reduction unit .........................................................................................................................................119 Side hubs..............................................................................................................................................................121 Tightening torques................................................................................................................................................122 Adjusting bevel gears ...........................................................................................................................................124 Adjustment of the internal control of the mechanical differential lock...................................................................125 Installing the differential assembly into the drive axle ..........................................................................................125 Diagnosing malfunctions ......................................................................................................................................126

5 - VEHICLE Brakes - General information................................................................................................................................127 Hydraulic pump.....................................................................................................................................................128 Assembly of brake master cylinder ......................................................................................................................130 Checking the front brake disks on 2WD and 4WD front axles and the rear brake disks...................................... 131 Adjusting service brake pedals .............................................................................................................................131 Correct installation of inspection cover for parking brake discs............................................................................132 Checking parking brake pads ...............................................................................................................................134 Bleeding air from the brake hydraulic system.......................................................................................................135 “Separate Brakes” valve .......................................................................................................................................136 Diagnosing malfunctions ......................................................................................................................................140 Hydraulic lift with “load sensing” ...........................................................................................................................141 Installing the lift and front cover plate of the gearbox ...........................................................................................142 Lift mechanism .....................................................................................................................................................142 Checking the safety valves ...................................................................................................................................142 Checking the protrusion of the non-return valve...................................................................................................143 Adjusting the lift ....................................................................................................................................................145 Lift hydraulic circuit ...............................................................................................................................................147 Sensing arm assemblyMontaggio dell'organo sensibile .......................................................................................154 Power-lift distributor valve spring setting specifications .......................................................................................155 Electronic lift .........................................................................................................................................................156 Control panel ........................................................................................................................................................157 Control level or depth control knob .......................................................................................................................157 Mix position/draft control.......................................................................................................................................157 Lowering speed control knob................................................................................................................................158 Maximum lift height control knob ..........................................................................................................................158 Up/Down control switch ........................................................................................................................................158 Up control .............................................................................................................................................................158 Control/Float mode ...............................................................................................................................................158 Lift status indicator light ........................................................................................................................................158 Remote pushbuttons for lift operation from ground ..............................................................................................159 Lift operation .........................................................................................................................................................160 List of electronic lift tests ......................................................................................................................................164 Precautions for electronic equipment ...................................................................................................................173 Checking the electronics system ..........................................................................................................................173 Checking mechanical components .......................................................................................................................173 Front hydraulic liftSollevatore idraulico anteriore..................................................................................................174 Hydraulic accumulator and antishock valve for front lift .......................................................................................176 Front power take-off - General information...........................................................................................................177 Section of the P.T.O. ............................................................................................................................................178 Fitting the "RING-FEEDER" rings.........................................................................................................................182 Checking the clutch ..............................................................................................................................................183 Diagnosing malfuntions ........................................................................................................................................184 Spring specifications.............................................................................................................................................184

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6 - CONTROLS Hydrostatic steering ..............................................................................................................................................185 Inspections and checks ........................................................................................................................................186 Steering pump ......................................................................................................................................................186 Directional control valve .......................................................................................................................................186 Check the setting of the pressure relief valve.......................................................................................................186 Bleeding the hydraulic circuit ................................................................................................................................186 Assembly of orbital pump unit ..............................................................................................................................186 Teering wheel shaft and steering cylinders .........................................................................................................187 Instructions for the hydrostatic steering distributor assembly ...............................................................................189 Diagnosing malfuntions ........................................................................................................................................192 Mechanical controls ..............................................................................................................................................196 Electro-hydraulic controls .....................................................................................................................................197 Front P.T.O. clutch engagement control...............................................................................................................202 Rear P.T.O. clutch engagement control ...............................................................................................................202 Differential lock engagement control ....................................................................................................................202 Front-wheel drive engagement control .................................................................................................................202 Rear P.T.O. engagement control ..........................................................................................................................202 Gearbox ................................................................................................................................................................202 Front and rear lift ..................................................................................................................................................202 Hydraulic circuit diagram ......................................................................................................................................202 Solenoid valve - Specifications .............................................................................................................................207 Adjustment of front and rear differential lock control ............................................................................................214

7 - BODYWORK Platform ................................................................................................................................................................215 Cab - General information ....................................................................................................................................216 Cab air filter ..........................................................................................................................................................218 Screen wash .........................................................................................................................................................218 Screen wipers (front and rear) ..............................................................................................................................218 Removing the driving platform complete with cab ................................................................................................219 Breakage of the top hood release cable ...............................................................................................................220 High visibility cab roof ...........................................................................................................................................222

8 - SYSTEMS Ventilation .............................................................................................................................................................223 Heating System ....................................................................................................................................................223 Air conditioning unit for cabs ................................................................................................................................227 Operation and maintenance of the air-conditioning system .................................................................................228 Water dripping from the points at which condensate drain lines are connected to the conditioning unit ............229 Checking system ..................................................................................................................................................231 System safety elements .......................................................................................................................................231 Temperature regulation ........................................................................................................................................231 Charging the system.............................................................................................................................................232 Filling the metering unit ........................................................................................................................................232 Refilling the system with oil ..................................................................................................................................232 Verifying operation of the system after recharging ...............................................................................................234 Directions for tightening air conditioning system pipeline fittings .........................................................................234 Diagnosing malfuntions ........................................................................................................................................241 Hydraulic system ..................................................................................................................................................242 Oil filters ................................................................................................................................................................243 Hydraulic pumps ...................................................................................................................................................243 Checking the relief valves of the hydraulic lift system ..........................................................................................243 Stripping the hydraulic pump ................................................................................................................................244 Auxiliary hydraulic spool valves ............................................................................................................................247 Checking the pressure relief valve setting ............................................................................................................250 Checking the operating pressure ..........................................................................................................................250 Conversion of auxiliary spool valves from double acting to single acting operation.............................................250 Checking the surface of the valve spools .............................................................................................................250 Trailer hydraulic braking system ...........................................................................................................................251 Use of the tractor with CUNA 341/01 hydraulic trailer braking .............................................................................253 Installing the hydraulic braking valve for trailers equipped with “safety brake” ( ITALIAN version) ................................................................................................................................................258 Electrical system AGROPLUS 60 (up serial number1017) - 70 (up serial number 2773) - 80.............................261 Electrical system AGROPLUS 60 (under serial number 1016) - 70 (under serial number 2772) ........................445

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General safety directions......................................................................................................................................446 Jump start utilizing another battery.......................................................................................................................447 Recharge system..................................................................................................................................................449 Heating system .....................................................................................................................................................450 Starting system .....................................................................................................................................................450 Ignition key ...........................................................................................................................................................452 Ventilation control .................................................................................................................................................452 Push button control...............................................................................................................................................452 Beacon push button..............................................................................................................................................454 Work ligths............................................................................................................................................................454 2-Speed windscreen wiper switch ........................................................................................................................454 Relay ....................................................................................................................................................................455 Electronic flasher unit ...........................................................................................................................................455 Switch controlling..................................................................................................................................................456 Switch controlling: differential lock - P.T.O. clutch - 4RM - 540 1000 rpm/min P.T.O. speed selector Economy P.T.O. - Live P.t.o. - electric starter system.........................................................................................456 Switch for emergency brake .................................................................................................................................456 Fuse box ...............................................................................................................................................................457 Instrument panel with digital display .....................................................................................................................458 Operation of the broken belts alarm control unit...................................................................................................460 Engine stop operation with a type 2MH engine control unit .................................................................................462 Electrical wiring.....................................................................................................................................................465

9 - APPENDIX Power lift tester version 1.24a ...................................................................................................................................I

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TRACTOR CONFIGURATIONS:

AGROPLUS 60 - 70 - 80

2RM 2RM 4RM 4RM

WITH PLATFORM WITH CAB WITH PLATFORM WITH CAB

CAB - ventilation - ventilation + heating - ventilation + heating + air conditioning

GEARBOX Fully synchronised: 20 Forward + 10 Reverse: 5 speeds x 2 ranges (Hair-Tortoise) + SYNCHROSPLIT (H/fast-L/slow-R/rearward)

30 Forward + 15 Reverse: 5 speeds x 3 ranges (Hair-Tortoise-Snail) + SYNCHROSPLIT (H/fast-L/slow-R/rearward) 45 Forward + 45 Reverse: 5 speeds x 3 ranges (Hair-Tortoise-Snail) + shuttle + version POWERSHIFT

-

-

CONTROLS - rear P.T.O. clutch with electro-hydraulic control - 4WD with mechanical control or optional electro-hydraulic control - electronic engine throttle

MECHANICALLY OPERATED REAR POWER-LIFT - with supplementary rams - without supplementary rams

MAIN EQUIPMENT - front P.T.O. - front lift - hydraulic pump capacities increased by 27 l/min (for hydrostatic steering, electro-hydraulic control unit and gearbox lubrication) and by 47 l/min (for trailer braking, auxiliary control valves and lift). - hydraulic trailer braking - 4-way or 6-way control valves with “Flow Divider” - etc.

6

DIMENSIONS AND WEIGHTS AGROPLUS 60 Length max: - without linkage - with front and rear linkage Width min./max. Height: - al telai di sicurezza - at cab (standard) - at cab (with air conditioning) Ground clearance Wheel base Front track base min./max. Rear track base min./max. Min. turning radius without brakes Operating weight (without front lift) - with plataform - with cab Max. permissible load - front - rear - block Tyres - front - rear

AGROPLUS 70 -80

2 WD

4 WD

2 WD

4 WD

(A) mm (A) mm (B) mm

3800 -

3835 4350

3930 -

3985 4480

1920 -2320

1920-2320

1920-2320

1920-2320

(C) mm (C) mm (D) mm (E) mm (F) mm

2420 2430 2595 345 2162

2420 2430 2595 345 2112

1490 1700 2360 365 2292

365 2242

(G) mm

1400 1440 1300-1600 1340-1740

1400 1440 1300-1600 1340-1740

(H) mm

1500 1500 1400-1900 1400-1900

1500 1500 1400-1900 1400-1900

(mm)

3500

4050

3700

4300

kg kg

2355 2550

2705 2900

2555 2750

2905 3100

kg kg kg

240 200 -

240 200 250

240 200 -

240 200 250

7.50-16 14.9R30

12.4R 20 14.9R30

7.50-16 16.9R30

11.2R 24 16.9R30

7

8

41 (10.8)

Engine AGROPLUS 70/80

Gearbox and rear axle

(*)1° replace after 50 hours (**) With filter + 1.5 litre

Lubrification points

Brakes and clutch control

Front PTO

Side reductions

MAX

6 (6.3) 1.5x2 (1.6x2) 2.5 (2.6)

11** (2.9)

Central axle

9.5** (2.5)

Litres (US gal)

Engine AGROPLUS 60

Part to be supplied

s

Product

AKROS GREASE T2

AKROS MATIC

AKROS MULTI

AKROS MULTI

AKROS TURBO 15W40

PRESCRIBED LUBRICANTS AND FUELS AGROPLUS 60/70/80

ATF DEXRON II D SDFG OF-1691 NLGI 2 - LITIO SDFG GR-1202 L

Sae 10w30 Sae 20w30 UTTO API GL4 SDFG OT-1891

Sae 10w30 Sae 20w30 UTTO API GL4 SDFG OT-1891

Sae 15w40 ACEA E3-96 API CF SDFG OM-1991 MIL-L-2104 E level MB 228.3 level

Specifications SDFG

50

1200

1200

500*

change hours

PRESCRIBED LUBRICANTS AND FUELS

CONVERSION TABLE FROM

FROM inch cm foot m yard m Eng. miles km Sq.in. cm2 Sq.ft. m2 Sq.yard m2 Cu.in. cm3 Cu.ft. Liter Cu.yard m3 Imp.gall. Liter US gall. Liter pint Liter quart Liter oz. kg lb. kg lb.ft. kgm lb/in. kg/m lb./sq.in. kg/cm2 lb./Imp.gall. kg/l lb./US gall. kg/l lb./cu.ft. kg/m3 cu.ft./lb. m3/kg Nm kgm kW PS bar kg/cm2 dm3 l

TO cm inch m foot m yard km Eng. miles cm2 Sq.ft. m2 Sq.ft. m2 Sq.yard cm3 Cu.in. Liter Cu.ft. m3 Cu.yard Liter Imp.gall. Liter US gall. Liter pint Liter quart kg oz. kg lb. kgm lb.ft. kg/m lb/in. kg/cm2 lb/sq.in. kg/l lb./Imp.gall. kg/l lb./US gall. kg/m3 lb./cu.ft. m3/kg cu.ft./lb. kgm Nm PS kW kg/cm2 bar l dm3

multiply by: 2.540 0.394 0.305 3.281 0.914 1.094 1.609 0.622 6.452 0.155 0.093 10.77 0.835 1.197 16.39 0.061 28.36 0.035 0.763 1.311 4.547 0.220 3.785 0.264 0.568 1.762 1.137 0.880 0.028 35.25 0.454 2.203 0.139 7.233 17.87 0.056 0.070 14.22 0.100 10.00 0.120 8.333 16.21 0.062 0.062 16.21 0.102 9.81 1.36 0.736 1.014 0.981 1 1

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HOW TO ORDER SPARE PARTS

To ensure perfect tractor efficiency thus avoiding serious drawbacks, and to optimize your investment and the operational expenses, the use of “ORIGINAL SPARE PARTS” is recommended. Spare parts orders must specify the following: Tractor serial number and engine serial number (if the engine is concerned). Spare part name and reference code.

ENGINE TYPE AND SERIAL NUMBER

10

TRACTOR FRAME TYPE AND SERIAL NUMBER

ENGINE

AGROPLUS 60 and AGROPLUS 70 are powered by F3L 913 / F4L 913 engines. The workshop manual for these engines cuold be ordered to the following addresse: DEUTZ-FAHR DEUTSCHLANDGmbH Abt. LT-ZE Deutz-Fahr-Straße 1 89415 Lauingen Telefax-Nr.: 09072/997-360 or -353 Using the following code: 0297 7293

11

2

Clutch and transmission

23

Clutch

Earshift clutch General specifications The clutch, a single stage type, comprises a friction disc, a pressure plate and a diaphragm spring. The hydrostatic control is self-adjusting: a master cylinder operated by the pedal directs oil to the slave cylinder mounted to the left hand side of the intermediate housing, which in turn operates the clutch release lever. Technical specifications

Agroplus 60

Type of clutch

Agroplus 70-80

Agroplus 60-70-80 (USA) 6 blades

single disc dry single disc dry single disc dry organic facing organic facing cerametallik facing hydrostatic with automatic take-up of free travel

Type of operation Disc p/n Disc diameter

mm

009.6913.3 279,4

009.6924.3/20 310

009.9770.3 310

Minimum permissible thickness of disc

mm

6

6

9,7

Thickness of friction disc Type of facing material on friction disc Type of master cylinder Type of oil

mm

+0, 3 -0, 3

+0, 3 -0, 3

8,5 TEXTAR T385

8,5 TEXTAR T385

10 +-00..22 UA 330 DX

Benditalia 3/4" AKROS MATIC

Spring specifications to Belleville washer for the clutch engagement Load on the pressure plate

Nm

11000

CAUTION: In the event the transmission being split to gain access to the clutch assembly, the pickup (A, fig. 1) must be removed to avoid its being damaged by the teeth of the engine flywheel.

Fig. 1 - Engine rpm pickup.

IIMPORTANT: In the event of the friction disc being removed, care must be taken during refitment to position the components correctly, as indicated, since the disc is not symmetrical.

12

Fig. 2 - Clutch unit for AGROPLUS 60

Clutch and transmission

2

Clutch

23

Fig. 3 - Clutch unit for AGROPLUS 70-80

13

2

Clutch and transmission

23

Clutch

Clutch unit for AGROPLUS 60-70-80 (USA) 6 blades

14

Clutch and transmission

2

Clutch

23

Fig. 4 - Components of clutch assembly

15

2

Clutch and transmission

23

Clutch

Fig. 5 - Checking clutch disk thickness.

Fig. 9 - Installing clutch assembly through n. 5.9030.256.4/10 equipment.

Cecking clutch Check the disk lining for signs of chipping and the disk friction face for scoring which may prevent the clutch from operating properly. Check that the sliding surface of the engine flywheel is not scored; if signs of scoring are evident, machine the surface. Check the disk thrust plate for scoring or bluish areas caused by tempering and also ensure the diaphragm-type spring has not lost its efficiency; if so the whole clutch assembly shall be replaced.

Fig. 6 - Clutch assembly hydraulic operating cylinder.

Be sure the clutch disk is free to move in its housing and the friction lining securing rivets are duly riveted. Should any wear be found on the thrust bearing or the diaphragm-type spring, an exhaustive check over the spring operating conditions installed in the disk thrust lever operating cylinder (see Fig. 6) shall be performed; replace if necessary. On reassembly ascertain dimension A (see Fig. 6) between the operating cylinder fixing face and the push rod contacting the en gagement lever is 195 mm. NOTE: To facilitate correct clutch disk assembly the use of no. 5.9030.256.4/10 centering tool is recommended. Warning: With engine running, never ride the clutch pedal with your foot to prevent the clutch disk from being damaged because of overheating. Important: The thrust bearing is prelubricated, and must never on any account be cleaned with fuel oil or other solvents as these will render the prelubrication treatment ineffective.

Fig. 7 - Checking operating cylinder inside spring efficiency.

Adjusting clutch control pedal Make sure the distance between pump fixing surface and fork hole centre is 106 1 (Fig. 15) otherwise loosen nut A and operate adjusting stay rod B (Fig. 15).

Bleeding air from the hydraulic circuit Operate the clutch pedal several times, then keeping the clutch pedal in fully depressed position, slightly unscrew and soon after tighten the air bleeding screw valve again (this being located on thrust lever operating cylinder). This operation should be repeated as many times as the oil flows out of the bleeding screw valve without air bubbles. Fig. 8 - Bleeding the air from the clutch hydraulic circuit.

16

A B C

Bleed screw Hydraulic pipe fitting Slave cylinder body

D E F

Clutch and transmission

2

Clutch

23

Spring Seal ring Piston

G H

Push rod Rubber boot

Fig. 10 - Clutch operating cylinder

Stripping the slave cylinder (Fig. 10) Remove the boot H. Withdraw the piston F carefully from the cylinder C, blasting with compressed air at low pressure to assist removal. Remove the spring D from the cylinder and loosen the bleed screw A. Remove the seals E fom the piston F. CAUTION: When cleaning the components of the cylinder, use only specifically formulated brake and clutch fluids (see page 110). Do not use petrol, paraffin or other mineral oils as these will damage parts in rubber.

Inspections — Check both internal and external piston surfaces for scratching. Replace if required. — Make sure the seal ring grooves are duly clean; blow the grooves with compressed air if necessary. — Inspect seal ring, dust boot conditions as well as spring efficiency, worn-out parts should be replaced. — Ensure the air bleeding hole is free from impurities.

Notes on refitment — When reconnecting the transmission housing, check that the clutch fork remains correctly positioned and free to rock on its fulcrum pivot. This can be ensured by removing the side plug from the flange of the intermediate housing and viewing the fork through the hole. In the event of the fork pivot being unseated, reposition correctly with the aid of a screwdriver inserted through the hole vacated by the plug. — Before refitting the slave cylinder, fill with the recommended oil so as to facilitate the subsequent bleeding procedure. — Once all components are correctly and securely in place, bleed the hydraulic circuit.

A - Control lever B - Dust boot C - Pushrod D - Union E - Piston F - Seal ring G - Cylinder casing H - Spring Fig. 11 - Clutch operating cylinder cutaway view.

17

2

Clutch and transmission

23

Clutch

A Hydraulic pump B - Delivery pipe union C - Delivery pipe D - Clamp E - Union

F G H I L

- Spring - Spring holder - Screw - Shoulder ring - Seal ring

M - Spacer ring N - Piston O - Seal ring P - Rod Q - Support disk

R S T U

- Snap ring - Guard boot - Nut - Yoke

Fig. 12 - Clutch hydraulic pump parts.

Stripping the master cylinder Referring to figure 14, remove the protective boot E, dislodge the circlip B and withdraw the rod D together with the disc C. Remove the piston together with the spacer, the seal, the backup washer and the spring beneath.

Fig. 13 - Clutch pump control positioning. A - Locknut B - Yoke

18

Fig. 14 - Pump control seal ring. A - Pump D - Rod B - Snap ring E - Guard boot C - Support disk

Clutch and transmission

2

Clutch

23

Inspections and checks WARNING: To clean and wash the hydraulic pump components use only the oil type recommended for brakes and clutch. Never use petrol, kerosene or other mineral oils to prevent damaging the rubber parts. Inspect both internal and external piston sliding surfaces for scratching. Replace if required. Make sure the seal ring grooves are duly clean; blow the grooves with compressed air if necessary. Inspect seal ring, dust boot conditions as well as spring efficiency, worn-out parts should be replaced. Inspect all pump internal compartments, apertures and passages and make sure these are properly clean and free from foreign matters. Check that the spring is neither lazy nor deformed; replace if necessary.

Reassembly Reassemble the cylinder, repeating the disassembly steps in reverse order and observing the following directions: — Lubricate surfaces engaged in relative sliding contact, using the recommended oil (see page 12). — Verify correct operation of the cylinder, making certain that the piston is able to complete its full stroke unimpeded. In the event that the fork linking the master cylinder with the pedal has been removed, check that with the push rod fully extended, the distance between the reference surface of the cylinder and the centre of the hole in the fork is as indicated in figure 15. If not (referring to fig 13), remove the boot, loosen the lock nut A and screw or unscrew the fork B to obtain the prescribed clearance, then retighten the lock nut and reposition the boot.

Fig. 15 - Section view of clutch master cylinder

Clutch greasing points. Apply Molikote Gn-plus at all the points indicated in the figure with letter A. Fit part B with Loctite 270. Fit pin C with Loctite 601.

Fitting the P.T.O. shaft oil seal Before fitting the oil seal 2.1529.517.0 apply Loctite 222 to the outer face A indicated in the figure.

19

2

Clutch and transmission Diagnosing malfunctions

clutch slips

clutch jerks

lubricant in clutch housing

renew the front gearbox oil seal and the rear engine oil seal

clean oil seal contact surfaces with petrol

replace disk

clutch worn

check condition of clutch disk

check condition of the spring disk

fit new clutch as sembly

thrust bearing sticking

clean surfaces and apply grease

replace thrust bearing

clean or replace the disk

clutch disk surfaces dirty

clean the friction surfaces

clutch disk warped

difficulty in enga ging gears when engine running

clutch fails to disengage

clutch disk surfaces dirty

replace clutch disk

clutch disk worn

replace clutch disk

plate seals loose

replace clutch disk

clutch disk warped

replace disk

hydraulic pump inefficient

check the stroke of the clutch control piston and replace any worn parts

clutch disk stuck to flywheel

clutch noisy when disengaged

20

worn parts in clutch engagement me chanism

replace parts

clean contact surfaces with a wire brush and petrol

Clutch and transmission

2

POWERSHIFT

27

POWERSHIFT unit The POWERSHIFT unit is composed of an epicyclic speed reducer and three oil-immersed multiple disc clutches (LOW - MED - HIGH). The unit is located between the clutch-coupled shaft and the gearbox. The speed reducer is engaged and disengaged selectively by way of the three clutches, which are a push button and

mounted to the knob of the shift lever.

Selecting the control, the MED clutch releases as the force of the belleville discs is overcome by hydraulic pressu re; at the same time, the HIGH clutch engages, locking the planet carrier of the epicyclic train to the relative housing so that drive is transmitted to the range input shaft with no speed reduction whatever. Selecting the control, the MED clutch releases as the force of the belleville discs is overcome by hydraulic pressu re; at the same time, the LOW clutch engages, and the shaft carrying the sun wheel is locked to the structure of the transmission housing. As a result, the planet carrier is made to rotate as one with the epicyclic housing and drive is transmit ted to the layshaft at a speed reduction of 0.687 (the ratio between the annulus and the sun wheel gear teeth). Selecting the control, the POWERSHIFT unit is isolated from hydraulic pressure altogether and the belleville discs are able to engage the MED clutch, with the result that the shaft in mesh with the larger planet wheel is locked to the transmission housing. This gives a reduction of 0.825, by reason of the compound ratio between the planet wheels and the flange of the speed reducer in mesh with the range input shaft. Technical specifications Clutch maker

SAME DEUTZ - FAHR

number of friction discs diameter of friction discs

7 129,5

4 129,5

2 129,5

overall thickness of assembled friction discs complete the intermediate discs

mm

25,2 ÷ 25,4

17,50 ÷ 17,60

11,70 ÷ 12,14

number of intermediate discs disc lubrication pressure

bar

3+1 5

2+1 5

2+1 5

maximum pressure

bar

16

16

16

piston thrust

Kg Nm

1986 19463

1986 19463

1986 19463

Epicyclic speed reducer - LOW

1 + (30/66) = 1,4545

- MEDIUM

1 + (21x18) : (66x27) = 1,2121

- HIGH

SLOW

1

MEAN

FAST

Fig. 1 - Range selection indicators mounted to the instrument panel.

Fig. 2 - Plate indicating selection of electrohydraulic control.

21

2

Clutch and transmission

27

POWERSHIFT

Fig. 3 - Diagram illustrating operation of the POWERSHIFT system.

Parts in movement

Parts locked to transmission housing

Fig. 4 - Diagram showing engagement of POWERSHIFT with MED range selected.

22

In rotation (idling)

Clutch and transmission

2

POWERSHIFT

27

Parts locked to transmission housing

Parts in movement

Oil circuit for operation of clutches

In rotation (idling)

Fig. 5 - Diagram showing engagement of POWERSHIFT with LOW range selected.

Parts locked to transmission housing Parts locked to epicyclic

Oil circuit for operation of clutches

In rotation (idling)

Fig. 6 - Diagram showing engagement of POWERSHIFT with HIGH range selected.

23

2

Clutch and transmission

27

POWERSHIFT POWERSHIFT UNIT DETACH FROM THE GEAR BOX

Fig. 7 - Detach the driving platform (or the cab, if fitted) from the tractor.

Fig. 8 - Detach the front part of the tractor complete with en gine from the gearbox.

Fig. 9 - Detach the front gearbox from the rear gearbox.

Fig. 10 - Remove the upper cover from the front gearbox.

Fig. 11 - Remove the internal clutch control from the front gearbox.

Fig. 12 - Remove the solenoid valve block from the front right-hand side.

24

Clutch and transmission

2

POWERSHIFT

27

Fig. 13 - The POWERSHIFT solenoid valve block is removed by pulling it outwards after having disconnected the pipes and removed the retaining screws.

Fig. 14 - Remove the hydraulic lubrication pipe of the POWERSHIFT unit by first disconnecting the part on the outside of the gearbox.

Fig. 15 - Disconnect the delivery line from the POWERSHIFT unit by unscrewing the union.

Fig. 16 - Using a drift as shown in the figure, drive the POWERSHIFT unit out of the front of the gearbox.

Fig. 17 - Remove the POWERSHIFT unit from the front end of the gearbox.

Fig. 18 - After having removed the POWERSHIFT unit, proceed with its disassembly, if necessary. Then remove the epicyclic reduction unit.

25

2

Clutch and transmission

27

POWERSHIFT

Fig. 19 - Remove the planet carrier flange from the epicyclic reduction unit.

Fig. 20 - Remove the circlip and the thrust washer. On re-assembly, the thrust washer must be fitted with the lubrica tion channels facing inwards towards the planet carrier flange

Fig. 21 - The play adjustment shim for the POWERSHIFT shafts is located between the housing and the epicyclic reduction unit.

Fig. 22 - To dismantle the POWERSHIFT unit, remove the circlip indicated in the figure.

Fig. 23 - Remove the circlip indicated in the figure using a pair of bent nose pliers.

Fig. 24 - Remove the thrust washer.

26

Clutch and transmission

2

POWERSHIFT

27

Fig. 25 - Unscrew the screws securing the LOW clutch hous ing to the POWERSHIFT unit.

Fig. 26 - Remove the retaining screws.

Fig. 27 - It is advisable to mark the relative positions of the parts prior to disassembly.

Fig. 28 - Using a screwdriver, separate the housing from the unit.

Fig. 29 - Remove the LOW clutch disc pack (7+7).

Fig. 30 - Inspect the clutch discs for wear.

27

2

Clutch and transmission

27

POWERSHIFT

Fig. 31 - Remove the circlip securing the hub of the LOW clutch.

Fig. 32 - Remove the hub of the LOW clutch.

Fig. 33 - Remove the circlip located behind the hub of the LOW clutch.

Fig. 34 - Proceed with the disassembly of the housing of the MEDIUM-LOW" clutches.

Fig. 35 - Using a drift, separate the MEDIUM-LOW housing from the rest of the unit.

Fig. 36 - Detach the MEDIUM-LOW housing from the unit.

28

Clutch and transmission

2

POWERSHIFT

27

Fig. 37 - Remove the Belleville springs from the MEDIUM clutch.

Fig. 38 - Remove the discs from the MEDIUM clutch.

Fig. 39 - MEDIUM clutch discs (4 friction discs+3 counterdiscs+2 thrust plates).

Fig. 40 - The control piston of the LOW clutch may be removed from the “MEDIUM-LOW” bell-housing using a press of the type illustrated below.

Fig. 41 - This piston can be removed by removing the circlip of the piston return spring located on the opposite end of the housing.

Fig. 42 - Remove the LOW clutch shaft.

29

2

Clutch and transmission

27

POWERSHIFT

Fig. 43 - Check that the oil ways in the shaft are not obstructed.

Fig. 44 - The LOW clutch control piston can be removed from the housing using a press of the type illustrated below.

Fig. 45 - This piston can be removed by removing the circlip of the piston return spring located on the opposite end of the housing.

Fig. 46 - Remove the circlip securing the HIGH clutch discs.

Fig. 47 - Remove the thrust washer of the HIGH clutch.

Fig. 48 - Remove the HIGH clutch disc pack (2 friction discs + 2 counterdiscs + 1 thrust plate).

30

Clutch and transmission

2

POWERSHIFT

27

Fig. 49 - HIGH clutch discs.

Fig. 50 - HIGH clutch control piston.

Fig. 51 - Separate the HIGH clutch housing from the MEDIUM clutch housing using a press to compress the springs and remove the circlip.

Fig. 52 - Remove the MEDIUM clutch hub and then the relative housing.

Fig. 53 - “ VESPEL” seals of the HIGH clutch housing.

Fig. 54 - Remove the HIGH clutch housing.

31

2

Clutch and transmission

27

POWERSHIFT

Fig. 55 - Remove the Belleville return springs of the HIGH clutch control piston from the MEDIUM shaft.

Fig. 56 - Examine the condition of the “VESPEL” seals on the HIGH clutch housing.

Fig. 57 - If necessary, remove the circlip and remove the bearing from the MEDIUM clutch housing.

Fig. 58 - Remove the piston from the MEDIUM clutch hous ing.

Fig. 59 - Examine the condition of the seal ring of the piston from the MEDIUM clutch housing.

Fig. 60 - Proceed to dismantle the LOW clutch control piston with the aid of a press.

32

Clutch and transmission

2

POWERSHIFT

27

Fig. 61 - Remove the circlip securing the springs.

Fig. 62 - Remove the assembly from the press and remove the Belleville springs.

Fig. 63 - Disassembly sequence for the 5 Belleville washers.

Fig. 64 - Remove the piston.

Fig. 65 - Groove for O-ring in the LOW clutch housing.

Fig. 66 - Examine the condition of seal ring of the piston from the LOW clutch housing.

33

2

Clutch and transmission

27

POWERSHIFT

A - Cover B - LOW clutch C - LOW clutch control piston D - Clutch housing MEDIUM - LOW E - LOW clutch belleville springs F - MEDIUM clutch belleville springs G - Actuator disc H - MEDIUM clutch

Fig. 67 - POWERSHIFT unit

34

I - Seeger L - Clutch hub M - Thrust plate N - Bearing O - Thrust plate P - MEDIUM clutch control piston Q - HIGH clutch housing R - HIGH clutch control piston S - HIGH clutch

T - LOW sun wheel U - Planet carrier V - Thrust washer Z - Ring gear X - Planet gears J - LOW shaft Y - MEDIUM shaft W - Secondary shaft K - Reduction unit shaft

Clutch and transmission

2

POWERSHIFT

27

Assembly of POWERSHIFT unit

Fig. 68 - Components of POWERSHIFT unit

The POWERSHIFT unit requires that the basic gearbox, with respect top the standard version, is equipped with a secondary shaft A and a range input shaft B, of specific type. Warning: no special tools are required to re-assemble this unit, just an M8x1.25x30 screw to hold the central shaft C in position during POWERSHIFT play adjustment. Assemble the unit as follows: — Fit the input ring gear D to the secondary shaft, securing it with circlip E; — Separately assemble LOW gear F with the planet carrier flange G . When fitting gear F, the planets must be positio ned so that their punch marks are aligned with the position reference marks on the carrier flange, (Fig. 69). Timing reference countermark

Fig. 69 - Timing the epicyclic speed reducer of the POWERSHIFT unit.

35

2

Clutch and transmission

27

POWERSHIFT

Timing marks on gear teeth of the epicyclic reduction of the POWERSHIFT unit.

Fig. 70 - Pre-assembly of parts on MEDIUM shaft.

36

Fig. Pre-assembly of MEDIUM-LOW clutches.

Clutch and transmission

2

POWERSHIFT

27

RE-ASSEMBLY OF THE POWERSHIFT UNIT.

Fig. 72 - Assemble the HIGH clutch. Fit the bearing with the relative snap rings in the MEDIUM clutch housing; fit the hub securing it with the relative circlip and fit the three service circlips to the housing. Fit the O-ring seals to the piston , then fit the piston.

Fig. 73 - Fit the LOW shaft, the relative roller bearings, and position the snap ring.

Fig. 74 - Fit the MEDIUM clutch discs.

Fig. 75 - Apply Loctite 510 sealing compound to the housing contact surfaces as shown in the figure. WARNING: when applying sealing compound take care not to obstruct the oil ways.

Fig. 76 - Fit the circlip and check that the shaft has certain amount of play.

Fig. 77 - Fit the MEDIUM clutch thrust washer with outlets oriented towards the circlip.

37

2

Clutch and transmission

27

POWERSHIFT

Fig. 78 - Join the two housings together; the studs will locate in the 3 holes to ensure the correct relative positions of the two housings. Rotate the shaft during this operation so as to centre the clutch discs.

Fig. 79 - Note that a small space will be left between the two housings; this is to allow preloading of the Belleville springs when the screws are tightened.

Fig. 80 - Fit the LOW clutch, first positioning the circlip on the shaft as indicated in the figure.

Fig. 81 - Then fit the clutch hub and position the second circlip.

Fig. 82 - Then install the discs of the LOW clutch.

38

Fig. 83 - The disc pack is completed with a final friction disc, the tabs of which do not engage the splines on the hub, and therefore, when refitting the cover, it is advisable not to rotate the shaft so as to allow the disc tabs to mesh correctly with the hub.

Clutch and transmission

2

POWERSHIFT

27

ADJUSTMENT OF END FLOAT IN THE POWERSHIFT UNIT (fig. 84) Screw one M8x1,25x30 bolt finger tight into the cover W (fig 84), so as to hold the centre shaft of the H-M-L unit in position during the adjustment. Measure dimensions X and Y with a gauge then calculate (X - Y - 1 mm) , which gives the thickness of the thrust washer K to fit. Example:

values measured

X = 191,88

Y = 188,24

(191,88 - 188,24 - 1) = 2,64 ~ 2,6 mm (2.1599.727.0/10 washer required) IMPORTANT: the thrust washer must be selected from those available to give either the exact thickness, or the next thickness down from the value calculated. washer p/n: 2.1599.725.0/10 thicknesst 2.2 mm 2.1599.726.0/10 thicknesst 2.4 mm 2.1599.727.0/10 thicknesst 2.6 mm 2.1599.728.0/10 thicknesst 2.8 mm 2.1599.729.0/10 thicknesst 3 mm 2.1599.730.0/10 thicknesst 3.2 mm 2.1599.731.0/10 thicknesst 3.4 mm 2.1599.732.0/10 thicknesst 3.6 mm 2.1599.733.0/10 thicknesst 3.8 mm 2.1599.734.0/10 thicknesst 4 mm — Fit a shim of the predetermined thickness on the LOW shaft with the relative circlip — Fit the epicyclic reduction unit in the gearbox and then fit the POWERSHIFT clutches unit, applying Silastic sealing compound to the contact surfaces.

Fig. 84 - Location of the preassembled POWERSHIFT unit in its housing.

39

2

Clutch and transmission

27

POWERSHIFT

A - pressure regulator valve (operating pressure 16 bar) B - gearbox lubrication oil pressure setting valve (setting 5 bar) C - anticavitation valve for safety steering (30 l/min.) D - oil pump (capacity 10 to 27 l/min.) E - suction filter (25 micron) Fig. 85 - Hydraulic diagram illustrating operation.

40

F - solenoid control valves G - electro-hydraulic control unit H - anticavitation valve for safety steering I - bistable valve L - safety steering valve M1 - pressure gauge with scale 0 - 40 bar M2 - pressure gauge with scale 0 - 40 bar M3 - pressure gauge with scale 0 - 10 bar T - lubrication

Clutch and transmission

1

POWERSHIFT

27

Fig. 86 - Electrohydraulic control unit for POWERSHIFT system.

PROCEDURE FOR CHECKING THE H-M-L CONTROL UNIT INLET PRESSURE

Referring to Fig. 86: 1 - Connect pressure gauge 5.9030.514.0 (0 ÷ 40 bar) at position M1. 2 - Connect pressure gauge 5.9030.515.0 (0 ÷ 10 bar) at position M2. Start the engine and throttle up to the revolutions indicated in the table; now verify that the inlet pressures are as prescribed. NB: Pressure tests should be conducted using oil at a temperature of 80 °C.

A - Test fitting for testing pressure of LOW clutch hydraulic circuit B - Bistable valve C - Valve body D - Non-return valve E - Non-return valve F - Oil pressure regulator valve G - Lubrication pressure control valve H - Delivery line to P.T.O. I - Delivery line to differential lock L - P.T.O. lubrication pipe M - P.T.O. disk lubrification manifold N - Manifold for P.T.O. clutch oil pipe O - Secondary shaft and POWERSHIFT lubrification pipe P - Pipe from radiator oil to the gearbox Q - Delivery line to front-wheel drive engagement piston M1 - Pressure gauge with scale 0 - 40 bar M2 - Pressure gauge for P.T.O. lubrication pipe M3 - Pressure gauge with scale 0 - 40 bar for pressure at P.T.O. 41

2

Clutch and transmission

27

POWERSHIFT

A - Gearbox lubrication oil pressure control valve (5 bar) B - Non-return valve 30 l/min C - Sequence valve (operating pressure 16 bar) D - Non-return valve T - Return L1- P.T.O. clutch line L2- Secondary shaft and POWERSHIFT lubrication

Fig. 87 - POWERSHIFT pressure control valves assembly

42

Clutch and transmission

2

POWERSHIFT

27

Fig. 88 - Hydraulic control circuit.

43

2

Clutch and transmission Diagnosing malfunctions

check the clutch assembly hydraulic system

clutch slips check piston free stroke

for

replace the defective parts

examine piston and manifold seal rings

replace defective parts

remove any roughness preventing piston from sliding freely

check the clutch plates for wear

replace the clutch disks

inspect the control mechanism

replace parts

defective

replace the disks inspect the disks

burnt disks

clutch won’t disengage

jammed disks

piston jammed in seat

44

relpace the piston

remove any roug hness preventing disks from sliding freely

Transmission

3

Gearbox

31

General specifications The basic transmission utilizes 5 speed synchromesh gearbox with 2 or 3 speed ranges. A shuttle, fitted as standard, makes the tractor easy to handle and manoeuvre. Options include Creeper, and Underdrive (in place of or in addition), giving a total of: For tractors equipped with platform or cab 20 FWD + 10 REV: 5 gears x 2 ranges (L-V) + mini-reduction + reverser shuttle 30 FWD + 15 REV: 5 gears x 3 ranges (SR-L-V) + mini-reduction + reverser shuttle. 45 FWD + 45 REV: 5 gears x 3 ranges (SR-L-V) + reverser shuttle + POWERSHIFT Each version is also available with 30 or 40 km/h top speed.

Technical specifications number of speeds gearbox ratios

shuttle range ratios rear axle ratios bevel gear pair

20 AV + 10 RM 1st gear 2nd gear 3rd gear 4th gear 5th gear

19/59 = 1/3,1053 23/50 = 1/2,1739 29/44 = 1/1,5172 35/38 = 1/1,0857 41/32 = 1/0,7805

forward reverse

29/37 = 1/0,7838 23/19 = 1/0,8261

low high 30 km/h 40 km/h

epicyclic final drive overall ratio backlash between crownwheel and pinion teeth

30 km/h 40 kmIh

1/32,9063 1/24,7502

mm

0,18 - 0,24 32/34 = 1/0,9412

Super-reduction

reference distance for adjustment of bevel gear pai

8/39 = 1/4,8750 9/33 = 1/3,6667 (12/12+69) = 1/6,7500

Mini-reduction axial play of the secondary shaft axial play of the gears of the change, of the reverser and mini-reduction

(19/50)x(22/46)= 1/5,5024 1

(19/50)x(22/46)x(19/50)x(20/48) = 1/34,7520 mm

0,09

mm

0,15 ÷ 0,30

rmm

2,5 ± 0,1

45

3

Transmission

31

Gearbox

Speed change configurations Powershift control

Gearshifting Control

Synchrosplit control

Speed range Control

NO. OF SPEED (forward + reverse)

20 + 10

30 +15

45 + 45

DURING TRANSPORT OPERATIONS ON PUBLIC ROADS BOTH BRAKE PEDALS MUST BE OBLIGATORILY COUPLED BY MEANS OF THE SPECIAL LOCKING LATCH. IN ANY CASE, ALWAYS OBSERVE LAWS AND REGULATIONS IN FORCE.

46

Transmission

3

Gearbox

31

* see technical characteristics of gearbox on p. 45 ** see technical characteristics of 4wd front axle on p. 115

Fig. 2 - Ratios of 5-speed x 2 range transmission with mini-reduction (20 FWD + 10 REV).

47

3

Transmission

31

Gearbox

* see technical characteristics of gearbox on p. 45 ** see technical characteristics of 4wd front axle on p. 115

Ratios of 5-speed x 2 range transmission with mini-reduction and super-reduction (30 FWD + 15 REV).

48

Transmission

3

Gearbox

31

* see technical characteristics of gearbox on p. 45 ** see technical characteristics of 4wd front axle on p. 115

Fig. 3 - Ratios of transmission with 3 ranges (Super-reduction) + POWERSHIFT (45 FWD + 45 REV).

49

3

Transmission

31

Gearbox

Assemble the front and rear gearboxes and the rear hydraulic lift, after having applied PIANERMETIC 510 to surfaces A and LOCTITE 636 to bushes B.

Fig. 4 - Front and rear gearbox.

50

Transmission

3

Gearbox

31

Fig. 5 - Longitudinal section through transmission.

51

3

Transmission

31

Gearbox

Fig. 6 - Longitudinal section through transmission with POWERSHIFT unit.

52

Transmission

3

Gearbox

31

Fig. 7 - Rear axle longitudinal section.

53

3

Transmission

31

Gearbox

B A

A

X

Y

Fig. 8 - Inversor lever (A -Side view and B -Front view) - C - Range reduction lever. X - Version with Mini-reduction Y - Version without Mini-reduction

54

C

Fig. 9 - Gear lever.

Transmission

3

Gearbox

31

Fig. 10 - Front view of gearbox with FULLDRIVE.

55

3

Transmission

31

Gearbox

Fig. 11- Views of the gearbox.

56

Transmission

3

Gearbox

31

Asse ruota

97080.2 +0.2

3.2

M16x1.5

127

1.5

70.7

±0.1

ø

0.4

0.25-0.75

Fig. 12 - Electro - hydraulic control for front-wheel drive engagement/disengagement.

57

3

Transmission

31

Gearbox

Fig. 13 - Gear selector rod. A - bolts securing hubs to rod.

58

Fig. 14 - Gear selector rod. B - C - bolts securing hubs to rod.

Transmission

3

Gearbox

31

Range selector rods and forks

Correct positioning of the gearbox, shuttle and range control levers. Fit the gearbox, shuttle and range control levers so that the grooves are oriented as shown in the figure.

Fig. 15 - Range selector rod. D - bolt securing hub to rod.

Fig. 16 - Correct positioning of the gearbox, shuttle and range control levers.

59

3

Transmission

31

Gearbox

REMOVAL AND REFITTING OPERATIONS

Removal of the front gearbox without removing the platform

— Disconnect the bracket located in the central part of the cable/pipe duct positioned above the engine, and disconnect the oil delivery line to the oil cooler from the hydrostatic steering control valve (this pipe is to be disconnected at its middle part). — Disconnect the front hydraulic lift delivery line from the cock located at the rear of the tractor above the lift. — Position tool 5.9030.002.0 (mobile stands on tracks) to support the front and rear gearboxes, then remove all the screws connecting the two gearboxes together.

— Place wedges under the front axle support and remove the rear wheels; — Disconnect the 3 pipes (supply, return and breather) and disconnect the electrical lead of the fuel level sensor; — Loosen the screws securing the fuel tank supports and remove the tank.

— Put the gear lever in neutral and loosen the two screws securing the relay hub complete with the lower rod which enters the gearbox and then remove the hub. — Put the inversor control lever in neutral and loosen the screw securing the lever in the control rod housing; remove the two relay hub retaining screws and remove the hub itself.

— Disconnect the rear brake pipes which pass over the two gearboxes, collecting the oil in a suitable container (all the oil in the brake oil reservoir will drain out).

— Loosen the hex socket screw (or the two hex socket screws if the tractor is fitted with a minireduction unit) securing the gear control rod (see fig. 28 page 62).

— Remove the two screws securing the platform to the front silent-blocks, and raise the front of the platform a few centimetres using a hoist or a support with adjustment screw; this operation is necessary in order to access and loosen the two upper gearbox retaining screws.

— Holding the rear gearbox in position, move the front wheels to separate the two gearboxes (time required 3,5 to 4 hours)

— Remove the guard from the front-wheel drive transmission shaft, then release the sleeve coupling the transmission shaft to the gearbox, by removing the snap ring securing the lock pin and then removing the pin.

WARNING: under no circumstances undo union B Fig 19 (hex head), located on the left-hand side of the gearbox.

— Slide the sleeve towards the front of the tractor in order to disengage the transmission shaft from the gearbox output shaft.

This union holds the oil manifold D Fig. 19 for engagement of the front-wheel drive transmission shaft. If this union is removed, the manifold would rotate downwards, thereby making it necessary to dismantle the gear hub in order to reposition it and refit the union.

— Using a pair of long-nose pliers, remove the circlip from the gearbox output shaft, thereby allowing the shaft to be withdrawn from the front gearbox. — Disconnect the oil delivery and return lines from the oil cooler located under the platform and to the right of the rear gear box (relative to the driving position). The return line is connected to the POWERSHIFT solenoid control valves as the oil returning from the cooler in the front engine compartment supplies the electro-hydraulic POWERSHIFT control circuit.

The delivery pipe C Fig. 19 of the front-wheel drive engagement actuator is connected at the opposite end, inside the gearbox, to the group of solenoid control valves for the hydraulic services E Fig. 19; if this group is to be removed, undo union A Fig. 19, to prevent deformation of the internal pipe.

— Disconnect the oil line between the POWERSHIFT control unit and the electro-hydraulic services control valve group, then remove the POWERSHIFTsolenoid control valve block, after having disconnected the electrical leads from the solenoid valves. — Disconnect the lubrication line from the solenoid valve block for electro-hydraulic controls to the gearbox. — Remove the tool box positioned on the right-hand side of the tractor under the driving platform. — Unscrew the oil drain plug located under the rear gearbox (a container of at least 33 litres will be required to collect the oil). — Disconnect all electrical leads from the starter motor and the lead connected to the engine oil pressure switch. — Unplug the bulkhead connector for the wires to the group of dashboard warning lights. — Detach the retaining strap of the brake/clutch oil reservoir, disconnect the level sensor lead and remove the reservoir (the reservoir will remain connected to its delivery lines). — Detach the throttle and engine stop Bowden control cables from the governor. — Disconnect the two oil delivery-return lines from the hydrostatic steering cylinder in the area above the engine and near the dashboard. Fig. 17 - Gearbox removal.

60

Transmission

3

Gearbox

31

Fig. 18 - Separate the rear gearbox from the front gearbox

Separating the front gearbox from the engine (this operation is necessary in order to access the POWERSHIFT unit) — Remove the engine pick-up from the top of the gearbox (in the area of the spacer housing). — Place wedges under the front axle support. — Disconnect the fuel delivery pipe in the area between the front gearbox and the engine. — Disconnect the two front brake pipes and the differential lock control pipe. — Support the front gearbox on a stand. — Remove the 10 screws securing the front gearbox to the engine flange, then detach the gearbox.

61

3 31

Transmission Gearbox

· Dismantling the gearbox. — Remove the 8 screws securing the top cover and then remove the cover itself. — Remove the gearbox clutch control located in the spacer housing as follows: — — Remove the thrust bearing. — Remove the lock pin and withdraw the control lever. — Undo the union and remove the oil delivery pipe to the POWERSHIFT unit. — Unscrew the 2 screws and the 2 nuts securing the POWERSHIFT unit; — Remove the 2 retaining screws of the POWERSHIFT control valve unit, (one of these screws also secures the fuel prefilter with the relative pipe). NOTE: one of the screws has an extension with a small plate to support the clutch control lever; these parts are to be re moved together with the screw.

· Removal of the gearbox input and P.T.O. shafts — Remove the circlip attaching the gearbox input shaft to the inversor shaft coupling sleeve. Withdraw the 2 shafts from the front of the spacer housing (the shafts should be withdrawn together to prevent damage to the seal ring positioned between them). NOTE: To replace the seal on the gearbox input shaft, it will be necessary to remove the cab or platform to gain access to the upper cover of the gearbox, from which the seal housing may be accessed.

· Separating the POWERSHIFT unit from the gearbox

— Using a copper drift, tap the housing of the POWERSHIFT unit in order to extract from the front part of the spacer housing; (if the purpose of this operation is solely to inspect or replace the hydraulic clutches, it will not be necessary to remove the epicyclic reduction unit from the gearbox or to remove the cab/platform). — If instead the epicyclic reduction unit is to be removed, simply withdraw it from the front of the gearbox, then remove the calibrated thrust washer and the circlip, and then remove the housing complete with the ring gear. — The POWERSHIFT clutch units are to dismantled on the bench.

NOTE: for instructions on dismantling the POWERSHIFT unit, see page 24.

62

Transmission

3

Gearbox

31

· Removal of the gear train positioned in the front gearbox WARNING: On tractors equipped with POWERSHIFT, first follow the instructions to remove the POWERSHIFT unit and the gearbox input and P.T.O. shafts. For the following operations the driving platform or cab must be removed in order to gain access to the upper gearbox cover.

Before proceeding with the removal of the gear train, it is necessary to remove the selector rods and forks. These operations are only possible after having separated the rear gearbox from the front; before separating the two gearboxes, remove D fig. 5 on page 51. Detach the front gearbox from the rear gearbox. To do this, it will be necessary to remove the 5 speed relay hub together with the intermediate support, located on the right-hand side of the rear gearbox. Remove screw A (fig. 14) screws B (fig. 15) and screw D (fig. 16).

NB: Remove the selector rod detent balls and springs by unscrewing the relative plugs located on the right-hand side of the gearbox. Then proceed with the separation of the two gearboxes. The 3 gearbox shafts (inversor, primary and secondary) and the gear selector and inversor control rods and forks will remain attached to the front gearbox. To remove these rods, it will first be necessary to remove the 3 shafts by removing the 3 circlips A - B - C fig. 5 on page 51 and then moving all 3 shafts simultaneously backwards to disengage them from their housings; the first shaft to be detached will be the primary shaft, followed by the secondary, and then the input shaft located at the uppermost part of the gearbox is to be withdrawn. Each selector rod will come away together with its shaft.

M16x1.5

E

A

D

C

B

Fig. 19 - Oil pipe from the solenoid control valve to the hydraulic actuator responsible for engaging/disengaging front-wheel drive. A Pipe union on solenoid valve end B Pipe union on actuator ende C Connection pipe. D Manifold E Solenoid valve assembly

63

3

Transmission

31

Gearbox

Fig. 20 - Retaining screws of the gear rods to be removed prior to detaching the front gearbox from the rear gearbox. A retaining screw of the inversor control rod hub B

retaining screws of the gear control rod hubs.

C Range gear control rod. D Gearchange control rod. E Inversor/minireduction control rod.

Disassembly of the inversor control rods and forks Disengage the fork from the sleeve and rotate it so that the hole in the fork is aligned with the retaining pin; then, using a drift as shown in figure 23, tap the pin out of the hole. On tractor equipped with a minireduction unit, repeat the above operations to remove the second selector fork.

Fig. 21 - Components of inversor rod and fork assemblye for gearbox with minireduction.

Fig. 22 - Rod and fork for gearbox without minireduction.

Fig. 23 - Removal of the fork retaining pin.

Fig. 24 - Removal of fork from control rod.

64

Transmission

3

Gearbox

31

Dismantling of the gearchange rod and fork assembly.

Fig. 25 - Detach the rod with forks from the secondary shaft by moving it laterally

Fig. 26 - Remove the screw securing the rod hub and remove the hub from the rod.

Fig. 27 - Disengage the 1st gear selector fork from the sleeve and rotate it to align the hole on the fork with the retaining pin. Then, using a suitable drift, drive the pin out of the hole. Detach the 2nd and 3rd gear selector forks and sleeves in the same way.

Fig. 28 - Withdraw the gearchange control rod.

Fig. 29 - Remove the sleeve located on the rod between selector fork.

Fig. 30 - Rotate the 4th and 5th gear the two forks. so that the hole on the fork is aligned with the retaining pin, then using a drift and a hammer as shown in figure 23, drive the pin out of the hole (the figure shows the components of the selector rods and forks assembly).

65

3

Transmission

31

Gearbox

Dismantling of the gearchange selector rods and forks assembly

Fig. 31 - Unscrew the 6 retaining screws and remove the cover giving access to the gearchange selector rods and forks assembly. Then using a spanner, unscrew the guide bolt of the super-reduction control fork.

Fig. 32 - Unscrew the guide screw of the central sleeve lo cated between the 2 forks. (NB. Loctite has been applied to these screws; we recommend that they are heated using an oxyacetylene torch to facilitate removal).

Fig. 33 - Unscrew the guide screw of the L-V selector fork.

Fig. 34 - Access the front compartment of the gearbox extract the rod by pulling the hub.

Fig. 35 - Remove all the parts mounted on the rod, recovering them from the lateral access hole.

Fig. 36 - Parts comprising the selector rod and forks them from the lateral access hole assembly for the super-reduction unit and range gears.

66

Transmission

3

Gearbox

31

Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive Separate the rear gearbox from the front gearbox, (it is first necessary to remove circlip (A fig 37). Unscrew union B ( fig 19 page 63) located on the left-hand side of the rear gearbox and remove the front shaft complete with the front-wheel drive actuator. IMPORTANT: Only unscrew union B fig. (19 page 63) located on the left-hand side of the rear gearbox when the two gearboxes are separated, as refitting is only possible in this condition. Disassemble the unit, removing the circlip securing the oil manifold and the circlip securing the thrust plate of the helical spring; then disassemble the unit into its component parts, inspecting for wear the two oil seals (on the shaft and in con tact with the control piston) and the areas in contact with the oil manifold. WARNING: the valve located inside the shaft must be positioned as shown on page 75.

A

DE F

G

CB

Fig. 37 - Front-wheel drive output.

Removal of the range gear shaft Separate the rear gearbox from the front gearbox, (it is first necessary to remove circlip A fig. 37) remove the right rear wheel support and the cover on which the electro-hydraulic control valves are mounted, detach the oil pipe for 4WD disengagement by undoing union B (fig. 19 on page 65) located on the solenoid valve mounting on the right-hand side of the gearbox. Remove the cover supporting the internal parking brake control. Then remove the synchronised P.T.O. shaft by removing the retaining flange mounted on the rear of the gearbox and remove the synchronised P.T.O. engagement sleeve mounted on the 4WD shaft, which can be accessed through the space left void by removal of the wheel support. Remove circlip B fig. 37 and thrust plate C fig. 37, which can be accessed through the space created by removal of the wheel support. Working through the aperture created by removal of the cover on which the electro-hydraulic control valves are moun ted, remove circlips D - E - F - G fig. 37 and pull shaft towards the front of the gearbox.

67

3

Transmission

31

Gearbox Examining parts removed Gearbox case Gearbox case should show no cracks, bearing seats must not be worn or damaged. If seriuos damage or excessive wear is occured replace the parts concerned.

Fig. 38 - Equipment 5.9030.002.0 for the dismantling the gearbox.

Whenever the gearbox is disassembled clean all sealing surfaces removing old adhesive and applying some new on all surfaces evenly when reassembling.

Shafts Examine shafts for excessive wear and shaft splines for pitting, these should allow the gears to slide freely.

Gears Examine gear teeth for wear or damage and make sure these work on the whole contact surface. Check also the gear-mounted bushings for seizing: if so replace them.

Synchronizers Fig. 39 - Visual control of the tooth of the gears.

Check the ring inside tapered portion for excessive wear or dama ge and be sure the gear part being frictioned by the synchronizer does not show signs of scoring which may prevent the gear from meshing correctly. To check the synchronizer ring for wear, measure the distance + 0, 3 from the friction cone; reading should be 125 , - 0,15 mm with a new synchronizer or drop to zero when the ring is maximally worn.

Bearings

Fig. 40 - Unit synchronizer.

Bearings should be in perfect conditions without showing excessive radial or end play. Holding the bearings pressed by hand and making them simultaneously turn in both directions of rotation a free sliding as well as no roughness at all should be felt. Examine the taper roller bearings for proper working conditions, these should be neither worn nor overheated, replace as soon as poor working efficiency is suspected, as an abnormal bearing operation may result in either gear tooth seizure or noisy gearbox. Warning: oil leakages from the clutch-disk-to-gearbox shaft or the engine-flywheel-to-P.T.O.-clutch shaft may be stopped when the assembly procedure is performed with the utmost care and operating in such a way that the splined parts are prevented from damaging the O-ring and also providing a thorough cleaning of the parts prior to being installed.

Fig. 41 - Checking slide of the bearing.

68

Transmission

3

Gearbox

31

ADJUSTING PLAY OF THE GEARBOX SHAFTS BY MEANS OF THE THRUST PLATES ON THE MINI/INVERSOR SHAFT AND THE SECONDARY SHAFT · MINI/INVERSOR SHAFTS

Circlip position for measurement of distance “X”

Adjusting the play of the minireduction gear mounted on the inversor shaft. Obtain an play X of 0.15 0.30 mm of minireduction gear (z=35) by selecting the thrust plate R of the appropriate thickness from among those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is to be measured by pushing the spacer B in the direction indicated by the arrow up to the point where the synchroniser is pushed up against point Y, while simultaneously pushing the forward speed gear (z=37) in the direction indicated by the arrow up against circlip A.

Circlip position for measurement of distance “X”

Adjusting the play of the forward speed gear on the inversor shaft (version with minireduction). Obtain an play X of 0.15 0.30 mm of the forward speed gear (z=35) by selecting the thrust plate R of the appropriate thickness from among those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is to be measured by pushing the gear (z=23) in the direction indicated by the arrow so that the synchroniser is pushed up against point Y, while simultaneously pushing the minireduction gear (z=35) in the direction indicated by the arrow up against circlip A.

69

3

Transmission

31

Gearbox

· REVERSE SHAFT

Circlip position for measurement of distance “X”

Adjusting the play of the reverse gearwheel mounted on the shuttle shaft. Obtain play X of 0.15 to 0.30 mm of reverse gearwheel (z = 23) by selecting and fitting a thrust washer R of suitable thickness from those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is measured by pushing the forward gearwheel (z=37) in the direction indicated by the arrow, thereby pushing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

· SECONDARY SHAFT 1st SPEED

Circlip position for measurement of distance “X”

Adjusting the play of the 1st speed gear (z=59). Obtain an play X of 0.15 0.30 mm of the 1st speed gear (z=59) by selecting the thrust plate R of the appropriate thickness from among those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is to be measured with a feeler gauge while pushing spacer B in the direction indicated by the arrow so that the synchroniser is pushed up against point Y, while simultaneously pushing the 2nd speed gear (z=50) in the direction indicated by the arrow up against circlip A. 70

Transmission

3

Gearbox

31

· SECONDARY SHAFT 2nd/3th SPEED

Circlip position for measurement of distance “X” Adjusting play of 2nd speed gear cluster Obtain play X of 0.15 0.30 mm of the 2nd speed gear cluster by selecting a thrust washer R of the appropriate thickness from among those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is to be measured using a feeler gauge while pushing the 3rd speed gear in the direction of the arrow, thereby pushing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

Circlip position for measurement of distance “X” Adjusting play of 3rd speed gear Obtain a play X of 0.15 0.30 mm of the 3rd speed gear by selecting a thrust washer R of the appropriate thickness from among those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is to be measured using a feeler gauge while pushing the 3rd speed gear in the direction of the arrow, thereby pushing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

71

3

Transmission

31

Gearbox

· SECONDARY SHAFT 4th/5th SPEED

Circlip position for measurement of distance "X" Adjusting the play of the 4th speed gear cluster. Obtain a play X of 0.15 to 0.30 mm of the 4th speed gear cluster by selecting and fitting a thrust washer R of the appropriate thickness from those available: cod.

008.0251.0

010.0629.0

010.0630.0

010.0631.0

010.0632.0

Play X is to be measured using a feeler gauge while pushing the 3rd speed gear in the direction of the arrow, thereby pushing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

SECONDARY SHAFT

INPUT SHAFT AND INVERSOR SHAFT

Shimming the front bearing of the secondary shaft Fit shims of appropriate thickness to reduce end-float between the shaft and the bearing to the minimum possible amount. By fitting the correct shims you can obtain a maximum play of 0.09 mm.

Fitting the bush joining the input shaft to the inversor shaft Fit bush A oriented as shown in the figure to facilitate subsequent removal.

72

Transmission

3

Gearbox

31

Fitting the spacer determining the stroke of the valve for hydraulic disengagement of front-wheel drive. To allow correct disengagement of the front-wheel drive, bush A must be installed as shown in the figure above.

WARNINGS RELATED TO ASSEMBLY OF THE GEARS OF THE P.T.O. UNIT, THE RANGE REDUCTION UNIT AND THE SYNCHRONISED P.T.O. SHAFT Assembly of the P.T.O. Install: — The synchronised P.T.O. output shaft (to be installed after the range reduction unit); — The P.T.O. output shaft and relative gears; — The rear P.T.O. Shaft.

Installation of the range reduction unit, the gear for the front-wheel drive shaft and the parking brake discs — Position on the bottom of the gearbox the L-V range reduction unit (complete with bushes and roller cage) and the super-reduction gear (complete with roller cage). — Slide the shaft, complete with circlip, through the front end of the gearbox, and fit the previously positioned gears onto the shaft. — Fit the thrust washer and 2 circlips. — Position the drive gear of the front-wheel drive complete with parking brake discs. — Fit the ball bearing for the rear end of the shaft, inserting it in its housing in the gearbox. — Insert the thrust washer and position the circlip. — Position the bearing and the bearing circlip in the housing; — Fit the thrust washer and the circlip; — Install the synchronised P.T.O. shaft in the rear end of the gearbox, and fit the control sleeve to the shaft. — Fit the bevel pinion and the gears of the range reduction unit with the relative synchroniser; — Fit the differential housing complete with the crown wheel and the internal differential lock control. Warnings: The spacer installed on the rear output shaft is fitted with an O-ring on the outer surface and an internal oil seal. To remove this spacer requires the use of a puller to be attached to the spacer using the two holes provided. At each dismantling of the pins of the brake and clutch control levers, check the bushes for wear.

73

3

Transmission

31

Gearbox

Fig. 42 - Range gearbox

Fig. 43 - Removal of the groundspeed P.T.O. sleeve.

Fig. 45 - Gears on range gearbox shaft.

74

Fig. 44 - Removal of the circlip securing the shaft.

Fig. 46 - Checking the oil seals on the 4WD shaft.

Transmission

3

Gearbox

31

Fig. 47 - Range gearbox synchronizer.

Fig. 48 - Secondary shaft cover plate

Range gearbox synchronizer. Warning: the synchronizer hub must installed so that the indicated by the arrow is positioned as shown in the figure.

Fitting the secondary shaft cover plate. Fit the cover A applying LOCTITE 601 around the hole of the front gearbox casing indicated X in the figure. B - secondary shaft

Fig. 49 - Fitting the transmission speed sensor pickup.

75

3

Transmission

31

Gearbox

Fitting the baulk ring of the synchronizer for the 1 speed gear mounted on the secondary shaft. Should it be necessary to restore the correct play X of 0.15 to 0.30 mm of the 1 speed gear (z=59), it is possible to select a synchroniser baulk ring of suitable thickness from the two available, as shown in the figure.

Fig. 50 - it the 50x90x20 ball bearing, indicated A in the figure, without the retaining ring.

Fig. 51 - Bearing for 4WD shaft.

Fig. 52 - Position the groundspeed P.T.O. cover plate as indicated in the figure.

st

st

76

Transmission

3

Gearbox

31

Points where sealant is to be used

Fig. 53 - Rear gearbox. Apply LOCTITE n° 601 to the base of studs A (n° 9) - B (n° 1) - C (n° 1), as shown in the figure, prior to assembly.

Fig. 54 - Fitting the wheel support. Apply PIANERMETIC 510 sealant to the surfaces indicated with the letter L in the figure; apply SILASTIK sealant to the surfaces indicated with the letter S.

77

3

Transmission

31

Gearbox

A

11"

12"

Fig. 55 - Correct installation of the support tube for the clutch control sleeve. Position the gearbox vertically with side A facing upwards. Apply Loctite 601 to the seat of the tube and fit the tube. Wait about 1 hour before returning the gearbox to the horizontal position.

Tightening torques Degrease and clean all bolts/screws before tightening.

Kgm

Nm

7÷8

68 ÷ 78

differential flange retaining bolts

6

58

bolts securing differential cage to half-shafts

6

58

9,2 ÷ 10,3

90 ÷ 100

10 ÷ 12

98 ÷ 115

9 ÷ 12

88 ÷ 107

bevel gear retaining nut

28 ÷ 30

274 ÷ 294

nuts securing gearbox to intermediate transmission casing

10 ÷ 12

98 ÷ 107

7÷8

68 ÷ 78

crown wheel retaining bolts

rear carrier retaining nuts (on assembly apply PIANERMETIC 510 sealant to threads) P.T.O. shaft retaining nut gearbox-engine flange bolts

hex socket screws for reduction unit ring gear (on assembly apply LOCTITE 242 to screws)

78

Transmission

3

Gearbox

31

IMPORTANT INSTRUCTIONS

Fig. 56 - Positioning of the 4WD shaft complete with engage ment/disengagement system. After positioning the shaft, connect the oil manifold to solenoid control valve (located on the mounting on the right-hand side of the gearbox) using the specially shaped pipe.

Fig. 57 - After positioning the pipe, connect the oil manifold by inserting union A from the left-hand side of the gearbox. The PICK-UP speed sensor must be installed in hole B indicated by the arrow (see instructions on page 77).

Fig. 58 - The pipe connecting the hydraulic control of the front-wheel drive must be connected to the solenoid valve block at the external fitting indicated by the small arrow.

Fig. 59 - The POWERSHIFT unit is to be installed in the gearbox and the shaft end-float adjusted with the shaft engaged with the epicyclic reduction unit.

Fig. 60 - End-float is to be adjusted by fitting a shim of appro priate thickness following the instructions given on page 35.

Fig. 61 - Checking shim thickness using a micrometer.

79

3

Transmission

31

Gearbox

Fig. 62 - Fitting the shim to adjust end-float of the POWERSHIFT shaft.

Fig. 63 - Positioning the epicyclic reduction unit of the POWERSHIFT in the front gearbox.

Fig. 64 - Fitting the epicyclic reduction unit inside the housing previously attached to the gearbox output shaft.

Fig. 65 - POWERSHIFT unit installed in the gearbox.

Fig. 66 - Oil seal on shaft between clutch and gearbox. This seal can be renewed by accessing the inside of the front gearbox.

Fig. 67 - Positioning the P.T.O. clutch unit inside the ge arbox.

80

Transmission

3

Differential gear

35

Bevel drive adjustment (see figs. 1 and 3) Install the pinion in the gearbox together with the bearings pack A (without interposing shims); position gear B and tighten ring nut to a torque of: 28 30 Kgm (275 294 Nm). Fit the differential housing without the crown wheel; shim up the tapered bearings D and E so that they rotate freely in the housings yet a slight preloading can be felt; then add a 0,1 mm. shim to the pack in order to preload the bearings. Adjust the distance F between the differential housing and the head of the pinion, interposing shims in the position G indicated in figure 1; the exact measurement for this adjustment is obtained by adding or subtracting the value stamped on one of the pinion teeth to/from the base value of 2.5 mm. Secure the bearings pack by inserting a circlip (select one from those supplied in thicknesses of 2.8 3.6 mm. (see figure 1) which fits perfectly in the seating preventing any bearing play. nstall the crown wheel in the differential housing and, with a dial gauge, measure the crown wheel/pinion backlash; the correct value range is 0,17 0,23 mm for tractor in the version 30 Km/h and 0,20 ÷ 0,27 mm for tractor in the version 40 Km/h (see figure 4 on page 82). If the measured backlash does not come within this range, remove shims from pack D and add them to pack E, to move the crown wheel nearer to the pinion, or vice versa to move it further away. NB.: On completion of the bevel drive adjustment operations, loosen off the ring nut, apply Loctite 270, then tighten to a torque of 28 30 Kgm (275 294 Nm) and then stake the pinion retaining nut. Tighten the crown wheel retaining screws to a torque of 7 8 kgm (68 78Nm).

Fig. 2 - Value stamped on a tooth of the pinion.

C - SNAP RING 2.1419.056.0/10 2.1419.057.0/10 2.1419.058.0/10

99x2,8 99x2,9 99x3,0

2.1419.059.0/10 2.1419.060.0/10 2.1419.061.0/10 2.1419.062.0/10 2.1419.063.0/10 2.1419.064.0/10

99x3,1 99x3,2 99x3,3 99x3,4 99x3,5 99x3,6

Fig. 1 - Shimming the bevel pinion.

Fig. 3 - Shimming the crown wheel.

81

3

Transmission

35

Differential gear

Fig. 4 - Checking the backlash between the crown wheel and pinion.

Servicing operations Installation of the bevel drive without renewing any parts. New adjustment is not required; make sure that the same shims packs are refitted in the same places, and check that the distance between the head of the pinion and the differential housing is as prescribed. Renewal of crown wheel bearings Shim the bearings to obtain a preloading of 0,1 mm; then adjust backlash between the crown wheel and pinion. Renewal of pinion bearings The bevel drive will require adjustment. Installing the rear differential lock The rear differential lock system does not require any adjustment.

Fig. 5 - Parts comprising the differential unit.

82

Fig. 6 - Rear differential lock control.

Transmission

3

Power take-off

36

Rear power take-off Rear P.T.O. gears The rear P.T.O. shaft, directly coupled to the engine, is equipped with a selector allowing selection of P.T.O. speeds of 540/1000 rpm or, on request, 540-750-1000 rpm. The selector is of the sliding sleeve type. The selector is mechanically controlled and can only be operated when the moving parts are stationary. The P.T.O. output shaft rotates in a counter-clockwise direction, as viewed from the rear of the tractor. Fitting the rear P.T.O. output shaft Before installing the studs, remove any oil/grease from the threads, then apply “LOCTITE 242". Technical characteristics P.T.O. speeds 540 r.p.m. 540 r.p.m. 750 r.p.m. 750 r.p.m. 1000 r.p.m.

AGROPLUS 60 AGROPLUS 70 - 80 AGROPLUS 60 AGROPLUS 70 - 80 AGROPLUS 60 - 70 - 80

14/53 13/50 16/50 15/46 20/46

= = = = =

1/3,7857 1/3,8462 1/3,1250 1/3,0660 1/2,3000

P.T.O. r.p.m.

engine r.p.m.

P.T.O. r.p.m.

P.T.O. r.p.m.

engine r.p.m. at max horsepower speed

P.T.O. r.p.m

engine r.p.m. at fas idling speed

engine r.p.m. at fas idling speed

for 60 HP 540 r.p.m. (2045 engine r.p.m.)

620/2350

3,7857

(657/2490) ÷ (665/2520)

(171/650) ÷ (184/700)

for 70 - 80 540 r.p.m. (2077 engine r.p.m.)

611/2350

3,8462

(647/2490) ÷ (655/2520)

(169/650) ÷ (181/700)

for 60 HP 1000 r.p.m. (2033 engine r.p.m.)

1022/2350

2,3000

(1082/2490) ÷ (1095/2520)

(282/650) ÷ (304/700)

for 70 - 80 HP 750 r.p.m. (2343 engine r.p.m.)

752/2350

3,1250

(797/2490) ÷ (806/2560)

(208/650) ÷ (224/700)

766/2350

3,0660

(812/2490) ÷ (822/2520)

(212/650) ÷ (228/700)

power take-off

for 60 - 70 - 80 HP 750 r.p.m. (2300 engine r.p.m.)

Synchronised P.T.O.

P.T.O. revolutions for each wheel revolution

14,7400

83

3

Transmission

36

Power take-off

Fig. 1 - 540 - 1000 r.p.m. selector.

Fig. 2 - 540 - 750 - 1000 r.p.m. selector

84

Transmission

3

Power take-off

36

ADJUSTMENT OF THE P.T.O. CONTROL LINKAGE Disconnect tie-rod B from lever D. Move control lever A and lever D to the 540 rpm position. Turn fork C to adjust the length of tie-rod B so that the hole in the fork is perfectly aligned with the hole in lever D; then screw in fork C by a 1/2 turn and connect tie-rod B to lever D. Warning: after adjusting the tie-rod, move the control lever to neutral position and check that the P.T.O. output shaft rotates freely when turned manually. NB: For versions with 3-speed P.T.O., check also that output shaft turns freely when the control lever is in the second neutral positi on.

2-SPEED VERSION 540 – 750 R.P.M. WARNING: on assembly, position the lever indicated with the arrow so that head of the lock screw is facing the front of the tractor.

2-SPEED VERSION 540 – 1000 R.P.M.

Fig. 3 - P.T.O. controls and output shafts (2-speed version) for 60- HP models

85

3

Transmission

35

Power take-off

Fig. 4 - P.T.O. controls and output shafts for 60 HP models (3-speed version)

86

Transmission

3

Power take-off

36

9 kgm (90 Nm)

Fig. 5 - P.T.O. controls and output shafts for 70 - 80 HP models (3-speed version)

87

3

Transmission

36

Power take-off

P.T.O. clutch General characteristics The P.T.O. clutch is a wet-type multidisc clutch and is operated by hydraulic pressure. The oil required for the P.T.O. hydraulic control is drawn from the gearbox and filtered before it arrives at the gear pump located on the right-hand side of the gearbox. The clutch control is electro-hydraulic. The electro-hydraulic system controls the circuit by means of a solenoid valve, which supplies oil under pressure to the clutch control piston. In both cases, the driving discs and driven discs are forced together, thereby transmitting drive to the output shaft. The P.T.O. clutch brake is operated mechanically by the piston during the return stroke determined by the helical clutch release spring. Three pins connected to the piston press against the brake counter disc.

Fig. 6 - Cross section view of the P.T.O. clutch.

88

Transmission

3

Power take-off

36

Technical specifications P.T.O. Clutch Clutch

oil-immersed multiple disc with axial piston

number of friction discs

5

diameter of discs thickness of assembled friction discs minimum maximum

105 mm mm

number of intermediate discs

27.32 29.90 5

disc lubrication pressure

bar

5

P.T.O. clutch relief pressure setting

bar

11

P.T.O. pressure control valve

bar

restrictor valve

mm

16

+2 0

1.1

Correct positions of P.T.O. sensors and cables

A - 3-speed P.T.O. for 70-75-85 HP models

B - 3-speed P.T.O. for 55-60-65 HP models

C - 2-speed P.T.O.

Springs technical data: Piston return spring diameter of wire

mm

6

external diameter

mm

52,5

spring relaxed

mm

50

spring compressed

kg 82 (808 Nm ) mm ) mm kg

98

(978

Nm

28 23,4

89

3

Transmission

36

Power take-off

WARNING: to prevent oil leaks between the oil delivery and lubrication manifolds, apply Loctite 542 to the threaded parts. CORRECT INSTALLATION OF PINS ON P.T.O. CLUTCH CONTROL PISTON Insert the three pins and install the three grub screws, applying IDRAULERMETIC 542 to the threads, and tighten up against the pins; then unscrew each screw by a 1/4 turn to obtain a clearance of 0.25 between the pins and the piston. Fig. 7 - Rear P.T.O. control.

90

Transmission

3

Power take-off

36

Clutch inspection Inspect the contact surfaces of the clutch friction discs. If worn or torn, the discs must be replaced. Inspect the control piston and replace if scored. Inspect the clutch hub. If depressions are worn into the tops of the splines on which the friction discs slide, the hub must be replaced. Check the efficiency of the piston return spring. The spring characteristics should match those specified in the relative table; if not, replace the spring. Examine the seals of the clutch control piston and the clutch brake piston and the brake disc. Replace if worn. At each assembly of the P.T.O. clutch, carefully clean the oil ways in the clutch housing; use a compressed air jet if ne cessary.

Checking clutch disc clearance With new discs installed, check that clearance A (Fig. 8) is 0.5÷2 mm . If the clearance exceeds the maximum value, fit one shim (code 2.1599.499.0) in the position indicated by the arrow. Warning: Apply IDRAULERMETIC 542 to the threads of the three screws A before fitting; fully tighten the screws and then back off each screw a 1/4 turn to obtain a clearance of 0.25 mm between the head of the pin and the piston.

Fig. 8 - Checking clutch disc clearance. A - If the clearance exceeds the maximum prescribed value, fit one shim code 2.1599.499.0

91

3

Transmission

36

Power take-off

Checking clutch hydraulic pressures Connect the mini fitting code 009.2923.4 (with M4 12x1.5 threaded fitting) to the electro-hydraulic control unit as shown in figure 9. Connect tool 5.9030.517.4 to the fitting and attach the pressure gauge 5.9030.514.0. Operate the control valve and check that the pressure gauge shows a reading of approximately 16 bar. For instructions on measuring pressure and relative values see the chapter “electro-hydraulic controls”.

Fig. 9 - Checking the operating pressure in the P.T.O. clutch control circuit.

92

Transmission

3

Power take-off

36

Checking the end-play of the front shaft of the P.T.O. clutch On the front shaft of the P.T.O., install circlip A and thrust washer B code 2.1599.761.0; position the shaft in the clutch unit and push it towards the front of the tractor so that it rest up against the oil seal shown in figure at C, then check that clearance between the thrust washer B and the clutch hub is not less than 1 mm. If the clearance is less than 1 mm, remove thrust washer B.

Fig. 10 - Checking the end-play of the front shaft of the P.T.O. clutch.

Installing the waterproof seals rear P.T.O. output shaft and synchronised P.T.O. Fit the seal using a suitable installation tool; the seal is to be oriented as shown in the figure and pressed in to the full depth of the tool. The measurements indicated here are to be used to construct the oil seal installation tool.

Fig. 11 - Installation of the waterproof seals.

93

3

Transmission

36

Power take-off

Fitting the P.T.O. shaft

In the event of interference between shaft B and flange A, heat the flange to allow cou pling. Before fitting plate D, apply Pianerme tic 510 to the surfaces E of shaft B. Tighten bolt C to a torque of 68 Nm (7 kgm).

Fig. 12 - Fitting the P.T.O. shaft with interchangeable output shaft (on certain models only).

RENEWAL OF THE REAR P.T.O. CLUTCH The P.T.O. clutch unit can be removed without having to remove the driving platform. proceed as follows: — Remove the top link; — Detach the lift rods of the 3-point linkagefrom the lift arms; — Detach the lift control rods from the control levers; — Disconnect the oil delivery pipe to the auxiliary control valves from the rear pump; — On models with 4-way control valves, detach the oil pipe from the lift control valve to the auxiliary hydraulic control valves. On models with 6-way control valves, detach also the pipe from hydraulic control valves to the upper gearbox cover plate (for 4-way control valves); — Disconnect the control levers of the hydraulic control valves from the relay levers connected to the control valves, by removing the relative cotter pins and retaining pins; — Remove the 3 screws securing the hydraulic control valve from the support bracket; — Disconnect the fuel tank breather pipe in the area above the lift; — Remove the 10 screws and the two nuts securing the lift unit to the rear gearbox; — Attach the lift unit to a hoist and lift it clear of the tractor (when removing the lift unit, take care not to damage the threads on the two studs); — Unscrew the screws securing the P.T.O. access cover (located above the gearbox) and remove this cover; — Using a suitable lever, push towards the front of the tractor the sleeve coupling the P.T.O. clutch output shaft to the P.T.O. rear shaft; — Loosen the two screws and remove the rear shaft bearing stop plate; NOTE: when removing this plate, take care that the spacers positioned underneath it do not fall into the gearbox. — Unscrew the 3 retaining screws and remove the top flange located at the rear of the gearbox. Then withdraw the bearing together with the upper 540 rpm gear. NOTE: when withdrawing the gear, take care that the roller bearing located in the gear does not fall into the gearbox. — Disconnect the pipe supplying oil for lubrication of the inversor shaft and to the oil-bath for the P.T.O. clutch discs, located on the right-hand side of the gearbox, by undoing the relative union; then remove the union of the oil supply pipe to the P.T.O. clutch; — With the aid of a lever, push the P.T.O. shaft a few centimetres to the rear; This will only be possible if the shaft is positioned in such a way that there is no interference between the teeth of the gear and those on the shaft; — Slide the sleeve onto the rear shaft after having first pushed the bearing located in the wall of the gearbox back a sufficient distance; — Push the clutch unit together with the front shaft and the output shaft to the rear, so as to be able to withdraw the front shaft to the front P.T.O. unit; — Extract the complete clutch unit, disengaging it from the rear shaft; — Inspect the clutch discs and renew them if necessary, removing the large circlip and the spacer. WARNING: on re-assembly, after having positioned the clutch unit complete with the front shaft, refit the two oil unions in order to ensure that the unit is positioned correctly, then insert the rear shafts and complete the assembly.

94

Transmission

3

Power take-off

36

MAIN OPERATIONS FOR REMOVAL OF THE REAR P.T.O. UNIT.

Fig. 13 - The rear P.T.O. clutch may be removed without hav ing to remove the cab from the tractor. Disconnect the controls of the auxiliary control valves.

Fig. 14 - Remove the lift and the front cover of the rear gearbox to gain access to the P.T.O. clutch unit.

Fig. 15 - Release the rear shaft of the P.T.O. towards the rear.

Fig. 16 - Remove the circlip on the front clutch shaft.

Fig. 17 - If necessary, push the rear shaft support bearing for ward and withdraw the sleeve coupling the 2 rear shafts of the P.T.O. together.

Fig. 18 - Disconnect the oil supply pipes and remove the complete P.T.O. clutch unit from the gearbox.

95

3

Transmission

36

Power take-off OPERATIONS FOR REMOVAL OF THE REAR P.T.O. UNIT

Fig. 19 - Withdraw the front shaft from the clutch unit.

Fig. 20 - Check that the clutch hub slides freely in its housing.

Fig. 21 - Check the condition of the lube pipe and nozzle for the hydraulic pumps drive gears.

Fig. 22 - Remove the circlip securing the clutch discs.

Fig. 23 - Remove the clutch discs.

Fig. 24 - The complete disc pack can be extracted along with the clutch hub.

96

Transmission

3

Power take-off

36

Fig. 25 - Inspect the piston; note the three pins of the clutch brake, which is engaged by the action of the clutch release spring in the absence of hydraulic pressure.

Fig. 26 - Remove the thrust washer from between the spring and the clutch hub.

Fig. 27 - Inspect the clutch discs for wear.

Fig. 28 - Examine the condition of the counter disc.

Fig. 29 - Examine the teeth of the clutch hub.

Fig. 30 - Remove the circlip securing the hydraulic manifold of the clutch unit.

97

3

Transmission

36

Power take-off

Fig. 31 - Remove the shoulder plate.

Fig. 32 - Remove the lube pipe for lubrication of the hydraulic pump gears.

Fig. 33 - Completely disconnect the lube pipe.

Fig. 34 - Remove the clutch oil supply manifold.

Fig. 35 - Check the manifold oil ways and check the manifold for wear.

Fig. 36 - Remove the snap rings and check for signs of wear.

98

Transmission

3

Power take-off

36

Fig. 37 - The two holes at the front of the manifold as shown in the figure serve for lubrication of the clutch discs, while the large hole to the rear of these supplies the oil to operate the clutch control piston.

Fig. 38 - Examine the seals on the oil supply fittings.

Fig. 39 - Dismantle the two oil supply fittings and examine them.

Fig. 40 - Remove the brake disc of the clutch unit.

Fig. 41 - Remove the circlip securing the brake disc thrust plate.

Fig. 42 - Extract the two thrust plates together with the brake disc.

99

3

Transmission

36

Power take-off

Fig. 43 - Examine the clutch brake disc pack.

Fig. 44 - Check the three pressure pins for wear.

Diagnosing malfunctions check the hydraulic system of the sole noid valve block

replace the springs of incorrectly calibrated valves check the seals on the piston and manifold

if necessary, replace the defective parts

the clutch slips check that the pi ston slides freely

eliminate any roughness preventing free movement

check the clutch plates for wear

replace the plates

check the control linkage

the clutch fails to disengage

100

incomplete control valve stroke, solenoid valve faulty

check the plates

piston stuck

replace the piston

replace the defective parts

replace the plates

plates burned

eliminate any roughness preventing free movement

plates jammed

Drive axles - axles

4

Rear axle

44

Rear axle

Fig. 1 - Rear axle.

Installing the rear half-shafts (fig. 2) — The half-shafts are fixed to the planet gear carrier flange of the epicyclic reduction unit by means of a plate inserted in the flange and attached to the internal face of the half-shaft by a screw. — The correct position of the half-shaft in the trumpet housing is determined by the shim pack A indicated in figure 2. To install the half-shafts, proceed as follows: — secure the half-shaft in a vertical position to prevent its rotation; — press the rings of bearings B and C into the respective housings in the trumpet housing; (before installing the ring of bearing C, position the cover underneath to retain the grease); — then fit spacer I, oil seal D and bearing E to the half-shaft. Slide the trumpet housing onto the half-shaft, fit oil seal H and bearing F, then position the planet carriers; — secure the assembly by way of the plate and screw G, interposing a shim pack A between the plate and the half-shaft to obtain a rolling drag torque of 8 to 12 Nm; — apply LOCTITE 270 to screw G and tighten to a torque of 18 kgm (177 Nm).

101

4

Drive axles - axles

44

Rear axle

Fig. 2 - Fitting of rear stub axles.

Fig. 3 - Fitting of rear stub axles.

102

Fig. 4 - Halfshaft securing plate. A - Planet carrier housing B - Spacer

Drive axles - axles

4

Rear axle

44

Fig. 5 - Fitting of bearing to halfshaft.

Fig. 6 - Fitting of O-ring to stub axles.

103

4

Drive axles - axles

44

Rear axle

Removal and disassembly of the epicyclic reduction unit Unscrew the three screws securing the planet carrier B ( Fig. 7) to the half-shaft. Then remove the spacer and the flange, and recover the underlying shim pack. Remove the epicyclic reduction unit and disassemble it into its component parts as follows: 1 - using a hammer and drift, remove the pin securing journal A of planet gear B (Fig. 8). 2 - withdraw the journal and remove the planet gear together with the roller cage and the two thrust washers. 3 - Remove bearing A from the flange of epicyclic reduction unit B, using a suitable puller (Fig. 9).

Fig. 7 - Removing the spacer. A - Flange B - Planet carrier

Fig. 8 - Epicyclic reduction unit. A - Journal B - Planet

104

Fig. 9 - Removing the bearing from the epicyclic reduction unit flange.

Drive axles - axles

4

Rear axle

44

FITTING LATERAL STUB AXLES OF THE WHEEL

Fig. 10 - Before installing the trumpet housing, position sleeve A of the synchronised P.T.O..

Fig. 11 - Position the inner half-shaft in the differential housing.

Fig. 12 - Fit the differential housing support flange and then install the brake piston and brake disc.

Fig. 13 - Install the thrust plate of the brake disc. The side shown in the figure is to be positioned in contact with the brake disc.

Fig. 14 - View showing the side of the brake disc thrust plate to be positioned in contact with the ring gear of the epicyclic reduction unit.

Fig. 15 - Fit the trumpet housing with the aid of a hoist.

105

4

Drive axles - axles

42

2 W.D. extendible axle

2WD extendible axle General information The wide sideways front axle swinging obtained through excellent anchoring, not only makes it possible to operate the tractor nimbly on steep slopes but also permits the axle to be easily removed from the tractor when any repair is to be performed. End play check is the only operation required on axle reassembly. The telescopic-type axle is extremely rugged and enables the tread to be adapted to any work requirements without removing the hydrostatic steering cylinders.

Fig. 1 - Extendible front axle pivot system.

Tecnical specifications front axle tread - minimum - base - maximum toe-in wheel caster angle

AGROPLUS 60-70-80 mm mm mm

1300 1400 1600

mm

2÷4 3°

axle swinging angle tyre inflating pressure lubricating grease type steering angle

106

10° bar Kg/cm²

2,4 2,40 NGLI 2 LITIO / Ca 70°

Drive axles - axles

4

2 W.D. extendible axle

42

Fig. 2 - Front axle assembly parts. 1 2 3 4 5 6 7 8 9 10

steering track rod clamp sleeve ball-and-socket joint external steering lever ubricating nipple snap ring thrust ring seal ring power steering cylinder

11 12 13 14 15 16 17 18 19 20

shoulder ring bushing seal ring bushing side LH axle cover seal ring castellated nut shoulder ring external bearing

21 22 23 24 25 26 27 28 29 30

wheel hub spacer ring internal bearing retaining ring wheel shaft O.ring axial bearing pin centre axle axle securing pin

31 32 33 34 35 36 37 38

shims pin disk lower taper roller bearing centre steering lever upper taper roller bearing cover spacer ring

107

4

Drive axles - axles

42

2 W.D. extendible axle

Removing the axle from the front support

Fig. 3 - Place some suitable vessels beneath the steering control cylinders, then loosen unions A of control cylinders C from hoses B side.

Fig. 4 - Loosen both securing screws of pin A to axle support B.

Fig. 5 - Using a hammer and light-alloy punch tap on rear end of pin A.

Fig. 6 - By way of both levers A withdraw pin B forward and re cover the shims interposed between flange and front support. Ensure the securing pin surface shows no flattening, craking or chipping, replace the pin if necessary.

WARNING: Keep the two shim packs separated so that the correct position can be restored on reassembly.

Fig. 7 - Remove the axle from the front support by tapping a few times the axle centre portion with the hammer. Lower axle A very slowly and make sure that it does not touch other parts in the process, then remove shoulder rings B.

108

Fig. 8 - Ensure that bushes A of the centre axle are not worn, checking for well-evident indentations, remove the bushes by hammer and punch if necessary.

Drive axles - axles

4

2 W.D. extendible axle

42

Carry out installation according to the following procedure: — Use very fine abrasive paper to remove any signs of oxidation from both pin and front support; — Bushes and pin should be properly lubricated with the specified grease type; — Coat the front support shoulder rings with grease to make positioning easier;

— Place rear shoulder ring D and push the pin almost fully inward; — Fit shims G adjusting as instructed on page 216 and then fasten front axle pin securing screws H; — Top up the oil in the hydrostatic steering system and bleed the air from the system (see chapter on hydrostatic steering).

— Making use of a hammer and light alloy punch tap on spacer F so as it may be moved toward the front side; — Insert pin E into the spacer and fit front shoulder ring B; — Lift the axle and insert the pin into bush C;

A B C D E F G H

Front carrier Front thrust plate Axle bushes Rear thrust plate Pin Spacer Shims Bolt

Fig.9 - Front axle longitudinal section.

109

A B C D E F G

4

Drive axles - axles

42

2 W.D. extendible axle

Snap ring Thrust ring Seal ring Power steering cylinder Grease nipple Pin Castellated nut

Fig. 10 - Front Axle A B C

Castellated nut Ball-and-socket joint External steering lever

— Check steering rod ball-and-socket joints for damage or wear and make sure the are able to rotate freely and without excessive play inside their seats. — Ensure the rubber ball joint guard is intact, otherwise replace the ball joints. — Examine the operating rods for damage or warping. Replace if required.

Fig. 11 - Steering arms.

110

Fig. 12 - Steering linkage. A Steering rods B Ball-and-socket joints C Centre steering lever

Drive axles - axles

4

2 W.D. extendible axle

42

Centre steering lever

— Use a universal puller to remove centre lever A together with bearing B. — Still using a universal puller (see fig. 15) remove bearing C and disk B along with O-ring A.

— Make sure the centre lever is not warped or damaged, otherwise replace.

Fig. 13 - Centre steering lever. A Centre steering lever B External bearing races

— Carefully examine the bearings turning them slowly, if the bearing is sound no vibrations, noise nor slight jam-ups shall be felt.

— Fix centre lever A in a vice if required, and using a light-alloy hammer and punch remove tapered bearing outside races B, located in the centre hole (Fig. 14), taking care to remove first the upper race having smaller diameter by tapping from inside outward. — Re-install the centre lever operating in reversed removing order and accordingly with the following procedure:

Fig. 14 - Centre steering lever bearing. A Centre steering lever B Upper tapered-roller bearing

– Before assembly carefully lubricate the tapered-roller bearings and related races.

– Before mounting the lower bearing in the axle fit a new disk and a new O-ring.

– When installing the castellated nut keep to the following instructions:

– Tighten the nut fully to bed the bearings properly – Loosen the nut and tighten again until all plays have been taken up,

then fit a new check pin. If the hole in the pin is not in the same line as the cut in the nut, tighten the nut furtherly as long as a new check pin can be inserted.

— When the reassembly is completed perform pin and bearing lubrication with the specified grease type just operating the lubricating nipples placed on the lever.

Fig. 15 - Removing the centre steering lever Cbearing. A O.ring B Disk C Tapered-roller bearing

111

4

Drive axles - axles

42

2 W.D. extendible axle

Fig. 16 - Removing the wheel hub. A Tractor wheel B Safety stand C Front axle

Fig. 17 - Removing the guard cover. A Check pin B Gasket C Cover D Hub E Nut

Fig. 18 - Using a puller to remove the wheel hub. A Wheel hub shaft pin B Whole wheel hub

112

Fig. 19 - Wheel hub components. A Ball bearing B Spacer C Hub

D E

Ball bearing Oil seal

Wheel hub — Using a universal puller withdraw whole wheel hub B from pin, (Fig. 18) . — Make use of a suitable puller to remove front ball bearing A and take spacer B, (Fig. 19). — Remove retaining ring E by prising, then using a proper puller remove rear ball bearing D, (Fig. 19). — Before assembly coat bearings B and D and new retaining ring A with the recommended grease, (Fig. 20). — Carefully insert retaining ring A using a light-alloy hammer and punch. — Install wheel hub C onto pin G tapping slightly with the hammer for proper bedding. — Tighten castellated nut E to the prescribed torque. — Make sure the nut cut is duly aligned with the check pin hole in the pin, otherwise tighten the nut furtherly to make them coinciding and re-install the check pin. — Ensure wheel hub C end play is 0.12 to 0.48 mm with respect to wheel shaft pin G.

Fig. 20 - Section view of the wheel hub. A Oil seal B Innner ball bearing C Whel hub D Outer ball bearing

E - Castellated nut F - Thrust plate G - Whel shaft pin H - Space

Drive axles - axles

4

2 W.D. extendible axle

42

Inspections and checks Clean bearings and the other parts carefully, then dry using compressed air. Carefully examine the bearings turning them slowly, if the bearing is sound no vibrations, noise nor slight jam-ups shall be felt. Carefully examine bearing race and rolling member conditions ensuring no scoring, marking, grinding signs due to foreign matter abrasion are noticed, otherwise replace the bearing.

WARNING: Should a bearing be no more serviceable, both the internal and the external bearings must be replaced.

Fig. 21 - Wheel hub lubricating hole. A Clearance hole B Wheel huba

Make sure the wheel shaft has suffered no damage and threading is whole, replace if required. Ascertain clearance hole A permitting the external cover to be fixed is not obstructed by foreign matters, if so remove any clogging to allow hub B to be properly lubricated. Wash any components carefully and dry with compressed air. Be sure no signs of oxidation are visible on the wheel shaft, if so remove with very fine abrasive paper. Check the shaft for either warp or damage, if so replace the shaft. Carefully inspect the axial bearing making sure no grinding, scoring or marking are evident neither on the rolling members nor on the bearing races, otherwise replace the worn parts. Check side axle upper and lower bushes B for wear, ascertaining they still show evidence of the purpose-made indentations, otherwise replace.

Fig. 24 - Wheel pivot bushes. A Clearance hole

Fig. 22 - Removing the steering lever. A External steering lever B Gasket C Wheel shaft

Fig. 23 - Removing the wheel pivot axial bearing. A Wheel shaft B Axial bearing C O.ring D Axial bearing race

113

4

Drive axles - axles

42

2 W.D. extendible axle Correct track rod assembly (Fig. 25). Rotate sleeve A around its axis so that knuckle B is in the position shown in figure, i.e. make sure the knuckle working angle is 90°, then insert and tighten both the sleeve securing bolts.

End float adjustment (Fig. 26). Push the axle towards the rear and, using a feeler gauge, check that the maximum end float “G” does not exceed 0.4 mm. — If the end float exceeds this value, proceed as follows. — Unscrew bolts E securing pin B to the front carrier A; — Slightly move the pin and remove some of shims D to restore correct end float. — Re-tighten bolts E and check end float again.

Fig. 26 - Track rods. A Sleeve B Steering knuckle

Fig. 25 - Adjusting the endfloat of the front axle . A Front carrier B Pin C Thrust plate D Shims E Bolt

114

Drive axles - axles

4

4 W.D. front axle

43

FRONT-WHEEL DRIVE Specifications Front drive axle ratios reduction gear-front-wheel drive

30 km/h 40 km/h

bevel gears final epicyclic reducer

21/47 = 1/2,2381 28/47 = 1/1,6786 (13/13+50) = 1/4,8462 1/23,8618

total reduction

30 km/h 40 km/h

1/23,8618 1/17,8966

30 km/h 40 km/h

1,3790 1,3830

mechanical ratio

(number of front wheel turns for each rear wheel turn)

bevel gear teeth backlash front drive axle end play

mm

front drive axle swinging steering angle

0,15 ÷ 0,20 0,1 ÷ 0,4 10° 50°

toe-in

see specification table here below

wheel caster angle camber

7° 1°

Check value for the adjusting the bevel gears

mm

1

Fig. 1 - Measuring front wheel toe-in and front wheel geometry. Adjusting toe-in Adjust the front wheel tie rod so as the difference A-B shown in figure 1 is: wheel rim keying diamete

r

up to 20” (508 mm) from 20” to 30” (509 ÷ 762 mm) over 302

2RM 2÷6 2÷6 2÷6

A-B mm

4RM 0±2 0±3 0 ± 3,5

Adjusting steering angles Make sure the front drive wheel steering angle is as specified in the table above. Otherwise adjust by way of the special setscrews or spacers.

Fig. 2 - Front-wheel drive steering angles.

115

4

Drive axles - axles

43

4 W.D. front axle Inspections and checks Carry out a thorough check and adjust the end play as follows: — Move the axle forward tapping with a non-ferrous metal hammer.

Fig. 3 - Removing/Installing the front drive axle. A Swivel supports B Front axle C Spacers D Swivel support

— Use thickness gauge A (see Fig. 4), to make sure that the end play between shoulder ring B and differential housing C is within specifications given in the related table (see page 213). If the end play is correct loosen the four nuts securing front swivel support C to drive axle A (see Fig. 5) and add or remove a number of shims B enough to obtain the recommended end play. — Bleed the air from the brake system. — Check the toe-in and adjust the differential lock operating rod if necessary. — Tighten the swivel support securing nuts to the specified torque.

Swivel support securing nuts front rear

89 Nm 142 Nm

Fig. 4 - Checking the front axle end play. A Thickness gauge B Shoulder ring C Differential housing

Fig. 5 - Front axle end play check point. A Front drive axle B Shims C Front swivel support

116

Fig. 6 - Power steering cylinder securing pin. A Pin securing pin B Power steering cylinder fixing pin C Power steering hydraulic cylinder D Dust cover E Spacers

(9,1 Kgm) (14,5 Kgm)

Drive axles - axles

4

4 W.D. front axle

43

Fig. 7 - Longitudinal section of the front-wheel drive.

117

4

Drive axles - axles

43

4 W.D. front axle

Fig.8 - Views and sections of the front-wheel drive.

118

Drive axles - axles

4

4 W.D. front axle

43

Final epicyclic reducer Disassembling the hub 1 - If the operation involves the bevel gear pair, removal is enabled simply by extracting the two hub swivel pins; the hub can then be distanced together with the halfshaft. 2 - If the operation involves the hub, proceed as follows: — remove the protective cap located at the centre of the epicyclic housing. — remove the circlip from its groove. — fit puller p/n 5.9030.618.4/10 and remove the flange (see fig 9). — remove the circlip from the groove at the end of the halfshaft. — screw two bolts into the holes indicated by the arrows (see fig 9) and separate the hub from the epicyclic housing. WARNING: Use a non-ferrous metal hammer and punch to tap on ferrous parts for removal if necessary.

Fig. 9 - Removing the hub flange with SAT no. 5.9030.618.4/10 tool.

Stripping down the epicyclic (fig. 10) Remove the ten securing bolts from the flange of the housing, then remove the flange and the shims beneath. Rest epicyclic reducer A on two wooden blocks as shown in figure and using a press and a punch operate on planetary carrier case centre B until the planetary carrier, bearing C and seal ring D can be removed from the bottom. NOTE: If oil leaks are noticed from seal ring D, this ring can be removed from its groove without requiring the planetary carrier case to be dismounted. In any case, when seal ring D is removed the damage it usually has to undergo is to such an extent to require replacement. Tap with a hammer and a punch on bearings C and E when having to remove, if necessary. Take planetaries A securing pins B; remove the planetaries and take roller cages C. Installation the hub Re-install the disassembled bearing C (Fig.10), in the planetary carrier case paying attention to the assembly direction. Install planetaries B with bearings C (Fig.11) into the planetary carrier case taking care to turn the pin dogs towards the hub centre. Make the planetary and the crown wheel teeth match avoiding any damaging when inserting the planetary carrier into the external case. Install bearing C (Fig.10) if previously disassembled, use a hammer and a punch to tap slightly and evenly on the outer race surface. Shimming epicyclic reducer bearings Fit a number of shims between the planetary carrier flange and the pin fixing plate, until the bearing rotate freely, even though a slight bearing preloading can be felt, then remove one 0.05 mm shim from the shim pack. Fit a new seal ring .

Fig. 10 - Disassembling the epicyclic reducer. A Epicyclic reduction gear B Planetary carrier case C Bearing

Fig. 11 - Epicylic reduction gear planetaries. A Pins B Planetaries C Roller cage

119

4

Drive axles - axles

43

4 W.D. front axle The following procedure should be observed on reassembly: 1 - Brakes Replace the brake control piston O-rings and insert piston in its seat with the oil grooves turned outwards. 2 - Final epicyclic reducer Install the final epicyclic reducer holding the axle shaft in position as shown in figure 12 by prising on cross journal A outwards; this to prevent the axle shaft from moving inwards. 3 - Axle shafts When inserting the axle shaft pay attention not to damage the roller bearing or the seal ring. The axle shaft end should be correctly introduced into the differential gear planetaries. Make sure the axle shaft is free to rotate without any hindrance.

Fig. 12 - Prising with a lever to hold the axle shaft in position when mounting the final epicyclic reducer.

4 -Forks After installing the bearings and the dust rings mount the fork by placing one 0.5 mm shim under the lower pin, then fit the pin, use a hammer if necessary, finally tighten the securing screws.

Fit a pack of shims thicker than the one taken on removal under the upper pin. Install the pin tightening the securing screws.

Adjusting wheel fork bearing preloading In the pack of shim to be put together for adjustment it is always advisable to group more shims in one: as an example, it is better one 0,2 mm shim be used instead of two 0,1 mm shims. Fit no. 5.9030.267.0 magnetic base with no. 5.9030.272.0 centesimal dial gauge onto the drive axle and then place the gauge feeler perpendicularly to the lower pin close to centre and set to zero. Using lever A as shown in figure 13, move the fork fully upwards and read the clearance on gauge dial. Loosen the two screws B and remove shims from pack C so that any clearance may be taken up without preloading the bearings. WARNING: The clearance amount should be reduced gradually by repeating reading with the dial gauge each time so that the bearings are not preloaded. After all clearance has been taken up, remove a 0.10 to 0.15 mm shim pack, so that a correct bearing preloading can be obtained. Tighten screws B and D to the specified torque. Fig. 13 - Checking wheel hub clearance. A Lever B Screws C Pack of shims D Screws E 0.5 mm shim.

120

After correctly performing adjustment, ensure the shaft taper roller bearing slide in their seats freely, even though a slight preloading is felt.

Drive axles - axles

4

4 W.D. front axle

43

Side hubs Disassemble the twin universal joints if required, keeping to the following procedure: — Remove both snap rings A from one cross journal B. A non-ferrous metal hammer and punch may help in carrying out this operation, (see Fig. 14). — Fix the joint fork in a vice provided with protective jaws. — Tap with a hammer on wheel shaft fork A (see Fig. 16), so that the bearing may be removed from its seat in fork A and taken from the top. Separate cross joint D from the fork. — Following the same procedure separate the cross joint from the universal joint fork as well as from the axle shaft fork. — Recover bearing rollers A along with dust rings B.

Fig. 14 - Twin universal joint. A Snap ring B Twin universal joint cross journal

Fig. 15 - Axle shaft twin-type universal joint bearing. 1 Rollers 2 Dust rings

Fig. 16 - Disassembling the twin-type universal joint from the axle shaft. A Wheel shaft forks B Roller bearing C Roller bearing D Cross joint

121

4

Drive axles - axles

43

4 W.D. front axle

Pins Check differential spider pin and final epicyclic reducer planetary holder pin surfaces for damaging; otherwise both pins are to be replaced. Follow the same procedure for pin housings.

Axle shafts Check for excessive wear: splines should not be nicked and permit a free gear movement. Spider forks should not be warped and bearings shall slide freely.

Gears Make sure all gear toothing is neither worn nor damaged, teeth should work on the whole contact face.

Bearings Examine bearings for proper working conditions, ensure they show neither excessive radial nor end play. Holding the bearings pressed by hand and making simultaneously turn in both directions of rotation, these should slide freely and no sliding friction felt.

Tightening torques Before tightening all screws should be degreased and cleaned.

Differential/bevel gear securing screws

Kgm 6 ÷ 6,5

Nm 58 ÷ 64

Bevel pinion fixing nut Bearing holding flange securing screws

21 ÷ 23 3

206 ÷ 226 29

7÷8

68 ÷ 78

14,5 9,1

142 89

Engine front support securing screws Hydraulic cylinder fixing pin

28 16

274 157

Ball-and-socket joint castellated nuts Transmission shaft flange securing screws *

12 5

119 49

11,5 ÷ 12

113 ÷ 118

Fork flange securing screws Axle swivelling pivot securing screws

- rear pin - front pin

Differential housing half securing screws * Coat the nut with a small amount of Loctite 242.

Check periodically that the wheel bolts are correctly tightened. — Front wheel bolts — Front wheel bolts

122

2RM (M20x1,5) 4RM (M18x1,5) (M20x1,5)

50 kgm (490 Nm) 36,8 kgm (360 Nm) 50 kgm (490 Nm)

Drive axles - axles

4

4 W.D. front axle

43

Installing the waterproof seal A inner half-shaft B outer half-shaft C pinion D hub E pinion X outline plug Using a suitable installation tool, install the seals oriented as shown in the figure and pressing them to the full depth of the installation tool. The measurements indicated here are to be used to construct the oil seal installation tool.

Fig. 17 - Waterproof seals.

123

4

Drive axles - axles

43

4 W.D. front axle Réglage du couple conique. 1 - Monter le boîtier de différentiel en interposant entre les flasques-supports de roulements une épaisseur de cales jusqu’à obtenir une précontrainte des roulements de 0,04 mm. 2 - Déposer à nouveau le boîtier de différentiel et monter le pignon en interposant un jeu de cales A de 0,50 mm et un jeu de cales B pour permettre, après avoir serré l’écrou au couple de 21 ÷ 23 kgm (206 ÷ 226 Nm), la libre rotation des roulements dans leurs logements respectifs malgré une légère précontrainte (ne doit pas être supérieure à 0,04 mm).

Fig. 18 – Mise en place d’épaisseur de cales pour roulements de pignon.

3 - Régler la distance E boîtier de différentiel-tête du pignon en agissant sur le jeu de cales A. La mesure exacte pour cette opération s’obtient en additionnant ou en retranchant de la valeur gravée sur le profil d’une dent du pignon la valeur de 1 mm. Remarque: après avoir réglé la distance entre le boîtier de diffé rentiel et la tête du pignon, il faut refaire le réglage de la précontrainte, pour détérminer à nouveau le jeu de cales B. 4 - Remonter le boîtier de différentiel et vérifier avec un comparateur le jeu d’entredent pignon-couronne: il doit être de 0,15 ÷ 0,20 mm; si ce n’est pas le cas, enlever des cales au jeu C et les ajouter au jeu D pour approcher la couronne au pignon et vice versa pour l’éloigner de celui-ci.

Fig. 19 – Mesure du jeu d’entredent pignon/couronne pour le réglage du couple conique.

Fig. 20 - Réglage du couple conique.

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Drive axles - axles

4

4 W.D. front axle

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Réglage interne du blocage de différentiel de type mécanique (Fig. 22). (Pour le réglage de la commande extérieure, voir chapitre “commandes”). 1 - Assembler les pièces en plaçant l’épaisseur de cales A du côté du circlip B; l’épaisseur de cales mise doit faire en sorte que le jeu de l’entretoise C soit de 0 ± 0,05 mm. 2 - Déplacer un certain nombre de cales du jeu A dans la position G jusqu’à obtention du déplacement du manchon D en position d’enclenchement. REMARQUE – Le déplacement des cales doit se faire par jeu d’une épaisseur non supérieure à 0,20 mm. L’enclenchement du manchon D sera correct quand le manchon recouvrira les billes F sans forcer pour se mettre dans la position indiquée par le repère E Fig. 22.

Montage du différentiel dans le pont Orienter le groupe de manière que le manchon du blocage de différentiel se situe du même côté du levier interne de commande.

Fig. 21 - Orientation du différentiel dans le pont.

Le manchon devra être déplacé vers l’extérieur afin de permettre aux patins du levier de s’engager dans la gorge. Après le montage du différentiel dans le pont, contrôler l’enclenchement du blocage en actionnant le levier et en tournant manuellement le pignon d’attaque.

Fig. 23 – Contrôle de la distance tête de pignon-surface rectifiée du boîtier de différentiel. A Jauge d’épaisseur B Tête pignon C Axe porte-satellites

Fig. 22 - Réglage du blocage de différentiel.

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Drive axles - axles

43

4 W.D. front axle

Diagnostic des inconvénients

Usure des croisillons à cardan

pont avant surchargé

n’employer que des chargeurs frontaux reconnus par le constructeur

contrôler l’usure des bagues d’étanchéité

changer les gues usées

reniflard d’huile obstrué

nettoyer

prévoir le lestage arrière du tracteur

ba-

Pertes d’huile

n’utiliser la double traction que sur terrain agricole

excessive exploita- monter des pneus tion du tracteur pour convenables transports routiers

usure non uniforme

contrôler le pincement des roues

prévoir le réglage

contrôler l’usure des pneus

si nécessaire prévoir la substitution

contrôler l’usure des articulation de direction

si nécessaire prévoir la substitution

contrôler les roulements coniques du moyeu

régler et les remplacer si nécessaire

usure uniforme

Usure des pneus

Oscillation des roues

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Brakes

54

Brakes General information The service brakes are located between gearbox and final epicyclic reducers and assure a precise and safe braking action. In addition, the four-wheel drive tractor models are also equipped with integral braking system providing braking on all tractor wheels. The braking system is sintered-lining, oil-immersed disk type. The right-hand brake control is completely independent from the left-hand brake control; this allows the tractor turning radius to be conveniently reduced (this operation is only possible when working on farm land and never during transport operations on public roads). The braking system is provided with the “SEPARATE BRAKES” valve which enables the front wheel braking to be excluded.

Fig. 1 - Front service brakes.

Each brake pedal controls a hydraulic pump which delivers oil under pressure to a disk thrust plate, which causes the brake disk to lock. Operating both brake pedals simulteneously by coupling them with the special joining latch, opens an oil duct connecting both hydraulic circuits to balance the baking pressure on the wheels. Brake maintenance is limited to an easy adjustment and a system air bleeding if necessary. The parking brake has mechanical control and acts on transmission downstream of gearbox. Pulling the control lever upwards makes the brake disks pack together thus locking the shaft being constantly meshed with the wheels. Maintenance is very easy and consists of replacing the friction pads when worn or adjusting the control lever travel.

Fig. 2 - Parking brake parts. Specifications service brakes Manufacturer Type number of disks each brake brake disk outside diameter original brake disk thickness brake disk minimum thickness allowable brake pedal free travel braking piston max. Play thydraulic pump type parking brake brake type number of braking pads double braking surface single braking surface original braking pad thickness double single braking pad minimum thickness allowable double single brake disk number parking brake control lever travel

front 2WD

mm mm mm mm mm

mm mm mm mm mm

2 (each side) 223,4 4,80 4,40

rear 4WD

SDF DEUTSCHLAND oil-immersed disks 1 (each side) 1 (each side) 223,4 280 4,80 7 4,40 6 40 1,15 Benditalia Ø 1’’ oil-immersed disks n° 2 n° 2 5 3,5 4,3 3,2 3 100

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Brakes

A - Oil tank B - Oil delivery pipes C - Oil pumps D - Pumps connection pipe E - Brake pedal coupling latch F - Block for types without front brakes G - SEPARATE BRAKES valve H - Brake pedals I - Parking brake lever L - Toothed quadrant M - Control rod

Fig. 3 - Brake control assembly parts.

Hydraulic pump Disassebly and checking procedure Referring to fig 4: — Remove guard boot A, take snap ring B and withdraw rod C along with the support disk.

Fig. 4 - Brake pump control unit.

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Referring to fig 6: — Fix the pump in a vice provided with protective jaws and pushing pistons into the pump partly, as shown in figure 6, loosen the piston retaining screws and then remove the pistons together with the spring down below.

A - Pump B - Delivery pipe union C - Delivery pipe D - Clamp E - Pipe fitting F- Spring

G - Snap ring H - Spacer I - Seal ring L- Intermediate piston M - Spring N - Seal ring O - Washer

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Brakes

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P - Piston Q - Seal ring R - Rod S - Support disk T - Snap ring U - Guard boot V - Nut

Z - Fork X - Stop screw Y - Gasket K - Pump union pipe

Fig. 5 - Brake pump assembly parts. — Examine the cylinder interior and the pistons for either scoring or rust. Replace if necessary. — Check cylinder and pistons for wear. If excessive plays are noticed replace either the whole piston or the whole cylinder assembly. — Inspect sealing rings and dust guard boot, replace any worn parts. — Inspect all pump internal compartments, apertures and passages and make sure all is properly clean and free from foreign matters. — Ensure the springs are neither yielded nor warped. Replace if necessary. Fig. 6 - Piston retaining screw.

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Brakes

12 - Guard boot 13 - Rod 14 - Nut 15 - Fork 16 - Snap ring 17 - Gasket 18 - Stop screw 19 - Seal ring 20 - Seal ring 21 - Spacer 22 - Snap ring

1 - Spring 2 - Pump 3 - Intermediate piston 4 - Spring 5 - Pipe fitting 6 - Gasket 7 - Seal ring 8 - Washer 9 - Piston 10 - Seal ring 11 - Support disk

Fig. 7 - section of the brake pump.

Assembly of brake master cylinder (see fig 5). Screw the front piston L and the rear piston P together, then check that there is clearance between the two. Insert the pistons into the cylinder, checking that the recess afforded by the outer piston P is aligned correctly with the seat of the limiter screw X. Verify correct operation of the cylinder, making certain that the pistons complete their full travel freely.

Fig. 8 - Installing the front brake disk pressure piston seal ring.

Fig. 10 - Brake assembly. Fig. 9 - Brake assembly flange. A - Brake assembly flange

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A - Brake disks B - Intermediate disk C - Brake control piston

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Brakes

54

Checking the front brake disks on 2WD and 4WD front axles and the rear brake disks. Check the ground surfaces contacting the brake disks for excessive scoring. If excess wear is found replace the worn-out parts. Check disk conditions and tickness, compare with specifications table. Examine the brake disk broaching for wear or damage. If excessive oil consumption is noticed, check the piston rings as follows: Connect no. 5.9030.520.4 hydraulic pump to the oil delivery circuit; if the hydraulic circuit is not fully oil-tight under a 1,5 bar pressure, the rings must be replaced. (To check the effectiveness of the seals more accurately, blow compressed air around the perimeter of the seal; if air bubbles appear, the seal is imperfect).

Fig. 11 - Brake housing. A - Locating dowels. B - Brake housing

Check each brake.

For 4WD front brakes and rear brakes only Mark piston and brake housing case with a reference near to a locating pin so as to make reassembly easier. Coat the brake housing case seal ring contacting surfaces of piston A with recommended grease, see figure 11.

Fig. 12 - Greasing the seal contact surface of the brake piston. A - Piston

Carefully mount piston into the brake housing case. Fit the brake housings and halfshaft trumpet housings, repeating the removal operations in reverse order and observing the following directions. Coat the brake housing case inner surface as well as both epicyclic gear crown wheel surfaces with recommended sealant. Tighten the securing nuts of the brake housings and trumpet housings to the prescribed torque (see values below). - brake housing bolts: - trumpet housing bolts:

3,3 ÷ 4,1 (32 ÷ 42) 8,6 ÷ 9,6 (84 ÷ 94)

Fig. 13 - Rear brake assembly.

Adjusting service brake pedals Operate right-hand pump fork A (figure 14) to adjust brake pedal position, until the most suited position for the operator is attained, and in such a way that the pedal may complete its whole travel freely when braking. Operate left-hand pump forkB (figure 14) to adjust the related brake pedal so that the coupling latch holes are in the same line. Fig. 14 - Adjusting the brake pedals.

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Brakes

Fig. 14 - Rear brakes for 2WD front axle.

Fig. 15 - Parking brake inspection window Correct installation of inspection cover for parking brake discs Before fitting the cover, apply the sealant PIANERMETIC 510 to the surfaces in contact with the gearbox (marked A in the figure), then tighten the three screws marked B in the figure to a torque of 5.8 kgm (55 Nm). Check that with the control lever positioned at angle of approx. 40° relative to the horizontal, the brake play is that indicated in the figure. If the play exceeds this value, replace disc C with the single braking surface with a discs with a double braking surface (to recover 1mm of play). Alternatively insert a shim (code 009.9648.0) between the disc C and the reaction plate (to recover 2mm of play).

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Fig. 17 - Section view of 4WD front brakes.

Fig. 18 - Section view of rear brakes.

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Brakes The parking brake, completely independent from the service brakes, is applied by pulling the special hand lever upwards. Once the parking brake is applied the related pilot lamp on the dashboard lights up.

Checking parking brake pads Examine the brake pads for wear. If brake pad thickness is out of specifications these shall be replaced. Brake pads can be dismounted after removing the lower brake pad lockpin, this permits access through the cover placed under the gearbox to be gained. Before installing new brake pads, check lockpin seal ring conditions, replace if necessary.

Parking brake control lever overall travel This travel should be 100 mm, otherwise operate the special adjusting screw until the specified dimension is obtained. Fig. 19 - Parking brakechecking and adjusting dimension.

Fig. 20 - Parking brake.

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Measuring the brake disk thickness.

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Brakes

54

Fig. 21 - Parking brake assembly; (A- Brakes disk).

Bleeding air from the brake hydraulic system Operate as follows: — unhook pedals by removing the coupling latch: afterwards place the “SEPARATE BRAKES” valve control in OFF position; — operate the right-hand brake pedal several times; — by holding the pedal in fully depressed position, slightly unscrew and tighten soon after the relevant air bleeding valve on the rear right-hand brake. This operation should be repeated until such time as the oil flows out of the bleeding valve without air bubbles. Repeat the same procedure on the front right-hand brake by acting on the related air bleeding valve.

Fig. 22 - Bleeding the air from the rear service brake hydraulic system.

Follow the same procedure on the front and rear left-hand brakes making use of the related air bleeding valves.

We recommend that only oil AKROS MATIC (with international specifications ATF DEXRON II) used in the braking system. Fig. 23 - Bleeding the air from the front service brake hydraulic system.

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Brakes “Separate Brakes” valve The “SEPARATE BRAKES” valve permits the front wheel side-slip to be removed when performing independent braking. (This prevents cultivation damage as the front wheel is under no braking action). The valve operation can be stopped by operating the special control tap A. When both brake pedals are operated at the same time (coupled pedals), the braking of the four wheels will be always obtained.

IMPORTANT: The “idrostop” sensor must be installed in the SEPARATE BRAKES valve housing, smearing Loctite 542 on the screw thread.

Fig. 24 - Different braking action diagram.

A = LH brake pedal B = RH brake pedal C = Both when coupled

Hydraulic connections PR - Rear RH brake L - LH brake pedal pump AL - Front LH brake

Fig. 25 - “SEPARATE BRAKES” valve.

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R AR PL H

- RH brake pedal pump - RH front brake - Rear LH brake - STOP pressure switch

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Brakes

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Fig. 26 - Hydraulic circuit diagram for SEPARATE BRAKES system

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Brakes

Fig. 27 - Brake hydraulic system schematic diagram with tap in position “ON”. A - oil pressure B - discharge oil

Hydraulic connections PR - Rear RH brake L - LH brake pedal pump PL - Rear LH brake

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R AR AL H

- RH brake pedal pump - RH front brake - Front LH brake - STOP pressure switch

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Brakes

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Fig. 28 - Brake hydraulic system schematic diagram with tap in position “OFF” A - oil pressure B - discharge oil

Hydraulic connections PR - Rear RH brake L - LH brake pedal pump PL - Front LH brake

R - RH brake pedal pump AR - RH front brake AL - Rear LH brake H - STOP pressure switch

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Brakes

Diagnosing malfunctions

poor braking

make sure no air is inside system

bleed the air

check for correct adjustment

adjust

check brake disks for wear

replace

make sure the recommended oil type is used

uneven braking

bleed the air

replace

check for correct adjustment

adjust

make sure the recommended oil type is used

replace

check brakes disk for wear

replace

noisy braking

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Hydraulic power-lift

59

Hydraulic lift with “load sensing” The automatic draft control device, connected directly to the top link, guarantees rapid lift operation and is highly sensitive to even minimal variations in the load on the implement. The hydraulic lift is equipped with an internal cylinder positioned horizontally. The hydraulic lift is equipped with an open-centre control valve. The oil in the suction line is drawn from the gearbox by a high-capacity pump (the same pump supplies the auxiliary control valves) ‘and filtered through a filter with an interchangeable. The oil under passes through the auxiliary control valves before arriving at the lift.

Fig. 1 - Lift lever shaft

Technical characteristics manufacturer lift type safety valve setting minimum operating pressure minimum permissible piston diameter maximum permissible cylinder diameter lifting capacity with load concentrated on lower link ball ends at height of rear wheel centres tightening torque for cylinder retaining bolts

bar bar mm mm

SAME DEUTZ-FAHR DEUTSCHLAND with open-centre control valve 190 +010 8 89,900 90,050

kg kgm Nm

1600 15 - 16,5 150 - 165

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Hydraulic power-lift

Installing the lift and front cover plate of the gearbox

Install the two lift mounting studs (A in figure) and the two cover plate retaining screws (B in figure), applying Loctite 242 to the threads in both cases.

Fig. 2 - Fixing the front lift and the front cover to the gearbox

Fig. 3 - Lift unit components.

Lift mechanism Inspect the splines for grooves or excessive wear; replace the levers if necessary. Inspect the splines of the lift shaft for excessive wear and check that the machined surfaces in contact with the supports are not damaged; carefully clean the lubrication slots for the shaft supports. At each dismantling, remove the seals and gaskets. Check that there are no oil leaks from the lift cylinder.

Fig. 4 - Hydraulic control valve.

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Checking the safety valves Check that the safety valve incorporated in the auxiliary control valves is set to 190 bar. Remember that to ensure the correct operation of the lift, the operating pressure in the lift circuit must not exceed 150 bar.

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Hydraulic power-lift

59

Checking the protrusion of the non-return valve control pin B Move the ball A so that rests on the valve body D, and move the valve body D so that it rests on the control valve housing, then insert pin B up against ball A (while making sure that the ball A does not move). Check that the pin B protrudes 15.8 ÷ 0.05 mm as indicated in the figure. Check that the moving parts slide freely For the control vale to function properly, the following parts must slide freely: - G - control valve spool - K - pilot valve - L - enabling valve Checks to be carried out after re-assembly of the control valve. - Check that the control valve spool slides freely. After assembly of the control vale housing with the connection housing, check that the spool Gslides freely in its bore. - Check coverage of lifting and lowering ports. Push the spool G in the direction of arrow E until the point where lifting commences. From this point, move the spool back in the direction of arrow F until lowering commences. Check that the spool travel between the lifting and lowering positions is 0.6 to 0.8 mm. - Check for leaks Check that no part of the control valve leaks (plugs, check valve, etc.) at a pressure of 150 bar. Apply Loctite 542 to all the control valve plugs before fitting. The spring calibration values must match those specified in the tables. For bench testing of the control valve use oil of the recommended type and a pump with a capacity of 10 to 15 l/min. Warning: the presence of emulsified oil may prevent correct operation of the control valve.

L

B

K

D F

15.8±0.05

P

A

G E

Fig. 5 - Hydraulic control valve.

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59

Hydraulic power-lift - first version

1 - MAX. controlled draft 2 - Green sector - CONTROL 3 - MIN. controlled draft 4 - Lowering 5 - Red sector float 6 - Mixed control 7 - Yellow sector position 8 - Raising

Fig. 6 - Lift control adjustment diagram. F - Position control lever (yellow knob) G - Draft control lever (green knob)

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Hydraulic power-lift

59

Adjusting the lift (Fig. 6) Warning: before adjustment, attach a weight of approx. 200 kg to the 3-point hitch. Adjust the forks of the external tie-rods of the lift control linkage so that the yellow lever and the green lever are free to move the entire length of the control slot.

Adjusting the lift travel - YELLOW LEVER Start the engine, and move the yellow lever to the maximum lift position and move the green lever to position 12 in its control slot. Adjust screw E (fig. 6), so that it is up against its stop when the reference marks on the right-hand side of the lift housing and the lift arm coincide. If necessary, also adjust fork B of tie-rod A.

Adjusting the GREEN LEVER Move the yellow lever to the position CONTR of its control slot, and check that when the green lever is moved from position 12 towards 0, the lifting action commences when the lever is in correspondence with position 4. If not, adjust fork D of tie-rod C.

Checking operation of the safety stop. Move the green lever to the maximum lift position (position 0). The lift arms will be raised, rotating through a further angle of approx. 4° (corresponding to a movement of the notch on the lift arm of 6 mm). Checking balance. With the yellow lever in the CONTR position, move the green lever from position 12 to 4 to find the point of balance (before the lifting action begins); check that when the counterweight applied to the lift arms is pulled upwards, the lift raises the arms, and that when the counterweight is pushed downwards, the lift lowers the arms.

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Yellow Blue Green Red

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59

Hydraulic power-lift

= Oil delivery to the hydraulic control valve = Oil flow from the control valve to the lowering valve = Oil for piloting the valves = Pressurised oil to the lift piston

1 - Valvematic 2 - Anti-shock valve 3 - Down valve 4 - Control valve 5 - Pilot valve 6 - Enabling valve 7 - Inlet valve P - Pump T - Return

Fig. 8 - Lift hydraulic circuit.

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Hydraulic power-lift

59

Yellow = Discharged oil Red = Pressurized oil Blue = Oil from hydraulic pump Green = Oil trapped at relative pression 1 - Directional control valve 2 - Enabling valve 3 - Enabling pilot valve 4 - Unloading valve 5 - Down actuator piston 6 - Valvematic 7 - Inlet valve 8 - Anti shock valve Fig. 9 - Hydraulic lift circuit - NEUTRAL

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Hydraulic power-lift

Yellow = Discharged oil Red = Pressurized oil Blue = Oil from hydraulic pump Green = Oil trapped at relative pression 1 - Directional control valve 2 - Enabling valve 3 - Enabling pilot valve 4 - Unloading valve 5 - Down actuator piston 6 - Valvematic 7 - Inlet valve 8 - Anti shock valve Fig. 10 - Hydraulic lift circuit - RAISING

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Hydraulic power-lift

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Yellow = Discharged oil Red = Pressurized oil Blue = Oil from hydraulic pump Green = Oil trapped at relative pression 1 - Directional control valve 2 - Enabling valve 3 - Enabling pilot valve 4 - Unloading valve 5 - Down actuator piston 6 - Valvematic 7 - Inlet valve 8 - Anti shock valve Fig. 11 - Hydraulic lift circuit - LOWERING

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Hydraulic power-lift

Fig. 12 - Control linkage for draft control.

Fig. 13 - Lift hydraulic control valve.

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Fig. 14 - Section views of the lift

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Hydraulic power-lift

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Fig. 15 - Pins of the draft control and position control levers

Fig. 16 - Control linkage for draft control and stop screw for the position control lever

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Hydraulic power-lift

Fig. 17 - Top view of the lift.

Fig. 18 - Rear view of the lift.

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Hydraulic power-lift

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Fig. 19 - Section views of the lift hydraulic control valve

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Hydraulic power-lift

Sensing arm assembly · · · · · ·

Install on screw A: ring B, spacer C, spring D, ring E, screw in nut F to take up all play.

–

Screw in nut F a further quarter turn to preload the spring.

–

Slide this assembly into spring holder G.

–

Fit eye H and tighten nut F against it to a torque of 100 ÷105 Nm (~10 Kgm), taking care that nut F does not turn on screw A.

–

Screw plug I into spring holder G to prevent axial movement of the previously assembled pack.

– –

Apply a small quantity of LOCTITE 242 before fitting plug I. Apply a small quantity of LOCTITE 242 before fitting nut F and eye H.

–

Grease spring D before fitting

G

I

Fig. 20 - Sensing arm assembly diagram

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B

A

C D

E

F

H

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Hydraulic power-lift

59

Power-lift distributor valve spring setting specifications

oil flow control valve spring no. of springs used wire diameter external diameter released spring loaded spring

pilot valve spring no. of springs used wire diameter external diameter released spring loaded spring

hydraulic distributor spring no. of springs used wire diameter external diameter released spring loaded spring

nonreturn valve spring no. of springs used wire diameter external diameter released spring loaded spring

valvematicspring no. of springs used wire diameter external diameter released spring loaded spring

(N 40,4) - kg 4,115 (N 66) - kg 6,727

n. mm mm mm mm mm

1 1,4 7,8 54 47,5 43,37

(N 21) - kg 2,133 (N 28,5) - kg 2,899

n. mm mm mm mm mm

1 0,9 7,8 25,5 15,2 11,5

(N 43) - kg 4,4 (N 39) - kg 4

n. mm mm mm mm mm

1 1,2 10,4 110 65 60

(N 29) - kg 2,96 (N 43) - kg 4,43

n. mm mm mm mm mm

2 1,1 8,8 25 17 13

(N 41,3) - kg 4,2 (N 54,3) - kg 5,5

Nº mm mm mm mm mm

1 1,2 9,5 57,3 35 25,8

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Electronic power-lift

ELECTRONIC LIFT The electronic lift is controlled by an electronic control unit and a control panel. The electronic control unit processes the signals from the input devices and generates the output signals for the electro-hydraulic control of the lift control valve. The system provides Draft and Position control functions. IMPORTANT The "ALL ROUND TESTER" provides the interface for electronic control unit self-diagnostic and programming operations. All the display messages are given in the chapter "LIFT TESTER Control unit version 1.24A" of the Appendix (see table of contents).

Fig. 1 - Configuration of the electronic lift system 1 - Control Unit 2 - Electro-hydraulically operated control valve (2 proportional solenoid valves) 3 - Hydraulic pump 4 - Draft sensor 5 - Position sensor 6 - Maximum lift height control knob 7 - Lowering speed control knob 8 - Draft/wheelslip intermix control knob 9 - Depth control knob 10 - Up/Down control 11 - Lock and alarm warning light 12 - Manual UP control (on the fender) 13 - Manual DOWN control (on the fender)

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Electronic power-lift

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Control panel The control panel comprises a series of potentiometers, lights and switches which serve to set the system operating mode, raise or lower the lift and to provide information about system status. The control panel is separate from the electronic control unit, to which it is connected by way of a multi-pin connector.

Fig. 2 - Control panel 1 - Lowering speed control knob 2 - Maximum lift height control knob 3 - Draft/wheelslip intermix control knob 4 - Up/Down control switch with integral Lock and Alarm warning light 5 - Depth control knob

Control level or depth control knob (5) Used to set the reference value for the control function. Informs the electronic control unit of the required level of working depth or draft control for respectively the position and draft control functions. This knob is fitted with a mechanical lock to prevent excessive force being applied at the limits of potentiometer travel. · Turning the knob to the left increases the working depth. The first sector on the left permanent Float control. Mix position/draft control (3) Used to select the control mode. · When turned fully to the left, pure draft control is selected. · When turned fully to the right, pure draft control is selected. · In the intermediate sector, sets the minimum depth for draft control: the function is disengaged by turning the knob to the right, the depth is decreased by turning the knob to the left.

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Electronic power-lift

Lowering speed control knob (1) Used to vary the at which the linkage is lowered. Sets the maximum aperture of the proportional solenoid valve that controls the lowering speed. Turning the knob to the left reduces the lowering speed.

Maximum lift height control knob (2) Used to set the maximum height to which the linkage is raised when the driver operates the lift control. Turning the knob to the left reduces the maximum lift height.

Up/Down control switch (4) Rocker switch used to raise or lower the linkage, incorporating a safety lockout/release.

Up control Pressing this button for at least 0.2 seconds raises the lift to the maximum lift height.

Control/Float mode If the Down button is pressed for less than 0.2 seconds, Control mode is activated. If the button is held pressed for longer, Float mode is activated. In the latter case, the implement will be lowered at the rate set by the lowering speed control knob and the lowering solenoid valve will be operated for as long as the button is held pressed. The moment the button is released, the system will exit Float mode and automatically resume Control mode.

Lock/release Activates/deactivates total lock out of the control panel. When the lock is activated, the warning light illuminates. On starting, the system is always locked; to release the lock, hold the Up control button pressed for 3 seconds until the light goes out. The light will flash rapidly while the button is pressed. To activate the lock, hold the Up control button pressed for 3 seconds after which the light will illuminate; again, the light will flash rapidly while the button is being pressed. On activating the lock, the linkage is immediately raised to the height determined by the maximum lift height control knob. Any subsequent alteration to the position of the lift controls (including the maximum lift height control knob) will have no effect on the position of the linkage until the lock is released.

Lift status indicator light This light provides information about the operating status of the lift. If the light is permanently illuminated, this indicates that the system is locked. If the light is off, this indicates that the system is operating normally. If the light is flashing, this indicates an alarm condition.

WARNING: only use the Up control button located on the solenoid valve of the lift control valve in cases of extreme necessity and when the engine is running at idle speed. Release the button before the linkage reaches the maximum height, as the automatic stop determined by the both position sensor and the safety switch is excluded during this operation.

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Electronic power-lift

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Remote pushbuttons for lift operation from ground Two remote pushbuttons are located on the rear fender. To enable these pushbuttons it is first necessary to release the lift control system. Operation of the manual controls overrides any current lift functions and places the control unit in STOP condition, awaiting new control signals.

Fig. 3 - Lift control pushbuttons

1 - Up

2 - Down

Fig. 4 - Ground-operated lift controls.

159

5

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59

Electronic power-lift

Lift operation On starting the engine, the lift is in Lock condition; to release the lift, press the UP switch for at least 5 seconds. The lift control system enters STOP status in which condition the lift may be raised to the maximum lift height by pressing the switch for at least 0.5 seconds but no more than 3 seconds. To activate the lift control system, press the DOWN switch for less than 0.3 seconds; if the switch is held pressed for longer, FLOAT mode is activated and CONTROL mode will only be resumed when the switch is released. The functions of the three potentiometers are as follows: 1 - MAXIMUM LIFT HEIGHT (used to set the maximum height to which the linkage can be raised) 2 - LOWERING SPEED (used to set the rate at which the implement is lowered). 3 - CONTROL (used to select the control type: when turned fully to the left POSITION control is selected, when turned fully right DRAFT control is selected). When turned to the intermediate sector, mixed draft and position control is selected. LIFT ALARMS CODE

MESSAGE ON TESTER

Alarm description

11

“EVUP DISCONN”

UP SOLENOID DISCONNECTED

12

“EVUP C.C. “

UP SOLENOID SHORT CIRCUIT

13

“EVDW DISCONN“

DOWN SOLENOID DISCONNECTED

14

“EVDW C.C. ”

DOWN SOLENOID SHORT CIRCUIT

15

EPROM CECK-

BLOCCO TOTALE DEL SISTEMA SOLLEVATORE-

21

“POS. SENS. C.C.”

POSITION SENSOR SHORT CIRCUIT

22

“POS. SENS. DIS”

POSITION SENSOR DISCONNECTED

23

“GEN. FAIL. CPU”

GENERAL FAILURE OF CPU.

24

-

25

-

31

-

41

“DRAFT SENS NC”

DRAFT SENSOR DISCONNECTED

42

“DRAFT SENS C.C.”

DRAFT SENSOR SHORT CIRCUIT

45

“EEPROM CECK“

EEPROM ERROR

Example display of code 23: on off

all times in seconds 2

0.3 0.3

0.3

1,2

0.2 0.2 0.2 0.2 0.2

The criteria for encoding are as follows: — light off for 2 seconds — number of 0.3 second flashes corresponding to the tens digit — light off continuously for 1.2 seconds — number of 0.2 second flashes corresponding to the units digit — repetition of the cycle until the alarm ceases

160

2

Fig. 5 - Electronic circuit diagram of the ECU

5

Electronic power-lift

59

PIN OUT REAR LIFT ECU 9

Mix

Main Control

L. Speed

Draft

5

11

10

+Vcc Sensors

8

7

Max H.

6

12

Position

Electrovalve DOWN

Electrovalve UP

4

ISO 9141

3

2

GND

1 Vcc

1 - Vcc 2 - UP solenoid valve 3 - DOWN solenoid valve 4 - GND 5 - Sensor Vcc 6 - Position 7 - Draft 8 - Lowering speed 9 - Maximum height 10 - Mix 11 - Main control 12 - ISO 9141

Vehicle

1K2 Lock/Alarm

Extern up

Extern down

A - UP solenoid valve B - DOWN solenoid valve C - Tester IN/OUT D - Position sensor E - Draft sensor F - Lowering speed G - Maximum height H - DRAFT/POSITION mix control I - Main control L - DOWN/UP control

Up

Down

1

2

1

1

2

3

V +

2

1

3

2

1

2

3

1

2

3

1

2

3

1

2

3

V

EVup

A

EVdown

B

Tester In/Out

C

Position Sensor

D

Draft Sensor

E

Lowering Speed

F

Maximum Height

G

Mix Draft/Pos

H

Main Control

I

Down/Up Control lever

L

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Electronic power-lift

Calibration of the AUTOMATIC 1 - Unlock the lift. 2 - Move the lift arms to the required height using the ground-operated UP/DOWN controls. 3 - Press the P.T.O. AUTO switch. 4 - Press the P.T.O. engagement switch for approx. 10 seconds. The selected height is set as the maximum height limit for P.T.O. operation. Emergency manual lift control In the event of a malfunction of the electronic system, the lift can still be controlled by way of the mechanical pushbuttons located on the solenoid valves of the lift control valve (see figure below). However this operation should only be carried in an emergency and with the engine running at idle speed. Release the pushbutton before the lift arms reach their maximum height, as the automatic stop determined by the position sensor is disabled during this manoeuvre.

Fig. 6 - Emergency manual lift control pushbuttons.

HYDRAULIC CONTROL VALVE (located on lift casing)

162

A - Up B - Down

Fig. 7 - Diagram of the hydraulic control valve. Hydraulic control valve of the electronic lift This control valve is of the open centre type and has two solenoid valves for raising and lowering the lift arms. The two solenoid valves are controlled directly by the ECU. Do not connect the solenoid valves directly to an electrical power source, as they would be irreparably damaged.

Vehicle

5

Electronic power-lift

59

LIST OF ELECTRONIC LIFT TESTS Connect the ALL-ROUND TESTER to the diagnostics socket and select option (2) [REAR LIFT CONTROL]. Press (0) twice and enter the password [BAC0] in order to modify the parameters. Press [E] twice to display the first screen page. The first screen indicates the selected tractor type (10N or 10S). If the selected tractor type does not correspond to the machine being tested, change the type by pressing the number alongside the required model and follow the on-screen instructions to store the new type in memory. Release 1.23A does not display the tractor type selection screen and the parameters are those relative to the 10S type. Enter the MENU screen and press (0) to enter the modification menu. 2 - Modification menu. 1 - Monitor 2 - Parameters 3 - Tests 4 - Max/min height calibr. 5 - Alarms 6 - Calibr. PWMmin

- MONITOR Displays data related to the control algorithm and the PWM controls (sensor and potentiometer status). - Parameters 10S - Programming parameters of the control solenoid valves (Ev). - Tests - allows you to test ground-operated pushbuttons and display sensor values. - MAXIMUM/MINIMUM LIFT HEIGHT CALIBRATION Allows you to calibrate the maximum lift height and the lifting speed. DEFAULT VALUES 10S: 1 - max. Height 880 2 - Lifting speed. 500 To calibrate the maximum height, put the lift control in STOP condition (seeLIFT OPERATION) and select "CALIBRATION" from the main menu. Then select option 1 from the "CALIBRATION" menu, turn the MAXIMUM LIFT HEIGHT knob to the maximum position and, using the ground-operated UP/DOWN pushbuttons, position the lift arms at the required maximum height. Press "E" and "C" to save and confirm the new maximum height value. Exit the "CALIBRATION" menu and continue the tests.

6

(V=0.84 dm )

3

Rear lift 210 Bar

5

Fig. 8 - Functional diagram of the lift control valve. 1- UP valve 2- DOWN valve 3- Enabling valve 4- Antishock valve 5- Check valve 6- Lifting cylinder

B

4

2

1

3

P

163

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Vehicle

59

Electronic power-lift

Fig. 9 - Control valve hydraulic circuit - NEUTRAL 1 - UP solenoid valve 2 - DOWN solenoid valve 3 - Enabling valve 4 - Check valve P - Oil flow

164

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5

Electronic power-lift

59

Fig. 10 - Control valve hydraulic circuit - LIFTING 1 - UP solenoid valve 2 - DOWN solenoid valve 3 - Enabling valve 4 - Check valve P - Oil flow

165

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59

Electronic power-lift

Fig. 11 - Control valve hydraulic circuit - LOWERING 1 - UP solenoid valve 2 - DOWN solenoid valve 3 - Enabling valve 4 - Check valve P - Oil flow

166

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Electronic power-lift

59

Fig. 12 - Hydraulic control valve for electronic lift.

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59

Electronic power-lift

Fig. 13 - Position sensor calibration of the electronic lift.

POSITION SENSOR CALIBRATION If a new position sensor is fitted, it will have to be adjusted. Proceed as follows: 1 - Move the lift arms to the minimum height position, connect the "ALL AROUND TESTER" and access the maximum height calibration screen; screw the sensor in or out until a number between 4 and 10 is displayed. 2 - Tighten down the sensor 3 - Proceed with the calibration of the maximum height.

168

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Electronic power-lift

59

2 1 3

Fig. 14 - Pin for draft control of the electronic lift 1 - Pressure test fitting for lift cylinder pressure 2 - Lift control valve 3 - Anti-shock valve

169

5

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59

Electronic power-lift

A

Fig. 15 - Rear view of the electronic lift.

170

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Electronic power-lift

59

A (ALIMENTAZIONE DA REGOLATORE DI FLUSSO)

27 L/min MAX.

(ALIMENTAZIONE DA POMPA O DA FRENATURA IDRAULICA) 27 L/min 26°30'

Corsa sensore 10

Quota sensore montato: 117.5

Quota sensore libero: 119

8.43

73°30'

26°30'

B

B

Fig. 16 - External hydraulic circuit of the lift. A - Lift control valve

171

172 Asse tubo alim. da regolatore di flusso x sollev. meccanico

T. E LE S A

Vehicle

59 Electronic power-lift

Fig. 17 - Top view of the electronic lift. (Salita)

(discesa)

PA

5

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5

Electronic power-lift

59

Precautions for electronic equipment The tractor is equipped with a number of sensitive electrical devices and electronic components. In particular, electronic components do not tolerate polarity inversion, over-current, connection errors, etc.. The electronic components are provided with internal and external protections, but the following precautions are still necessary: — Switch off the control panel before carrying out any work on electrical components. — Do not use a screwdriver of light bulb to test for electrical current; only use the appropriate diagnostic equipment (tester). — Do not apply excessive force when connecting and disconnecting electrical connectors; do not prise connectors apart using a screwdriver, and always respect the polarity of the connection. — In the event of a fault in a circuit controlled by an electronic control unit, do not immediately replace the control unit, but first check that the sensors and actuators are functioning correctly. — When replacing a defective electronic control unit, only unscrew the retaining screws; avoid interfering with other screws as these could be calibration screws. — Inspect contacts on sensors and connectors for corrosion. — Do not use arc welding in the vicinity of electrical circuits. — Avoid short-circuits and polarity inversion. — When working on components controlled by microprocessors, always disconnect the power supply by turning the ignition key to the STOP position before disconnecting the component. — If the tractor is to be resprayed and passed through a paint baking oven, remove all electronic components. — Do not insert the probes of the tester into multi-pole sockets on connectors or other devices (this deforms the contacts and thus leads to poor connections). — Do not test for the presence of electrical current by causing a spark, i.e. by short-circuiting components across wires or to earth. — Do not reverse the polarity or swap over wires in multi-pole connectors. CHECKING THE ELECTRONIC SYSTEM · — — —

Elements to check: Sensors Electronic control units Actuators

1) Checking the system power supply: — current present at input to the connector plugged into the device; — current present at output from connector — earth connection — voltage correct. 2) Check downstream components: sensors. 3) Check upstream components. CHECKING MECHANICAL COMPONENTS Check the splines on the external and internal lift arms for damage or excessive wear; replace the levers if necessary. Check the bushes of the lift arm shaft for scoring or excessive wear. Check the bushes and the pins connecting the lift arms to the hydraulic cylinder are not worn and are firmly inserted in the seats on the levers. Check the diameters of the rod and bushes in the cylinders and compare with the maximum wear limits in the table. Check that the splines on the lifting shaft are not excessively worn and that the machines surfaces in contact with the support bushes are not damaged. NOTE: whenever the lifting cylinders are dismantled, new seals must be fitted.

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Front hydraulic power-lift

Front hydraulic lift On request the tractor can be equipped with the front hydraulic lifting system. It is operated by means of two hydraulic cylinders actuated by the related control lever placed at the right-hand side of the operator driving position. The lever controls a single-acting distributor valve linked to the rear tractor power-lift case. Inspections Ensure that the cylinder pin bushings are not worn and be sure these are firmly secured in their seats. NOTE: Replace gaskets after each hydraulic lifting cylinder disassembly. Specifications power-lift type hydraulic cylinder type oil supply peak operating pressure cylinder stem diameter lifting stroke lifting capacity

A - Front lift cylinders (2) B - Hydraulic accumulator Volume 0.700 litres Nitrogen precharge 130 bar maximum operating pressure 250 bar C - Antishock valve D - Lowering speed regulator valve E - Lockout cock (prevents oil from discharging from the cylinders when transporting raised implements on the road).

Fig. 1 - Lift operation.

174

bar mm mm Kg

with two hydraulic cylinders and removable arms single-acting from the rear auxiliary hydraulic distributor 180 50 170 1500

Vehicle

5

Front hydraulic power-lift

59

Hydraulic accumulator and antishock valve for front lift The front lift is equipped with a hydraulic accumulator with an antishock valve. This improves hydraulic system performance and reduces strain on the front axle.

Fig. 2 - Front linkage components. The grease seal ring must be fitted as shown in the figure and must enter the housing bushing by 2 mm

Fig. 3 - Front linkage components with relative valves and accumulator.

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Front hydraulic power-lift

A - To lift cylinders B - Rate of drop valve C - Anti-shock valve D - Accumulator E - Lowering speed control valve F - Directional control valve Fig. 4 - Oil pressure accumulator and anti-shock valve. (The directional valve to which is connecting, is convertable into single-acting. For the operations to see auxiliary systems chapter).

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Front power take-off

59

Front power take-off General information The power take-off clutch is a multidisk, oil-bath and electro-hydraulic control type. The front power take-off is directly linked to the crankshaft by means of a flexing coupling; while the shaft-end is equipped by an universal joint. The oil used for P.T.O. operation is contained in the P.T.O. casing. A specific gear pump installed on the P.T.O. shaft sucks the oil, which flows first through a filter for being subsequently routed under pressure to the clutch assembly through an electro-hydraulic distributor. The oil is strained through a second (15 micron) filter placed on the pressurized circuit located between oil pump and hydraulic distributor.

Fig. 1 - Front P.T.O. shaft terminal.

A maximum 57 kgm (560 Nm) torque can be transitted to the hitched implement in this way, i.e. 80 CV max. (or 58 kW). To avoid these standards may be exceeded it is recommended that a special joint having proper specifications be installed between implement and P.T.O. The P.T.O. shaft rear teminal has clockwise direction of rotation (with respect to the driving position). Fig. 2 - Front P.T.O. clutch assembly.

Specifications clutch manufacturer clutch disk no clutch disk diameter clutch disk set thickness

mm - max. wear mm - standard wear mm

counterdisk number disk lubricating pressure bar peak calibrating pressure (to press the disks together): - of brake disk bar - of clutch disk bar piston axial thrust kg brake disk braking torque (peak pressure) kgm hydraulic pump oil flow rate (at engine peak speed) (dm/min) litre/min oil filter cod. filtering capacity micron filtering surface cm hydraulic distributor stroke mm rrear P.T.O. shaft terminal direction of rotation oil reservoir capacity litre (dm) oil type 3

2

3

SAME DEUTZ-FAHR DEUTSCHLAND 4 124,5 20,80 21,80 - 22,20 4 + 1(spacer) 1,5 4 13 1523 1 gear type 12 9012.424.2 90 222 1,5 1.3/8" - 6 splines with regard to driving position 2,5 AKROS MULTI 10W30 (APl-GL4)

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Front power take-off

engagement stage

A - Checking the clutch assembly engagement pressure (10 ÷ 13 bar).

Fig. 3 - Front P.T.O. clutch hydraulic circuit (engagement stage).

178

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5

Front power take-off

59

disengagement stage

A - Checking clutch assembly engagement pressure (4 ÷ 6 bar).

Fig. 4 - Front P.T.O. clutch hydraulic circuit (disengagement stage).

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Front power take-off

Apply some LOCTITE 510 (red) on the surface betuen cover and box

Fig. 5 - Longitudinal section of the front P.T.O. assembly. A - Solenoid valve C - brake apply press. control valve E - Strainer

Fig. 6 - Front P.T.O. shaft flexing coupling.

180

B - Clutch pressure control valve D - Clutch engagement pressure accumulator F - Oil level indicator plug

Vehicle

5

Front power take-off

59

Apply some LOCTITE 212 (sky-blue) on the screw threads.

Fig. 7 - Cross-section of the front P.T.O. assembly. A - Brake disc D - Input shaft G - P.T.O. shaft

B - Clutch discs E - Strainer

C - Oil pump F - Oil drain plug

Fig. 8 - Top view of front P.TO.

Correct fitment of front P.T.O. shaft bearing Locate the bearing 2.2421.012.0 with the shoulder directed toward the gear as indicated in fig 8.

181

9

Vehicle

59

Front power take-off Installing “RING-FEEDER” rings Install all the parts following the order shown in figure. Thoroughly tighten the pulley hub on engine crankshaft to 38 ± 2 kgm (380 ± 20 Nm). Fit an intermediate flexible coupling with a torsional rigidity of 25,145 kgm/rad; the maximum applicable inertia must not exceed 0.5 kgm . 2

Fig. 9 - “RING-FEEDER” rings installed.

Fig. 10 - Front P.T.O. assembly parts

182

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Front power take-off

59

Checking clutch Make sure that the clutch disk friction linings are neither worn nor torn, if so replace the disks. The control piston should be replaced if signs of scoring are noticed. If the splined sliding surface of the clutch disk hub is sunk in its upper part, the hub should be replaced. Check the efficiency of the piston return spring. The spring specifications should correspond to those indicated in the specific table. Replace if necessary. The clutch and brake piston sealing rings as well as the brake disk itself should be replaced if excessively worn. If either the rotary seals or the relevant seats are worn, these should be replaced. Every time the assembly is taken to pieces, carefully clean the oil passages in the clutch casing; use compressed air if required.

Check the clearance of the clutch friction discs With new discs in place, check that distance A (Fig 11) is between 0,5 and 2 mm. If the clearance is greater than the maximum value indicated, add 1 x shim p/n 2.1599.499.0 at the position arrowed.

Fig. 11 - Checking disk clearance of front power-take-off.

Checking clutch assembly engagement pressure Fit no. 5.9030.517.4 equipment to the oil supply pipe using no. 5.9030.632.0/10 union as shown in figure 3 at pages 254-255 and then connect no. 5.9030.514.0 oil pressure gauge. With the P.T.O. engaged Let the oil circulate within the clutch casing and then be sure the following conditions are established: with engine running at peak idling speed the pressure reading should be 13 ± 1 bar; with engine running at the lowest idling speed the pressure reading should be 10 ± 1 bar. N.B. - Make sure the P.T.O. shaft terminal is turning. With the P.T.O. disengaged Let the oil circulate within the distributor casing and then be sure the following conditions are established: with engine running at peak idling speed the pressure reading should be 6 ± 0.5 bar; with engine running at the lowest idling speed the pressure reading should be 4 ± 0.5 bar. N.B: Make sure the P.T.O. shaft terminal is being braked.

Fig. 12 - Electro-hydraulic control valve.

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Front power take-off

Diagnosing malfunctions Verify activation of the solenoid valve

check piston free stroke

clutch slipping

P.T.O. brake does not apply

for

replace the solenoid valve if necessary

recheck pressure

replace the springs of inefficient valves

replace the defective parts

inspect O-rings on piston and manifold

replace the solenoid valves if necessary

verify movement of piston

remove any roughness preventing smooth action

inspect clutch discs for wear

replace discs

Check the solenoid operated control valve

replace the solenoid valve if necessary

Check engage ment pressure

inspect O-rings and replace if necessary

piston jammed

replace out-of-setting valve springs

Spring specifications piston return spring wire diameter external diameter released spring loaded spring hydraulic system valve springs quantità wire diameter external diameter released spring loaded spring

184

cod. mm mm mm - kg 75,7 (Nm 742) mm - kg 79,7 (Nm 782) mm

2.4019.373.1 6,5 79,5 61,5 30 28

cod. numero mm mm mm - kg 3.6 (Nm 35) mm - kg 4.6 (Nm 45) mm

2.4019.179.1 2 1.2 8.8 63 44,6 39.5

Controls

6

Hydrostatic steering

63

Hydrostatic steering code 290.6310.4/10 Danfoss type for 4WD code 010.8555.4 danfoss type for 4WD with double steering cylinder and oversized pump capacity of 14cc code 009.3141.4/10 Danfoss type for 2WD

General information There in no direct mechanical connection between the wheels and the steering wheel and therefore no vibration can reach the driver. Turning the steering wheel operates a rotary distributor connected to an oil flow control shutter permitting the pressure oil to be directed to the hydraulic cylinder in the amount necessary to provide the desired steering action. The steering system is an open-centre reactive type: the user can directly feel the steering response on the steering wheel and perform a prompt correction of the driving direction. In addition, the remarkable wheel caster angle will help increase the wheel self-centering effect as the wheels will automatically get in a straight line when the steering wheel is released. The hydraulic circuit is fully independent. The oil drawn from the gearbox flows first through a high-delivery filter before being routed under pressure to the distributor by a pump constantly in mesh driven by the engine and fitted on gearbox left-hand side. Two powerful cylinders, connected to the front wheel hubs, ensure the thrust necessary to steering under any working conditions. Oil returning from the power steering unit is directed to the unit piloting the electrohydraulic controls and sole function to lubricate the gearbox. Moreover this system offers the advantage that the tractor can be driven also in the event of either a pump failure or an engine stop. A valve within the distributor will allow the oil to be drawn from the discharge circuit through the oil control shutter, whenever a pressure drop occurs in the pump delivery circuit. hydraulic directional control valve type of valve relief valve setting

bar bar mm

clearance between spool and sleeve turns of steering wheel before road wheels respond - engine running - engine at standstill steering cylinders working stroke of piston rod rod diameter pushing force steering wheel turns to full lock

tightening torques valve cover securing screws cylinder securing bolt

2WD 4WD 2WD 4WD

ospc 80 or open-centre reactive type for 2WD and 4WD ospc 125 or open-centre reactive type for 4WD with oversized oil pump and double steering cylinder 150 for 4 WD 100 for 2 WD 0,03 0° - 2° 0° - 6°

mm mm mm kn kn nº

171 42 50 13,6 19 2.17

kgm kgm

3 16

Nm Nm

29 155

185

6

Controls

63

Hydrostatic steering Inspections and checks Steering pump Clean all component parts of the pump thoroughly, using petrol. Check that the gears are not unduly worn, otherwise replace.

Directional control valve Clean all parts of the valve thoroughly. Check, utilizing a comparator for internal dimensions, that the clearance between spool and sleeve (A - B - Fig 1) is no greater that 0.03 mm: otherwise replace. The two components are not available separately as spare parts.

Check the setting of the pressure relief valve Fig. 1 - Fit diameter between internal and external elements of the control valve.

Couple pressure gauge 5.9030.513.0 by means of adaptor 5.9030.579.0 to the fitting of the left hand steering cylinder (as indicated in fig 2). Start the engine and allow to idle for a few minutes; then, with the steering on full right hand lock, turn the wheel further until the hand of the gauge stabilizes at around the maximum pressure. If this is different to the maximum operating pressure (150 bar for 4WT and 100 bar for 2WT), adjust the setscrew (A - fig 10, page 192) of the valve until the requisite value is re-established in the circuit. Repeat the same sequence of operations with the pressure gauge and adaptor fitted to the right hand steering cylinder, this time on the left hand lock.

Fig. 2 - Testing pressure in the hydraulic steering circuit. A - fitting B - cylinder

Bleeding the hydraulic circuit Start the engine and allow to idle at minimum rpm. Loosen the two fittings at the cylinder and turn the steering wheel each way until oil emerges devoid of air bubbles.

Assembly of orbital pump unit

Fig. 3 - Correct assembly of orbital pump unit

186

Locate the rotor A in the stator B as illustrated, making certain that the pin C is perpendicular to the plane x - x of the valve body as indicated in fig 3.

Controls

6

Hydrostatic steering

63

Teering wheel shaft Verify the integrity of the steering column, and in particular, make certain that the surfaces of the bearings are not scored, also that the splines are neither damaged nor showing signs of excessive wear. Do not grease or oil the bearing inside the sleeve. Check that the steering column rotates freely, without sticking, but also without excessive play. Before refitting the rubber boot A (Fig 4), smear the steering column B with the grease at the position indicated in fig 4. Having tightened all components, check that the steering wheel continues to operate correctly even when at its two height adjustment limit positions (fully raised and fully lowered).

Fig. 4 - Section through steering wheel shaft A - Rubber boot B - Steering column

Steering cylinders Clamp the cylinder in a vice and withdraw the piston G (fig. 7); If necessary, remove the circlip F (fig. 8) from its groove with the aid of a suitable tool to allow withdrawal of the ball end G (fig. 8).

Fig. 5 - Steering column. A - Bearing B - Sleeve

A - Shock valves B - Anticavitation valves C - Pressure relief valve (150 bar) D - Emergency steering check valve E - By-pass valve (redirects return flow to inlet) F - Orbital pump unit G - Directional control valve

Fig. 6 - Components of directional control valve

187

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Controls

63

Hydrostatic steering

I - Snap ring L - Head M - Gasket N - Dust seal O - Spring P - Ring nut

Fig. 7 - Single acting cylinder. A - Snap ring B - Ball C - Cylinder D - Self-locking nut E - Guide ring F - Seal G - Piston H - Shaft

Servicing Verify the integrity of the O-ring and wiper seals. Replace any components showing signs of wear or damage. Inspect the sliding surfaces both of the rod and of the cylinder for signs of scoring, heavy wear or any kind of damage; if any of these are discernible, replace the affected component. Check for correct operation of the ball end, ensuring that it betrays no signs of heavy wear, scoring or oxidation, the presence of which dictates replacement. Lubricate the wiper seals and ball end with care. Reassemble the cylinder, repeating the dismantling operations in reverse sequence.

Fig. 8 - Ball joint F - Circlip G - Ball joint

Fig. 9- Section through single acting cylinder. A - Wiper B - Ring nut C - Gasket

188

D - Head E - Cylinder F - O-ring

G - Self-locking nut H - Ball end I - Circlip

L - Piston M - O-ring N - Shaft

Controls

6

Hydrostatic steering

63

Instructions for the hydrostatic steering distributor assembly

1 - Insert the spring set (blue) as shown in figure.

2 -Insert first the two external spring blades into the rotary distributor and subsequently the two internal ones.

3 - Press the spring blades to align in centre position.

4 - Reassemble the rotary distributor.

5 - Act on springs in such a way they are prevented from projecting outwards with respect to the rotary distributor outside surface.

6 -Fit the spacer onte the distributor.

7 - Insert the drive pin into the cylinder

8 - Install the axial bearing following the assembly order shown in next figure.

9 - Axial bearing installation.

10 - Use no. 5.9030.480.0 tool to fit the seal ring.

11 - Insert the O-ring after fitting the tool sleeve into the distributor case.

189

6

Controls

63

Hydrostatic steering

12 - O-ring as installed on the plug.

13 - Insert the O-ring into the sleeve and press until it is fully inserted.

14 - Pull out the tool.

15 - Insert the distributor from the bottom trying to make installation easier alternately rotating in both directions.

16 - Press the distributor until the plug is pushed out of the opposite side.

17 - Turn the distributor case upside down holding the rotary distributor in place and iserting the shunt valve as in dicated by the arrow in figure.

18 - Screw down the valve grub screw in its seat.

19 - Insert the balls as shown by the arrow.

20 - Insert the two pins in the same posi tions as previously shown.

21 - Fit the seal ring in the related seat.

22 - Fit the spacer in such a way the holes in it are in the same line as the corresponding grooves.

23 - Insert the drive shaft in the distribu tor so that the notching may engage into the pin in a position being parallel to the distributor face.

190

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Hydrostatic steering

63

24 - Place the fork as shown in figure so as the drive shaft may be held in position.

25 - After inserting the two O-rings pro perly lubricated into the oil flow control shutter fit the stator positioning as shown in figure.

26 - The rotor should be placed to the sta tor and then swiveled with regard to the drive shaft as shown in figure.

27 - Place the spacer ring, (only for those models which the spacer is fitted).

28 - Install the pin screw in the special hole (the ball valve hole).

29 - Fit the cover.

30 - Fix the cover with the securing screws by tightening to the recommended torque.

31 - Fit the seal ring.

32 - Insert the seal ring into its seat.

33 - Install the pressure relief valve.

34 - Insert the spring.

35 - Fit the pressure relief valve cap screw.

191

6

Controls

63

Hydrostatic steering

A - pressure relief valve B - check valve C - from pump D - anticavitation valve E - emergency steering check valve Fig. 10 - Distributor cross-section.

192

F - return flow L - to left hand cylinder R - to right hand cylinder P - pump T - discharger

Controls

6

Hydrostatic steering

63

1 - Oil to the main pump 2 - Oil to the flow control shutter 3 - Oil to the steering cylinder 4 - Oil trapped in closed circuit 5 - Oil in the discharging line 6 - Oil in the aspirating line 7 - Right-hand rotation 8 - Left-hand rotation 9 - Neutral position

Fig. 11 - Reactive-type, open-centre hydraulic distributor schematic diagram.

193

6

Controls

63

Hydrostatic steering Greasing the steering shaft

On assembly, grease the areas shown on the left with Molikote GN-PLUS

Fig. 12 - Greasing the steering shaft.

Fig. 13 - Components of steering controls and hydrostatic power steering support

194

Controls

6

Hydrostatic steering

63

8 Bar L

R

OSPC 80 OR

100 Bar 2 WD 0.009.3141.4/11 150 Bar 4 WD 0.290.6310.4/10 T

P

Fig. 14 - Hydrostatic steering operation diagram.

195

6

Controls

63

Hydrostatic steering

Diagnosing malfunctions Check oil level in tank

Restore level Check for air in system

Bleed the system

Check for shorn distributor securing pin

Replace pin

Unable to steer tractor Check safety valve setting

Reset or replace if necessary

Hard steering

Check safety valve setting

Distributor and oil flow Check oil filter for dirt control shutter worn

Blocked distributor

Check for dirty oil

Bleed the system Check for air in the system

Check for leakage Replace worn seal from the distributor rings and the piston seal rings in the hydraulic cylinder

Change oil and replace filter Check that the oil is of prescribed type

Change oil and replace filter

Clean distributor and replace oil Check that oil is not excessively hot

Stop tractor and let oil cool

Bleed the system

Wheels oscillation

196

Check for air in system

Check for oil leakage in the hydraulic cylinder

Replace seal ring

Check valve setting

Adjust

Controls

6

Mechanical controls

64

Mechanical controls Given the constructional simplicity of these controls, we present a series of figures illustrating the individual components of the controls. Only some of these controls require adjustment; for instructions for these adjustments, refer to the chapter dealing with corresponding unit. Fig. 1 - Gearbox inversor control Fig. 2 - Gear-change control Fig. 3 - Gearbox reduction unit control Fig. 4 - Synchronised P.T.O. control Fig. 5 - Hand throttle control Fig. 6 - Accelerator pedal control Fig. 7 - Lift controls Fig. 8 - Ground-operated lift controls Fig. 9 - Auxiliary control valve controls

N.B.: For P.T.O. controls see instructions on page 178.

WARNING: It is important that those tie-rods fitted with adjustable forks are adjusted so that their respective control levers can be moved through their entire range from min. to max. without obstruction.

Fig. 1 - Gearbox inversor control

197

6

Controls

64

Mechanical controls

Fig. 2 - Gear-change control.

Fig. 3 - Gearbox reduction unit control.

198

Controls

6

Mechanical controls

64

Fig. 4 - Synchronised P.T.O. control.

Lever play adjustment: insert a washer 2.1311.010.2 and , if necessary, other washers 2.1580.004.0 in the space A to obtain a play of 0.5-1 mm.

Fig. 5 - Hand throttle control. Control adjustment: tighten nut A to a torque of 7 kgm (70 Nm), screw in screw B to obtain lever movement with a load of 70N

Turn the control lever backward and forward 2-3 times through approx. 25° and re-check the load on the lever; adjust if necessary. 199

6

Controls

64

Mechanical controls

FITTING AND ADJUSTMENT OF THE GOVERNOR

EXTERNAL CONTROLS OF THE MECHANICAL

Accelerator pedal (fig. 6). Attach the throttle cable A to bracket C and then to lever D, then fit spring P. Adjust the position of screw G to obtain a pedal travel of 75 mm as shown in figure 6 (corresponding to an angle of approximately 32°) and secure in position with locknut Q. Hand throttle Attach the throttle cable B to bracket E by tightening screw N and positioning the locknuts O and then attach the cable to lever V. Connection of the accelerator pedal and hand throttle cables to the governor. Attach the throttle cable to bracket H of the governor by way of screw L, and secure with locknuts I; Connect the throttle cable to bracket M of the governor. Adjust the freeplay of the throttle cable by turning the screw L (after having undone the locknuts I) so that the cable is correctly tensioned, then re-tighten the locknuts. Attach the throttle cable S of the hand throttle to bracket T and then attach it to lever U. Then apply a force f = 5 to lever F and screw in self-locking nut R until the force applied is no longer capable of moving the lever. Move the hand throttle lever to the “MAX” position and manually push lever F to the end of its travel, then screw in screw N until the throttle cable is fully tensioned, then tighten locknuts O. ±0,5

Fig. 6 - Adjustment of the external controls of the mechanical governor.

200

Controls

6

Mechanical controls

64

Control adjustment: screw in the screw with spring (Belleville) to obtain lever movement with a load of 35N. Turn the control lever backward and forward 2-3 times through approx. 22° and re-check the load on the lever, and reset the load to 45N.

Fig. 7 - Lift controls.

Fig. 8 - Ground-operated lift controls.

Fig. 9 - Auxiliary control valve controls.

201

6

Controls

68

Electro-hydraulic controls

Electro-hydraulic controls Front P.T.O. clutch engagement control The front P.T.O. can only be engaged when the engine is running. Pressing the pushbutton engages the front P.T.O.. The integral light illuminates to indicate that the P.T.O. is engaged.

Rear P.T.O. clutch engagement control Activation and deactivation of the P.T.O. clutch are piloted by a dedicated control unit. The activate/deactivate control function is se-lected by pressing the button, which returns to the off position when released. An integral light shows when the function is activated, and serves also to indicate the type of fault that may affect the electrohydraulic control. When the engine is started, the warning light blinks to indicate that the control system is activated. The P.T.O. is engaged by pressing and holding the button for at least 2 se-conds. If the button is held for more than 10 seconds, or if there is a fault with the electrohydraulic control, the P.T.O. will be deactivated automatically. The control unit also disengages the P.T.O. every time the engine is swit-ched off. The rear P.T.O. can be engaged by pressing the ground-operated pushbutton located on the rear right-hand fender.

Differential lock engagement control Pressing the pushbutton engages the front and rear differential locks. The integral light illuminates to indicate that the locks are engaged. Pressing the pushbutton again disengages the locks.

Front-wheel drive engagement control Pushbutton with integral indicator light. Press to engage front-wheel drive; press again to disengage. N.B. Engagement of the above devices is also signalled by indicator lights on the console.

Gearbox The POWERSHIFT transmission offers the possibility to select each speed in or or (using the gear and range lever) without having to depress the clutch pedal simply by pressing the electro-hydraulic control switch. This is achieved by way of three multi-plate clutches.

Front and rear lift The front lift is operated by way of the control lever of the auxiliary service control valves located on the right of the driving seat, after first opening the shut-off cock in the oil delivery line to the front lift. The mechanical rear lift is operated by controls located to the right of the driving seat. For tractors equipped with electronic lifts, see p. 157 for a description of the controls.

202

Controls

6

Electro-hydraulic controls

68 R

F

210 Bar

4RM

Rear lift

(V=0.84 dm )

2RM

T

8 Bar L

R T

A - Main oil filter on supply circuit B - Hydraulic pump for auxiliary service control valve and power lift C - Hydraulic pump for hydrostatic steering and electro-hydraulic controls E - Hydrostatic steering control valve F - Steering cylinders G - Oil cooler H - Pressure control valves I - Gearbox lubrication L - Hydraulic power unit M - Differential locks N - 4WD engagement O - Rear P.T.O. clutch P - Auxiliary service control valve Q - Front lift hydraulic control valve R - Lifting cylinder

3

T

OSPC 80 OR

Q

T Lift

E 100 Bar 2 WD 0.009.3141.4/11

Neutral

6 Bar

Lower

P

T

150 Bar 4 WD 0.290.6310.4/10 P

O N Dis.

Rear

4 Wd

Main shaft

A

0

Sec. shaft

T

P

T T

P

0

P

H.P.C.

1

T

190 Bar

A

2

2

P

A

T

1

1

A

A

P

E ø 1.1

G

B

I

Inn.

Front

Dis.

Inn.

Diff.look

B

P.T.O.

32 cc

M

0

T

2.3719.730.0 11 bar

L 16 bar

5 bar

H 11 cm 3 27 L/min.

19 cm 3 47 L/min.

x

B

Rh

14 cm 3 35 L/min.

N.giri/min.pompe:2522

Lf

C

Rapp. 1/1.0732 (44/41)

150 Micr.

A

Fig. 1 - Hydraulic circuit diagram (with electronic lift - STANDARD version).

203

6

Controls

68

Electro-hydraulic controls F 6

(V=0.84 dm )

Rear lift

U

L

3

R

R

210 Bar 2.3729.320.0

A 4

700 cc

OSPC 80 OR

E

5

70 Bar 2 V1

1

100 Bar 2 WD 0.009.3141.4/11 150 Bar 4 WD 0.290.6310.4/10 T

P

3

V2

Q

P S 2

1

Rear free return

O

Rear

4 Wd

Main shaft

X

I

B

A

B

A

190 bar

P-Ecc.

N

L

A

A

P

T

P

Sec. shaft

P-Reg.

A T

P

T

T G

11 bar

16 bar

P

H

T

P

A

P

5 bar

T

3 11 cm 27 L/min.

A H

M

Rh L

x

25 Micr. A

D

Fig. 2 - Hydraulic circuit diagram (version with full complement of optional equipment).

N.giri/min.pompe:2522 Rapp. 1/1.0732 (44/41) C

25 Micr.

2.3719.810.0/10 (Italia) 2.3719.550.0/20 (Francia)

11 cm 3 27 L/min. Lf

B

Z

204

A

3

Trailer brake ø 1.1

ø1

3

Inn.

Front

N

32 cc

Diff.look

Dis.

Inn.

A - Main oil filter on supply circuit B - Hydraulic pump for auxiliary service control valve and power lift C - Hydraulic pump for hydrostatic steering and electro-hydraulic controls D - POWERSHIFT E - Hydrostatic steering control valve F - Steering cylinders G- Delivery line filter H - Pressure control valves I - Gearbox lubrication L - Hydraulic power unit M - Differential locks N - 4WD engagement O - Rear P.T.O. clutch P - 6-way auxiliary service control valve Q - Front lift hydraulic control valve R - Lifting cylinder S - Shut-off valve for front lift T - Control valve for hydraulic trailer braking U - Front lift cylinders V1 - Anti-shock valve for front lift V2 - Lowering speed control valve for front lift Z - Hydraulic unloader (oil level pump)

1

T

P.T.O.

Dis.

M

B

2

Y Tractor brake

Freno inser.=13 bar,disinser.=5 bar =3 bar

2.3719.740.0/10

P

Controls

6

Electro-hydraulic controls

68

A - Check valve B - Check valve C - Gearbox lubrication pressure control valve (5 bar) D - Sequence valve (16 bar) P - Pump T - Oil return L1- Gearbox lubrication L2- PTO lubrication 1 - Rear PTO 2 - Differential lock 3 - 4WD

Fig. 3 - Hydraulic circuit on right-hand side of gearbox.

205

6

Controls

68

Electro-hydraulic controls

The hydraulic injector A inserted in the transfer pipe B equalises the oil levels in the front and rear gearboxes. The injector allows oil in the front gearbox to flow easily into the rear gearbox.

TECHNICAL CHARACTERISTICS

Flow used Pressure of jet Flow transferred

1,8 l/min 16 bar 25 l/min

A - Hydraulic injector B - Transfer pipe C - Front gearbox D - Rear gearbox E - Venturi pipe

Fig. 4 - Details of front and rear gearboxes.

206

Controls

6

Electro-hydraulic controls

68

A - Circuit transmission lubrification\PTO B - Flow control valve

Fig. 5 - Machine with electrohydraulic controls operating differential lock, four wheel drive and power take-off, equipped with POWERSHIFT.

207

6

Controls

68

Electro-hydraulic controls

A - Circuit transmission lubrification\PTO B - Flow control valve

Fig. 6 - Machine with electrohydraulic controls operating differential lock, four wheel drive and power take-off, not equipped with POWERSHIFT.

208

Controls

6

Electro-hydraulic controls

68

Specifications Solenoid operated valve controlling four wheel drive engagement, differential lock, equipped with POWERSHIFT and the rear P.T.O. clutch. Code 2.3719.670.0

max. delivery rate l/min 12

max. pressure bar 210.

Before tightening the lock nut, smear the thread with LOCTlTE 242 (blue).

Fig. 7 - Solenoid valve

209

6

Controls

68

Electro-hydraulic controls

Specifications Solenoid operated valve controlling the front P.T.O. clutch Code 007.5339.0/10

max. Delivery l/min 12

max. pressure bar 210.

Before tightening the lock nut, smear the thread with LOCTlTE 242 (blue).

Fig. 8 - Solenoid valve

210

Controls

6

Electro-hydraulic controls

68

Fig. 9 - POWERSHIFT solenoid valves - LOW clutch engagement

211

6

Controls

68

Electro-hydraulic controls

Fig. 10 - POWERSHIFT solenoid valves - MEDIUM clutch engagement

212

Controls

6

Electro-hydraulic controls

68

Fig. 11 - POWERSHIFT solenoid valves - HIGH clutch engagement.

213

6

Controls

68

Electro-hydraulic controls

Adjustment of front and rear differential lock control Turn fork A and lock nut B to preload spring C, so as to obtain a distance X allowing contact with piston E (with spring D attached) when the piston is positioned flush with surface F (on version with electrohydraulic controls) or protrudes 18.5 mm (on version with mechanical controls). Also check that the shoes of the fork do not rub against the sides of the engagement sleeve. For adjustment of engagement sleeve, see chapter on front-wheel drive. To make sure that the shifting of the piston of the rear differential look is of 12 mms.

Fig. 12 - Front and rear differential lock control.

214

Body

7

Driving position

71

Platform

Fig. 1 - Instrument panel.

Fig. 2 - Roll bar.

Fig. 3 - Structure of the platform.

215

7

Body

71

Driving position

Cab general specifications The cab responds to international standards in terms both of safety and of internal noise levels. The enclosure is equipped with ventilation, heating and air conditioning systems. Versions available are: — Cab with ventilation and heating — Cab with ventilation, heating and air conditioning

Fig. 4 - Structure of cab.

Fig. 5 - Front window glass and seals.

Fig. 6 - Front windows glass and seals.

Fig. 7 - Cab doors

216

Body

7

Driving position

71

Fig. 8 - Rear window.

Fig. 9 - Internal claddings

Fig. 10 - Cab roof.

Fig. 11 - Screenwash pump and liquid container.

217

7

Body

71

Driving position

Fig. 12 - Cab air filter unit 1 - Air filter 2 - Protective grille

Cab air filter

Periodically (as dictated by operating conditions): clean the filter. To gain access to the filter, lower the protective grille,release the two filter clamp knobs, and remove The filter is cleaned as follows: — blast with compressed air (6 bar max) in the direction opposite to that of normal filtration, until all accumulated dust has been dislodged; — wash for about 15 minutes in a solution of detergent and water at 40 °C; — rinse clean in running water; — leave to dry naturally at ambient temperature. Important: the filter must be replaced if damaged, or renewed routinely after cleaning 6 times.

Screen wash

Periodically (as dictated by operating conditions): check the level of screenwash liquid in the plastic container located at the rear of the machine. In the event of the jet being rendered defective by an obstruction, this will be remedied generally by freeing the nozzle outlet with a pin. If necessary, reposition the nozzle so that the jet strikes the screen at the top of the sweep made by the wiper blade. It is good policy during winter months to add antifreeze solution to the screenwash liquid, or methyl alcohol. Warning: it is important that all glass in the cab is kept thoroughly clean. The rear view mirrors must always be kept clean and properly positioned.

Screen wipers (front and rear)

The wiper blade has a bayonet fitting. The blade is removed by lifting the catch of the central mounting.

218

Fig. 13 - Front screen wiper.

Body

7

Driving position

71

Fig. 14 - Rear screen wiper.

REMOVING THE DRIVING PLATFORM COMPLETE WITH CAB NOTE: even though not strictly necessary, we advise that you remove the rear wheels to facilitate access to parts requiring disconnection. PROCEED AS FOLLOWS: — Using a hydraulic jack, raise the rear of the tractor and place stands under the rear trumpet housings, then remove the rear wheels; — Remove the top engine hood; — Remove the front panel, disconnecting the leads of the front lights and then disconnect the positive (+) and negative(-) battery leads; — Disconnect the leads from the starter motor and the engine oil pressure switch; — Disconnect the bulkhead connector of the dashboard warning lights; — Disconnect the leads on the right-hand side of the gearbox connected to the solenoid valves of the electro-hydraulic services and the POWERSHIFT unit; — Disconnect the lead connected to the actuator of the electronic accelerator (only on tractors equipped with electronic governors); — Disconnect the two tie-rods of the THROTTLE and ENGINE STOP from the governor; — Disconnect the lead connected to wheel speed sensor positioned on the left-hand side of the front gearbox; — Disconnect the three leads connected to the PTO selection sensors (540-775-1000 rpm); — Disconnect the lead to the cab heating element from the heater alternator; — Disconnect the oil pipe from the clutch control actuator; — Disconnect the brake pipes from the “separate brakes” valves; — Disconnect the lift control rods and remove them from the tractor; — Disconnect the hydrostatic steering oil delivery and return pipes underneath the platform and on the right-hand side of the gearbox; — Disconnect the three 3 control levers GEARCHANGE-INVERSOR-RANGE GEARS from underneath the platform, removing the retaining screws of each lever; — Remove the two securing straps of the exhaust silencer and remove the silencer itself;

219

7

Body

71

Driving position

— Detach the two pipe clamps positioned in the channel passing over the engine and disconnect the oil return pipe from the cooler and the oil pipe of front lift; — Disconnect the two hydrostatic steering delivery-return pipes from the hydrostatic steering oil cooler; — Disconnect the lead and remove the brake and clutch oil reservoir securing strap; — Disconnect the handbrake control and the synchro PTO control rod on the left-hand side under the driving platform; — Loosen the 4 screws securing the platform to the silent-blocks; — Disconnect the air conditioning system pipes at the quick-fit couplings and then loosen the respective retaining nuts of the pipes connected to the cab so that they may be detached from their support brackets; — Connect the cab to a suitable hoist and raise it, taking care that it disengages form the tractor, then remove it from the tractor;

Fig. 15 - Disconnecting the parts connectinga the cab to the tractor.

Fig. 16 - Lifting the cab off the tractor using a hoisting.

Remove cab. WARNING: during the cab hoisting operation, check carefully that all the parts have been disconnected and that the cab disengages from the tractor. IMPORTANT: If the fuel tank is also to be removed, disconnect the flexible pipe from the rigid injector leak-off pipe.

Refitting the cab or driving platform. Refitting: the reverse of removal.

BREAKAGE OF THE TOP ENGINE HOOD RELEASE CABLE To open the hood, insert a screwdriver between the hood and the grille to operate the hood catch. Push the screwdriver to the left (relative to the driving position) to release the hood.

Fig. 17 - Position the cab on suitable supports and proceed with the operations on the tractor.

220

Body

7

Driving position

71

Fig. 18 - Hood catch release control.

Fig. 19 - Condenser and filter/dryer unit.

Fig. 20 - Air conditioning system pipes from compressor to condenser and from the condenser to the filter/dryer.

Fig. 21 - Air conditioning system compressor

221

7

Body

71

Driving position

84

Fig. 22 - High visibility cab air filter

Fig. 24 - High visibility cab roof.

222

Fig. 23 - Coverings and outlets for air circulation in high visibility cab

Systems

8

Air conditioning

86

Ventilation The ventilation unit is housed in the cab ceiling. To switch it on and adjust it, turn the electrical fan switch to the desired speed. The cab becomes slightly pressurized when the ventilation system is in operation, so that fresh air can enter only by way of the filter installed in the rear section of the cab roof. The fan switch can be operated only after the ignition key is inserted. The air flow can be regulated and directed by suitably positioning the air diffusers. Air can be taken in fresh from outside or recirculated from within the cab by way of the relative side inlets. · Recirculation inlets fully closed: air is taken in entirely from outside the cab through the rear grille and filtered through a paper element positioned behind the grille. · Either fully or partially open air recirculating grille: now the air is recirculated inside the cab. N.B. - It is very important that the air diffusers never be completely closed so as to allow for a steady air flow. To obtain a greater pressurization inside the cab, it is necessary to take the air from the outside, therefore the inside air recirculating grille should be fully closed.

Climate control system A - Condenser B - Temperature sensor C - Control switches D - 2400 Watt electric heating element (resistance across terminals 0.655 ohm) E - Defroster F - Ventilation unit

Heating System The heater is switched on and adjusted by rotating the control knob at the roof console, then switching on the blower and setting the selector at the preferred speed. To warm the cab up quickly, the knob should be rotated fully clockwise and the blower set to speed III. The screen is demisted or defrosted by air directed through a slot vent. For defrost or fast demist, all other vents should be closed off. IMPORTANT: ventilation is provided by a single blower unit serving both the heating system and the air-conditioning system. After reaching the desired temperature adjust the system to suit your needs. N.B. - For ideal system operation, the engine must run at 1600 r.p.m. WARNING:Before starting the engine, make sure the system is off (by turning off the ventilation fan) so as not to overload the battery. After using the system at full power for a long period of time, never turn it off suddenly but let it first idle for about 20 seconds.

223

8

Systems

86

Air conditioning

System configuration The heating system consist of two units: 1 - Electric heater 3 (3 fig. 1) and blower unit (4 fig. 1) installed behind roof console. 2 - Power supplyng set, consisting of an auxiliary alternator (1 fig.1) located front of the engine and driven by a belt di rectly linked to the engine pulley. If the air does not come out from the diffusers right away as soon as the system is started, turn off immediately and identify the fault. N.B. Never turn on the heating system when working in dusty environments. In the event of the system failing to operate, check the fuse in the roof terminal box.

Fig. 1 - Configuration of ventilation and heating unit. 1 - Alternator 2 - Compressor 3 - 3 speed fan 4 - Electric resistence 5 - Evaporator 6 - Ventilator 7 - Dehydrating filter 8 - Condenser 9 - Air filter 10 - Recirculation inlets 11 - Pivotable air diffusers

224

Systems

8

Air conditioning

86

Temperature sensor

Ventilation switch

Temperature control potentiometer

Fig. 2 - Ventilation - heating system.

225

8

Systems

86

Air conditioning

Temperature control knob

Blower motor

Heating relay

Fig. 3 - Components of the ventilation - heating system.

226

Systems

8

Air conditioning

86

Air conditioning unit for cabs The air conditioning system will operate only with engine running and the 3-speed electric fan unit switched on. Technical specifications type of refrigerant inlet circuit pressure (*): high bar normal bar low bar delivery circuit pressure quantity of refrigerant in circuit quantity of oil cc type of oil minimum pressure switch settingbar maximum pressure switch setting electric fan pressure switch setting tightening torque for pipeline fittings

bar g

bar kgm (Nm)

R 134 a 2,5 0,8 ÷ 2,5 0,8 see page 350 1400 200 Suniso SP20 2 27 close at 15 bar - open at 11 bar 6 (58)

(*) Pressure is influenced by ambient temperature; in normal operating conditions, with a temperature of 27 °C, pressure in the delivery circuit will be 12 bar. Pressure in the same system will register at around 16 bar with an ambient temperature of 38 °C.

1 - Electromagnetic coupling 2 - Compressor 3 - Condenser 4 - Fan 5 - Filter 6 - Sight glass 7 - Minimum pressure switch 8 - Electric fan control pressure switch 9 - Maximum pressure switch 10 - Expansion valve 11 - Evaporator 12 - Bulb 13 - Potentiometer

Fig. 4 - Diagram showing operation of air conditioning system.

227

8

Systems

86

Air conditioning

Operation and maintenance of the air-conditioning system Air-conditioning process The cooler is provided with a three-speed fan which aspirates the air from the cab interior thereafter forcing it across the radiant block, thus making it cool down. The heat exchange occurring between the gaseous coolant and the air lapping the walls of the cooler radiant block results in air cooling.

The conditioned air undergoes a humidification process, as the low temperature inside the cooler causes a great deal of condensate to deposit on the external walls of the cooler. This condensate is subsequently conveyed under liquid state outside the cab through a special drainage system. The coolant at the cooler exit is still under gaseous state and has a temperature of 5 to 10°C, in spite of the thermal exchange that has taken place, and then it is aspirated by the compressor again.

How to operate the system Before starting the air-conditioning system set the electric fan onto the desired speed. If the electric fan is switched off, the conditioning system will not start. The air-conditioning system is turned on by progressively rotating the control potentiometer clockwise, which is located in the front top section of the cab compartment. Rotate it anticlockwise to turn the system off. Warning: Before starting the engine, always make sure the air-conditioning system is switched off so that the battery will not be overloaded. When the air-conditioning system is operating, the pivotable air diffusers should never be completely closed. To obtain a quick cab environment cooling the following is recommended: — Fully open the air recirculation grating and the pivotable air diffusers; — Turn first the fan control and then the potentiometer control all the way out; — Open the doors a few seconds so as to let the hot air out of the cab compartment if the tractor has stood under the sun radiation for a long period; — Adjust the system according to personal preference when the desired temperature has been attained.

Checking the air-conditioning system charge System fully charged

(refrigerant entirely in liquid state)

Sight glass clear

System fully discharged

(refrigerant entirely in gaseous state)

System not fully charged

Refrigerant in part gaseous and part liquid state

228

Sight glass cloudy (Bubbles or foam visible)

Systems

8

Air conditioning

86

The system is activated by way of the 3 speed electric fan switch.

Switching on the air conditioning

Once the potentiometer is moved beyond the initial contact, a voltage of 12 V is generated between terminal B (red wire) and the brown wire terminal of the potentiometer. Engagement and disengagement is piloted by the temperature control potentiometer, and by the pressure switch located at the demoisturizing filter which cuts in respectively at: 2 bar and 27 bar.

Electromagnetic coupling

Pressure switch (positioned on demoisturizing filter). Comprises 3 switches: — 1 controlling minimum pressure — 1 controlling maximum pressure — 1 controlling the electric fan of the condenser. The electric fan unit is interlocked to the pressure switch, which is set: - to close the circuit at 15 bar - to open the circuit at 11 bar

Pressure switches Expansion valve Temperature sensor Electric fan unit

By-pass the pressure switch (place jumpers across the two terminals of the pressure switch and the 2 leads of the fan unit). If the fan operates:

the pressure switch is defective

If the fan does not operate:

a) check the fuse; b) check the relay.

Tracing faults in the electric fan unit Fault Fan does not start

Causes

Action

Defective pressure switch

Replace pressure switch

Defective relay

Replace relay

Defective electrical or mechanical

Replace fan unit

Relay (see electrical diagram) Place a jumper across terminals 30 and 87a; if the fan comes into operation, the relay needs to be replaced.

Water dripping from the points at which condensate drain lines are connected to the conditioning unit The problem can be overcome by loosening the clip that fastens the drain line to the cab upright and pulling the tube downwards, so that the water can run away freely.

229

8

Systems

86

Air conditioning

Fig. 5 - Compressor, air conditioning system.

Fig. 6 - Demoisturizing filter, air conditioning system.

230

Systems

8

Air conditioning

86

Checking system Check belt tension: under finger pressure applied to the mid point between the two pulleys, belt should not deflect more than 8 to 10 mm maximally. Always keep condenser fins duly clean. Cleaning should be carried out by a water or air jet (be careful not to bend the fins, use the special combing tool to straighten them again). Ascertain the compressor is firmly secured to tractor and the pulleys are properly aligned. Warning: When removing the strainer or the air-conditioning unit it is required to plug the inlet and the outlet pipes at once, this is to prevent both dust and moisture from entering. Even a few minutes’ exposure to the environmental humidity makes it necessary to replace the filter.

System safety elements Minimum pressure switch (7 Fig. 4). Switches the system off when a failure causes the pressure to drop below 2 bar within the high pressure circuit. Maximum pressure switch (9 Fig. 4). Switches the system off when pressure exceeds 27 bar inside the circuit as a result of an excessive setting or a failure (high pressure area). Condenser fan control pressure switch (8 Fig. 4) Switches the condenser fan on when coolant attains the same pressure of the switch setting pressure. Note: The above three safety devices are grouped inside the thermostatic bulb located on the dehydrator filter. (figura 6 page 230).

Temperature regulation Temperature regulation is obtained through the potentiometer, which automatically regulates the temperature of the air flow from the radiator according to the environmental temperature, through a combined action with the fan. A pressure switch located on the electric circuit opens and closes the electric circuit of the compressor electromagnetic coupling as a consequence of the potentiometer operation. When the circuit is open the pulley will be idling, on the other hand, when the circuit is closed, this will operate integrally with the compressor shaft.

231

8

Systems

86

Air conditioning

Charging the system with recharging station p/n 5.9030.508.6

1 - High pressure gauge 2 - Low pressure gauge 3 - Low pressure valve 4 - Vacuum pump valve 5 - Metering pipeline valve 6 - Recharge pipeline valve 7 - Metering pipeline 8 - Vacuum pump pipeline 9 - Low pressure circuit recharge pipeline (blue) 10 - High pressure circuit recharge pipeline (red) 11 - Vacuum pump 12 - Electric switch 13 - Metering gauge 14 - Air bleed valves 15 - Metering unit 16 - Electrical power supply 17 - Compressor 18 - Refrigerant bottle 19 - Electric leak detector 20 - Electric heater element for refrigerant

Fig. 7 - Charging station for air conditioning circuit.

Filling the metering unit Connect the refrigerant bottle to the metering unit by means of the high or low pressure hose (9 - 10 Fig. 7). Make certain that the valve (5 Fig. 7) is securely shut, then open the valve of the bottle. As the refrigerant flows into the metering unit, open and shut the air bleed valve (14, Fig. 7) intermittently. Read the value given by the hand of the metering unit pressure gauge (13, Fig. 7) and position the value against the indicator. Once 1400 grams of refrigerant have been transferred into the metering unit, close the valve of the bottle and detach the hose.

Refilling the system with oil Connect the high pressure hose (9, Fig. 7) of the recharge station by way of the smaller diameter valve A (Fig. 8) positioned on the pipeline connecting with fitting D (Fig. 5) at the compressor (mounted in the engine compartment), and the low pressure hose (10, Fig. 7) of the station by way of the larger diameter valve B (Fig. 8) positioned on the pipeline connected with fitting S (Fig. 5) at the compressor; then activate the pump for 30 minutes approx to establish a vacuum in the circuit. The valves (3 - 4 - 5 - 6, Fig. 7) must remain open during this operation.

232

Systems

8

Air conditioning

86

Filling the system with oil Detach the low pressure hose from the recharge station and immerse the end in a graduated vessel containing 200 g approx of SUNISO SP 20 or equivalent oil. Allow 250 grams of the oil to be drawn into the circuit. Reconnect the hose to the station. Filling the system with R134a refrigerant When the low pressure gauge (2, Fig. 7) registers a minimum value (760 mm Hg) that remains stable for between 5 and 10 minutes, close the valve (5 Fig. 7). Open the filler valve (5, Fig. 7) and wait until the specified quantity (1800 g) of refrigerant has entered the system. In the event that the flow of refrigerant contained in the metering unit should be interrupted, warm the unit by means of the electric heater (20, Fig. 7), rechecking the pressure on the relative gauge. Should this not be sufficient, start the engine and throttle up to 1200 rev/min approx. Switch on the air conditioning system, and the R 134a refrigerant will be drawn directly into the circuit by the compressor. Close the filler valve (5, Fig. 7), and check with the leak detector that there is no escape of fluid from the fittings of the circuit. Should any leaks be detected, these must be eliminated, and the refrigerant reintroduced. Caution: In the event of oil leaks being detected, the circuit must be emptied completely and the entire recharge procedure recommenced.

Fig. 8 - Valves for connection of the tractor to the air conditioning recharge and service station. A - “HIGH PRESSURE” valve B - “LOW PRESSURE” valve

Final checks Once all the refrigerant has been put into the air conditioning circuit, check (with the engine running and the system in operation) that the high pressure gauge shows a value of between 15 and 20 bar, and the low pressure gauge a value between 1.5 and 2.5 bar.

233

8

Systems

86

Air conditioning

Verifying operation of the system after recharging The system can be regarded as performing to its full capabilites when the delivery pressure gauge shows the following values: Ambient temperature °C Delivery circuit pressure 27 32 35 38 40 43

12 bar 14 bar 15 bar 17 bar 18 bar 20 bar

The temperature values indicated are those likely to be encountered in the course of a typical twelve month period. Having established that the system is operating correctly, detach the high and lower pressure hoses of the station from the tractor and check again with the leak detector that there is no escape of fluid from any part of the system.

CAUTION: use only R 134a refrigerant as indicated on the data plate attached to the compressor of the air conditioning system.

Connecting the tractor to the air conditioning system recharge and service station.

Directions for tightening air conditioning system pipeline fittings. All fittings have an internal seal. Screw the two parts of the fitting together by hand until the nut is finger tight, then holding the one part steady with a fixed wrench, apply a torque wrench to the nut and tighten to the value indicated in the table.

234

Type

Thread

6

5/8” - 18 UNF

13,6 ÷ 20,3 Nm (1,4 ÷ 2,1 kgm)

Tightening torque

7

3/4” - 16 UNF

33,5 ÷ 40,0 Nm (3,3 ÷ 4,0 kgm)

8

7/8” - 14 UNF

35,5 ÷ 42,0 Nm (3,6 ÷ 4,3 kgm)

9

1 1/16” - 14 UNF

40,3 ÷ 47,3 Nm (4,1 ÷ 4,8 kgm)

Systems

8

Air conditioning

86

Fig. 9 - Control switches 1 - Heating control. 2 - Air conditioning control. 3 - Ventilation control.

Fig. 10 - Receiver-drier located in cab roof.

Fig. 11 - Ventilation - conditioning - heating.

1 - Level sight glass.

235

8

Systems

86

Air conditioning

Fig. 12 - Components of the ventilation - conditioning - heating system.

236

Fig. 13 - Air handling unit for high visibility cab

Systems

8

Air conditioning

86

Fig. 14 - Condenser and fan unit for high visibility cab

237

8

Systems

86

Air conditioning

Fig. 15 - Ventilation-heating unit for high visibility cab

238

Systems

8

Air conditioning

86

Fig. 16 - Ventilation-heating unit components for high visibility cab

239

8

Systems

86

Air conditioning

Fig. 17 - Climatisation system components for high visibility cab

240

Systems

8

Diagnosing malfunctions

86

Diagnosing malfunctions LOW PRESSURE CIRCUIT release system pressure through the compressor needle valves

excessive pressure in the high pressure circuit

compressor not operatin smoothly

overcharged circuit

too a low pressure in the high pressure circuit

pressures inside both high and low pressure circuits tend to balance

expansion jammed up

excessive pressure in the high pressure circuit

bubbles are visible through the filter inspection glass

air in the circuit

dehydrate the circuit

normal pressure in the high pressure circuit

poor system efficiency

Out-of-setting compressor needle valves

replace the valves

after some working time

humidity inside the replace the filter and bleed the air. Recircuit charge the circuit

expansion jammed up

replace the expansion valve

Excessive pressure

Normal pressure

Excessively low pressure

normal pressure in the high pressure circuit

valve

valve replace the valve

blocked circuit

change the part and replace the filter

low pressure in the high pressure circuit

discharged system

recharge system

burnt fuse

replace the fuse

disconnected wires

connect the wires

coolant leaks

inspect with leak-finder

System fails to operate

Poor system efficiency

a

stop the leakage and recharge the system

241

8

Systems

82

Hydraulic system

Hydraulic system

KEY TO FIGURE 1:

1 - Delivery line pressure test point 2 - Hydrostatic steering - maximum hydrostatic steering pressure (see instructions on page 186-192) 3 - 4WD steering cylinder pressure test point 4 - 2WD steering cylinder pressure test point 5 - Gearbox oil cooler 6 - Electro-hydraulic control unit (see instructions on page 92) 7 - Hydraulic power unit pressure test point (see instructions on page 40-92) 8 - Lubrication oil pressure test point 9 - POWERSHIFT 10 - Hydraulic unloader for equalising oil level in gearboxes 11 - Gearbox lubrication 12 - Rear P.T.O. (see instructions on page 92) 13 - Diff. lock hydraulic actuators 14 - 4WD engagement hydraulic actuator 15 - Trailer braking hydraulic control valve 16 - Pressure test point for trailer braking hydraulic control valve 17 - 8-way auxiliary control valve (see instructions on pages 250) 18 - Pressure relief valve oil pressure test point 19 - Kick-out oil pressure test point (see instructions on page 250) 20 - Hydraulic ways oil pressure test point 21 - Connected implement 22 - Rear lift 23 - Front lift antishock valve and accumulator (see instructions on page 174) 24 - Implement coupled to rear lift 25 - Lifting cylinder 26 - Rear lift antishock valve 27 - Front lift (see instruction on page 174) 28 - Lifting cylinder pressure test point 29 - Front lift antishock valve 30 - Shut-off valve for oil supply to front lift 31 - Free oil return line on rear of tractor (for hydraulic motors) 32 - Front P.T.O. control valve (see instructions on page 178)

242

R

Pressione di esercizio

2

SOLLEVATORE POSTERIORE

A

29 100 Bar 2 WD

P

30

150 Bar 4 WD

18

6/20 L/min.

5

21

Rear free return

32 cc

Dis.

Diff.look

12

Dis.

31

16

PTO

14 A

ø 1.1

16 bar

A

T

T

P

6

B

A

B

A

P-Ecc.

17

DISTRIBUTORE IDRAULICO

N

Sec. shaft

A

P

A

T 190 bar

11

Inn.

4 Wd

Main shaft

B

Trailer brake

13

ATTREZZO COLLEGATO

19

20

190 bar

Rear

190 bar 150 bar

P

Inn.

26

22 B

GUIDA IDROSTATICA

P

210 Bar

27

OSPC 80 OR

Front

25

70 Bar

SOLLEVATORE ANTERIORE

T

3

A 700 cc

L

82

Rear lift

8 Bar

100 bar

Hydraulic system

(V=0.84 dm )

Sollevatore anteriore con attrezzo collegato

28 150 bar

23

Pressione dii esercizio

4

8

24

ATTREZZO COLLEGATO

3

Systems

15

1

P-Reg.

DISTRIBUTORE IDRAULICO PER LA FRENATURA DEL RIMORCHIO

T

Y Tractor brake

CENTRALINA COMANDI ELETROIDRAULICI

11 bar

7

16 bar

P

T

99

P

T

3

POWERSHIFT

A

Rh

ø1 H

M

x 3

V max 14.7 cm

Lf

L

10 V max 11.6 cm

3

V max 13.9 cm

11 cm 3 27 L/min.

19 cm 47 L/min.

AGROSHIFT

A

Freno inser.=13 bar,disinser.=5 bar

8

5 bar

16 bar

P

5 bar

25 Micr.

N.giri/min.pompe:2522 Rapp. 1/1.0732 (44/41)

25 Micr.

13 bar

4 bar

32 VALVOLA DI COMANDO PTO anteriore

3

F.to A2

Fig. 1 - Points provided for measurement of oil pressures in the tractor’s hydraulic system (see references on page 242).

243

8

Systems

82

Hydraulic system

Oil filters The oil filters are mounted to the rigth hand side of the transmission at the rear end, and are easily replaced. Filters must be replaced whenever the blockage indicator lights up at the instrument panel. The filter blockage pressure switch is set at 0.5 bar, and must be replaced with another of identical specifications if faulty. Ensure that the replacement is stamped with the correct 0.5 bar setting. Whenever the transmission is stripped down for servicing or overhaul, clean the mesh strainer fitted to the bottom of the housing. CAUTION - Operate the lift system and auxiliary spool valves only when the blockage indicator is no longer alight. IMPORTANT - If during normal operation of the machine the clogging filter indicator should light up, remplace the filter.

Hydraulic pumps The hydraulic pumps require no servicing or adjustment even after a long period of operation, although the splines of the pump shaft must be inspected with care: there must be no signs of wear or damage. Checking the relief valves of the hydraulic lift system Using tool 5.9030.520.4, check that the circuit pressure relief valve incorporated into the auxiliary spool valves is set at 190 bar and the system pressure shock valve at 210 bar. Remember that for the lift to function correctly, operating pressure in the circuit should not exceed 150 bar. The operating pressure can be measured by coupling a gauge to the oil pressure line between the directional control valve and the lift; for machines with assistor cylinders, the gauge can be coupled to the pressure line connecting with the assistors.

Fig. 3 - Pump assembly cover. A - Cover B - Pump case C - Base

Fig. 4 - Pump case. B - Pump case.

Stripping the hydraulic pump Removal The pump is secured to the tractor by 2 of the 4 bolts holding the pump assembly together. These two bolts are diagonally opposite. Having removed the pump from the vehicle, the components are freed by unscrewing the two remaining bolts which keep the cover A (see fig 3) clamped to the frame C and the pump body B; this done, remove the washers and then the cover. Using a proper pointed tool remove gasket E (Fig. 6 pag. 343), mark with a reference the position of the bearings with respect to the pump case and then take the bearings from their seats by pushing from inside outwards and being careful the connecting pin neither be lost nor damaged.

A - Snap-ring B - Seal ring C - Cover D - Gasket E - Gasket F - Gasket G - Feather key

H - Bearing I - Bushes L - Driver gear M - Pump case N - Gasket O - Driver gear P - Cover

Block the pump case in a vice as shown in figure and then remove snap ring F. Remove the seal ring.

Fig. 5 - Pump disassembly. B - Pump case C - Base D - Bearings G - Gears I - Screw

Fig. 2 - Component parts of the hydraulic pump assembly

244

Systems

8

Hydraulic system

82

WARNING - If pump bearings, pinions or casing are found to be damaged or worn, these parts cannot be repaired because of their construction tolerances. When performing checks, because of an oil leakage or an excessive and irregular delivery pressure, only the gaskets indicated in the spare parts lists can be replaced.

D - Bearing E - Gasket

After checking the pump for wear due to abrasion from impurities and for any other visible damage, when reassembling use, in any case, a new set of gaskets. It is also indispensable to mark each single part to reinstall correctly.

Inspections and checks After removing all gaskets, both on the covers and in the pump casing, carefully clean all parts using a proper solvent. Carefully dry all parts with compressed air; this is to avoid that any solvent residuals may damage the gaskets on reassembly. Visually check the pump case internally and ascertain it is not damaged. Check both pinions and bearings for wear, abrasion due to foreign matters or cavitation.

Fig. 6 - Internal pump case parts.

NOTE: Should any damage, wear or in any case a component replacement be required, with the exception of the gaskets, the entire pump must be replaced. WARNING: Do not press onto the stop ring to prevent any damage. + 0, 05 Use a dial gauge to make sure the stop ring height be 21 , - 0,15 mm, otherwise replace taking care the new stop ring installed be measured accordingly. If reading is above specification fit the new ring in reversed position.

C - Housing D - Bearing G - Gear H - Bush Fig. 7 - Pump gears.

A - Stop ring B - Gasket C - Bearings

C - Base F - Snap ring Fig. 9 - Inside seals.

Fig. 8 - Snap ring removal.

245

8

Systems

82

Hydraulic system

1064-48

A - Seal ring Fig. 10 - Seal ring.

Fig. 11 - Piloted check valve components

Assembly Before assembly all parts shall be oiled. Correctly position the gaskets in their seats paying particular attention stop ring A and gasket B be correctly fitted into bearings C (see fig. 9). Coat the cover inner side with a slight grease layer then apply to pump case and tightening the securing screws to the recommended torque. WARNING:The securing screws should be tightened gradually making also sure that rotors are not hampered in their movements. Tightening torques Pump cover securing screws: - M8 2 kgm (20 Nm) - M10 5 kgm (49 Nm) Restore the recommended oil level and then bleed the air from the hydraulic circuit.

Fig. 12 - Connection of check valve to hydraulic control valve.

NOTE: To ensure correct operation of the check valve, it must be connected to the element of the control valve fitted with DETENT (as shown in the figure ) 246

Systems

8

Auxiliary systems

88

Auxiliary hydraulic spool valves Auxiliary spool valves are used to control hydraulically operated external implements. The controls consist in 2 levers for a 4-way valve, or 3 levers for a 6-way valve. The levers are located on the driver’s right hand side. Auxiliary hydraulic spool valves: Version 1: 4 way, 2 way double acting - 2 way double acting convertible to single acting, with spool detent Version 2: 6 way, 2 way double acting convertible to single acting, with kickout - 2 way double acting convertible to single acting, with spool detent (with perfect sealing valve) - 2 way double acting with float position - throttle valve (FLOW DIVIDER) with tap in cab - quick coupling for free discharge. NB:with the auxiliary spool valve in use (unless a Flow Divider is incorporated), the operation of the hydraulic lift system remains inhibited (except in FLOAT position). Important: the lever should be recentred to the neutral position as soon as the external actuator has reached its stroke limit, to ensure that the hydraulic circuit does not remain pressurized any longer than strictly necessary; prolonged pressure will result ultimately in the hydraulic system being subjected to hazardous levels of stress. Auxiliary spool valves levers must always be in the neutral position when external services are not in use.

Fig. 1 - 4-way auxiliary control valves. A - Quick coupling for free discharge

247

8

Systems

88

Auxiliary systems

Fig. 2 - 4-way auxiliary control valves. A - Quick coupling for free discharge B - Pressure relief valve.

248

Systems

8

Auxiliary systems

88

NOTE : The 6-way auxiliary spool valve incorporates a FLOW DIVIDER which ensures that oil can be delivered at a constant flow rate of between 3 and 42 l/min to the 2-way kickout section (first valve alongside the flow divider). The tap has set in the cab, to left hand of the place of guide.

4

NB: Even when the flow divider is shut off by turning the knob fully in the direction marked (-), a residual flow of oil will continue to reach the valve at a steady rate of 3 l/min.

B

A

5 5

5 5

B

A

B

5 5

Float A

C

T

P

N

B KICK-OUT

B DETENT.

FLOAT

A

B

A

B

A

B

A T

190 bar

P-Ecc.

P

N

P-Reg.

Fig. 3 - 6-way hydraulic control valve.

A - Pressure relief valve B - Screws to convert from double-acting to single-acting control valve C - Perfect seal valve P - Hydraulic pump N - To rear lift T - Return

249

8

Systems

88

Auxiliary systems Checking the pressure relief valve setting The setting of the pressure relief valve must always be 190 bar, and can be checked by fitting gauge p/n 5.9030.513.0 to either of the valve work ports and operating the relative lever. If the gauge reading is not correct, adjust the pressure relief valve see pages 248 - 249 NOTE: Remember that the purpose of the relief valve is to maintain pressure in the hydraulic lift circuit within a given safety limit, in this instance 190 bar.

Fig. 4 - Checking the operating pressure of auxiliary spool valves. A - Quick coupler B - Implement oil line C - Tee

Checking the operating pressure (see fig 4). To verify the operating pressure of an implement connnected to the work ports of the auxiliary spool valves, proceed as follows: — Connect a Tee between quick coupler A and the implement pressure line B. — Connect pressure gauge p/n 5.9030.513.0 to the Tee. — Start the engine, apply the parking brake in the interests of safety, and operate the spool valve connected to the implement. — The gauge will show the operating pressure currently registering in the circuit. The operating pressure depends on the weight of the hitched implement, and should not normally exceed 150 bar.

Fig. 5 - A conversion screw allowing conversion from double to single acting operation; B conversion screw lock washer.

Conversion of auxiliary spool valves from double acting to single acting operation (see fig 5) Where particular requirements dictate, a double acting spool valve can be converted to operate in single acting mode. To effect the conversion from double to single acting, hold the fitting secure and loosen the screw A by between 4 and 5 turns. NOTE: Once slack, the screw is best rotated by hand to avoid applying excessive force and unseating the lock washer B; if this were to happen, the washer would find its way into the hydraulic circuit and disallow normal operation of the lift system. The conversion from single to double acting operation is effected by tightening the screw A fully.

Checking the surface of the valve spools Check that the machined surface of the spool is free of scoring or any other kind of wear. Fig.6 - Longitudinal section through 4/6-way spool valve.

250

Systems

8

Auxiliary systems

89

Trailer hydraulic braking system The tractor can be equipped with a trailer hydraulic braking system on request. For trailers with “safety brake” (ITALY version), the system is equipped with a specific distributor. The oil used is drawn from the tractor’s main hydraulic system by a special distributor. This distributor is activated by a valve which is hydraulically connected to the tractor hydrostatic braking system control.

Trailer hydraulic braking distributor unit Specifications (see Fig. 2, page 254)

P N B T Y E

Supply Constant pressure in B (only for distributor ITALY version) Maximum pressure in B (only for distributor ITALY version) Maximum operating pressure in N (distributor ITALY version) Working temperature Supply in P Pilot Y (supplied from below)

supply services connections trailer brake connection oil discharge trailer braking system connection parking brake signaling pressure switch

l/min bar

20 ÷ 80 12,5 ± 2

bar

135 ± 5

bar

200

°C

-20 + 100 with hydraulic mineral oil with hydraulic mineral oil

251

8

Systems

89

Auxiliary systems

Fig. 1 - Oil lines connected to directional control valve of hydraulic trailer braking system. A - bistable valve (fitted only in conjunction with ITALY version of the control valve) allows trailer brake to be applied even when tractor brakes are operated independently.

252

Systems

8

Auxiliary systems

89

Use of the tractor with CUNA 341/01 hydraulic trailer braking The trailer hitched to a tractor equipped with this type of trailer braking requires a constant pressure of 12.5 ± 2.5 barin order to release the parking brake ( spring operated). Therefore, before hitching or unhitching the trailer, this pressure must be eliminated at the coupler by switching off the engine, or better still, by applying the tractor handbrake. The female quick-action couplers are specially-designed to remain connected if the internal pressure exceeds 1.5 bar. Unless the driver waits the few seconds required to eliminate the pressure, the coupling or uncoupling operation will be extremely difficult if not impossible. The correct type of female coupler inserts are marked FASTER VFBO/1815F and can also be identified by the release ring, which is 44 mm in diameter and 38 mm long. When uncoupling is performed to hastily, the pressure in the trailer's hydraulic system will lock the coupling, and in addition to compromising the efficiency of the emergency brake, it will prevent re-coupling. In this event: — Uncouple the push-pull coupler which passes through the reservoir mounted on the trailer, by pulling on the pipe connecting the trailer to the tractor. — Discharge the pressure. — Re-couple Special recommendations In order to change from parking brake applied from the trailer (tractor handbrake in lowered position) to efficient service braking, the tractor needs to send large quantities of oil to the cylinders. Some time is therefore required before trailer braking reaches full efficiency and therefore, should it be necessary to use the service brake urgently, after having released the parking brake, accelerate the engine to maximum speed before releasing the tractor handbrake. In general, remember that if the engine revs are high, braking will be more responsive. Users who have trailers with "France" type non-type approved hydraulic braking may adapt the SAFIM brake valve to this type of operation by unscrewing the hex socket screw on the pilot side cover by three turns (6 mm Allen wrench). In this way, the 12.5 bar pressure is eliminated, the red light remains on, only going out on braking. It is dangerous to leave the valve by-pass lever in the braking position; trailers which do not conform to the Cuna 341/01 standard are not equipped any protection against this. The lever on the valve serves to completely by-pass the valve when trailers are not to be hitched to the tractor for long periods (on trailers which conform to the Cuna 341/01 standard, even if the lever is left in the OFF position, the trailer parking brake is not released).

253

8

Systems

89

Auxiliary systems

Starting

1 - Trailer parking brake control knob (present only on mechanically operated valves) A - Rotation for engagement B - Rotation for disengagement

Fig. 2 - Control valve for hydraulic trailer braking.

No special precautions are required, simply start the engine and allow time(10-15 seconds) for the hydraulic pipes to fill with oil before operating the brake pedal. Checking operation The red indicator light illuminates when the pressure at the trailer brake coupling is less than 10 bar; the light therefore gives an indication of whether the system is functioning correctly. During normal operation, providing the handbrake is released and the brake pedal is not depressed, the red light should be off. When the handbrake is applied, the light will stay on even if the brake pedal is pressed. The light also comes on if the engine stalls under load, as there will be no pressure at the trailer brake coupling. In normal operation with the handbrake released, on pressing the brake pedal it is possible to hear the pump as it increases the pressure. To test the pressures, apply a pressure gauge with a minimum full-scale value of 160 bar to the trailer brake coupling.

254

Systems

8

Auxiliary systems

89

Fig. 3 - Operation of the hydraulic control valve 1 - Brake ON/OFF control 2 - Lift 3 - Trailer brake 4 - Trailer brake lever

255

8

Systems

89

Auxiliary systems

The pressure readings to be taken are: — Engine running with handbrake released: 12.5 ± 2.5 bar (10 to15 bar) — With handbrake applied: 0 bar — With handbrake released and brake pedal depressed, the pressure will rise from 12.5 to 130 ± 10 bar (120 to 140 bar). N.B.: the valve is factory-set by Safim. ( ) values in brackets refer to pressure limits specified by the Cuna standard.

Malfunctions Insufficient pressure

For valves with mechanical parking brake control

Check the position of the valve by-pass lever, which should be aligned with the axis of the valve.

Release the handbrake lever. Check that the lever on the valve returns to the limit stop when the handbrake is lowered. Check that the microswitch is functioning correctly (operated when the handbrake is lowered).

For electrically controlled valves

Check the power fuse and the power supply in general. Check the connections to the coil on the two opposite poles. If the coil is energised, by loosening the retaining nut it is possible to feel the pull of the magnet; the coil will be very hot.

The valve pressure rises very slowly

The parking brake is slow to release

Low and high pressure settings

256

Clean the holes of the main piston; to access the piston, remove the plug on the opposite side to the pilot side (27 mm wrench). Withdraw the piston and blow clean. Close the hex socket adapter screw (France type).

Clean the holes (by washing and blowing) the rapid discharge piston, which can be accessed by first removing the solenoid valve and the adapter. Warning: the valve has been tested and calibrated correctly prior to delivery. Before attempting to adjust the springs and the shims, to solve pressure problems, clean all the holes of the piston and solenoid valve with petrol and compressed air. The pressure settings are regulated by way of shims, which can be accessed by removing the pilot valve and withdrawing the 25 mm diameter piston. The internal spring regulates the pressure of 12.5 ± 2.5 bar, while the outer spring regulates the pressure of 130 ± 10 bar.

Systems

8

Auxiliary systems

89

Fig. 4 - View of the hydraulic control valve. 1 - Lever position with handbrake fully applied 2 - Start of trailer braking 3 - Lever position with handbrake released

257

8

Systems

89

Auxiliary systems

Installing the hydraulic braking valve for trailers equipped with “safety brake” (ITALY version) For correct valve and related controls installation, it is necessary to proceed as follows: — Secure the distributor to the tractor and connect the various oil tubes; — Bring the tractor parking brake lever to position A (4th notch of the toothed sector) and carry out the parking brake adjustment so that, in this position, the tractor is braked. Then bring the parking brake lever to position B (stop notch). — Keeping the parking brake lever in position B, hook the hose fork to lever Y, pushing it against stop screw X. Then connect the hose to lock plate C by means of the special adjusting nuts. Under these conditions, acting on the parking brake hand lever of the tractor synchronizes the tractor and trailer stationary braking. — Connect the wiring of the pressure switch, that is screwed on the distributor, to the specific warning light installed on the instrument panel of the dashboard. Then, when engaging the parking brake, the tractor warning light and the trailer warning light will light up at the same time. CAUTION: When the trailer is hitched to the tractor the knob on the control valve must always be turned counter-clockwise to position "1". When a trailer is not hitched or during trailer hitching/unhitching operations, the lever on the control valve must always be in the position "0". On the hydraulic distributor is placed a sensor (E Fig, 5). This sensor active the warning light on the dashboard, when the trailer brakes is operated.

Fig. 5 - Diagram illustrating adjustment of brake control valve for trailer equipped with safety brake (ITALY version)

258

Systems

8

Auxiliary systems

89

Fig. 6 - Components of the hydraulic control valve - FRANCE version.

259

8

Systems

89

Auxiliary systems

Fig. 7 - Components of the hydraulic control valve - FRANCE version

260

Systems

8

Electrical system

84

ELECTRICAL WIRING AGROPLUS 60 (up serial number 1017) - 70 (up serial number 2773) - 80 CONTENTS THE STRUCTURE OF THE UNIT ..................................................................................263 HOW TO CONSULT THE UNIT......................................................................................264 1. 1.1 1.2 1.3

1.4 1.5

INTRODUCTION.........................................................................................................265 List of wiring looms....................................................................................................265 Definition of components and symbols .....................................................................266 General rules.............................................................................................................266 1.3.1 Modification of the tractor’s electrical/electronic circuits ............................266 1.3.2 Main wiring faults .......................................................................................266 1.3.3 Removal, refitting and drying of connectors and wiring .............................266 Diagnostic instruments..............................................................................................268 Wire colour codes .....................................................................................................268

2. 2.1 2.2 2.3

INDICES......................................................................................................................269 Component description index....................................................................................269 Component code index .............................................................................................274 Connector index ........................................................................................................278

3. 3.1 3.2 3.3

COMPONENTS ..........................................................................................................286 Connector layouts .....................................................................................................268 Component technical data ........................................................................................288 Pinouts and descriptions of electronic control units ..................................................296 3.3.1 HML control unit.........................................................................................296 3.3.2 Power lift control unit .................................................................................297 3.3.3 Analogue instrument panel ........................................................................298 3.3.4 Digital instrument panel .............................................................................300

4. SYSTEMS ...................................................................................................................302 4.1 Earthing points ..........................................................................................................303 4.2 Starting and preheating.............................................................................................305 4.3 Lights - steering column switch unit (platform)..........................................................306 4.4 Lights - steering column switch unit (standard cab) ..................................................307 4.5 Lights - steering column switch unit (high-visibility cab)............................................308 4.6 Accessories - Diagnostics (platform).........................................................................309 4.7 Accessories - Diagnostics (standard cab).................................................................310 4.8 Accessories - Diagnostics (high-visibility cab) ..........................................................311 4.9 Wipers (standard cab)...............................................................................................312 4.10 Wipers (high visibility cab).........................................................................................314 4.11 Front instrument panel ..............................................................................................312 4.12 Radio (version with standard cab).............................................................................315 4.13 Radio (version with high-visibility cab) ......................................................................315 4.14 Heater (standard cab) ...............................................................................................316 4.15 Heater (high-visibility roof) ........................................................................................317 4.16 Heating and air conditioning (standard cab) .............................................................318 4.17 Heating and air conditioning (high-visibility roof).......................................................319 4.18 Braking system - trailer braking.................................................................................320 4.19 HML transmission .....................................................................................................321 4.20 Electronic lift..............................................................................................................322 4.21 Rear and front PTOs .................................................................................................323

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Electrical system LAYOUTS, ELECTRICAL WIRING DIAGRAMS, CONNECTOR POSITIONS Engine wiring ....................................................................................................................... 325 Central wiring....................................................................................................................... 333 Front light wiring (Version with cab) .................................................................................... 335 FULLDRIVE wiring .............................................................................................................. 349 Electronic lift wiring.............................................................................................................. 353 Standard cab Roof wiring........................................................................................................................... 359 Worklights wiring ................................................................................................................. 367 Screenwash pumps wiring................................................................................................... 373 Windscreen wiper wiring...................................................................................................... 375 Speaker wiring..................................................................................................................... 375 Roof power supply wiring .................................................................................................... 381 Heater wiring ....................................................................................................................... 387 Air conditioning wiring.......................................................................................................... 393 Air conditioning fan wiring.................................................................................................... 399 High-visibility roof Roof wiring........................................................................................................................... 403 Worklights wiring ................................................................................................................. 409 Screenwash pump wiring .................................................................................................... 413 Windscreen wiper wiring...................................................................................................... 415 Speaker and radio wiring..................................................................................................... 417 Roof power supply wiring .................................................................................................... 423 Heater wiring ....................................................................................................................... 429 Air conditioning wiring.......................................................................................................... 435 Air conditioning fan wiring.................................................................................................... 441

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THE STRUCTURE OF THE UNIT For easier consultation, this unit has been divided into the following chapters:

1. Introduction Contains a brief description of the terminology used, the procedures to follow for troubleshooting and repairs, and the instruments required for troubleshooting.

2. Indices Contains the indices arranged by connector name, by component code and by component description.

3. Components Contains the layouts of the connectors used in the electrical system, descriptions of the components installed on the tractor, the technical data necessary for functional testing and the pinouts of the electronic control units.

4. Systems Contains the electrical diagrams of the tractor’s systems.

5. Layouts, electrical wiring diagrams, connector positions Contains the layouts, the wiring diagrams and the positioning of connectors on the tractor.

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Electrical system How to consult the table

HOW TO CONSULT THE UNIT A

The quickest way to determine the cause of a malfunction of a component (e.g. the starter motor) is to check all the components in the system in which the component is incorporated. The example given on this page assumes a malfunction of the starter motor, which fails to start the engine. 1 -Look in paragraph «2.1. Component description index» (figure A) for the starter motor and identify the system in which it is incorporated. The system is indicated in the column «System (para 4.xx)» and in this case is “2” (figure A). 2 - 2 -Consult paragraph «4.2 Starting» (figure B), in which all the components in the system are indicated in the electrical diagram; these components are accompanied by numbers that correspond to the key on the same page. 3 - 3 -Check all the components in the system, starting, for example, with the switch “12”. 4 -Look in paragraph «2.1. Component description index» (figure A) for “Rear PTO control switch” and check in the column «Technical description (para 3.2.xx)» if there is a technical description of the component (in this case it is given at n° 42 of the paragraph «3.2 Component technical data») (figure C). Make a note also of the name of the connector to which the component is connected (in this case “X10”).

B 2 9 2.7659.108.0

42

X10

2

40 12

Motorino d’avviamento

2.9619.360.0

X37

2

0.011.6955.4

Interruttore comando PTO posteriore

X10

22

E

C

X10

X10

42

12

Interruttore comando PTO posteriore

D

X10

0.011.6855.4

6

0.011.6955.4

2.7659.108.0

Interruttore comando PTO posteriore

F X10

G 6

0.011.6855.4

264

Only if the position of the component is not known 5 - Look in paragraph «2.3 Connector index» (figure D) for the name of the connector to which the component is connected (in this case “X10”) and note down the wiring loom in which it is incorporated (in this case “0.011.6955.4” or “0.011.6958.4”) and the type of connector (in this case “6”). 6 - 6 -Look for the wiring loom in chapter «Layouts, electrical wiring diagrams, connector positions» using the main index . 7 - 7 -Look for the name of the connector in the photos attached to the electrical diagrams and determine its position on the tractor from the drawing (figure E). NOTE. The electrical diagrams (figure F) contain the names of the connectors and the descriptions used in all the tables in chapter 2. 8 - 8 -Using the data contained in the paragraph «3.2 Component technical data» (figure C) at position n° 42, check the operation of the switch. If the pinout of the connector is not known, look in paragraph «3.1 Connector layouts» (figure G) for the number found in the column “Type” of paragraph «2.3 Connector index».

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1. INTRODUCTION This section of the workshop manual is intended as a practical guide to troubleshooting the tractor’s electrical and electronic systems. The following pages provide the technician with all the necessary information about 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, we are obliged to state that the data contained in this document are subject to modification and as such are not binding. 1.1 LIST OF WIRING LOOMSI DESCRIPTION

NOTES

CODE

Cab accessories wiring

Standard roof

0.009.7851.4/40

POWERSHIFT lever wiring

0.011.7972.4

Roof power supply wiring

Standard roof

0.009.7852.3/40

Roof power supply wiring

High-visibility roof

0.011.3761.3/30

Speaker wiring

Standard roof

0.011.0729.4/10

Speaker and radio wiring

High-visibility roof

0.011.3596.3/30

Air conditioning wiring

Standard roof

0.010.2130.1

Air conditioning wiring

High-visibility roof

0.010.2562.1

Front light wiring

Only with cab

0.010.5582.3/01

Central wiring Worklights line wiring

0.010.5303.4/60 High-visibility roof

0.011.3595.3/10

Engine wiring

0.009.7624.4/50

Electronic lift wiring

0.011.6943.4/10

Roof wiring

Standard roof

0.009.7850.4/50

Roof wiring

High-visibility roof

0.011.3606.4/51

Screenwash pump wiring

High-visibility roof

0.011.3743.3

Screenwash pumps wiring

Standard roof

0.009.7854.3/10

Heater wiring

Standard roof

0.010.2123.2

Heater wiring

High-visibility roof

0.010.2558.1

Windscreen wiper wiring

Standard roof

0.010.4516.3/01

Windscreen wiper wiring

High-visibility roof

0.011.3597.3/03

Air conditioning fan wiring

Standard roof

0.009.7853.3/21

Air conditioning fan wiring

High-visibility roof

0.011.3610.3/20

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1.2 DEFINITION OF COMPONENTS AND SYMBOLS To prevent any misunderstanding or ambiguity, listed below are definitions for some of the key terms used in this unit. TERM

DESCRIPTION

Connector

Element used to connect two components (e.g. wiring-switch, wiring-wiring)

Temperature sensor

Electrical component that converts the temperature of a medium (air, water, oil, etc.) into a voltage or resistance

Pressure sensor

Electrical component that converts the pressure of a medium (air, water, etc.) into a voltage or resistance

Position sensor

Electrical component that converts the angular or linear position of an object into a voltage

Pressure switch

Switch that changes state (opens or closes a contact) according to the operating pressure in the circuit in which it is installed

Thermostat

Switch that changes state (opens or closes a contact) according to the temperature of the medium in which it is immersed.

Switch

Mechanical component that opens or closes one or more electrical contacts.

Solenoid valve

Valve operated by applying electrical current to a coil (or solenoid)

Chapter “3.2 Component descriptions” contains the wiring diagrams for some switches and pushbuttons. The following symbols are used for clarity: SYMBOL

DESCRIPTION Contact between pins CLOSED (stable switch position) Contact between pins CLOSED (non-stable switch position) LED warning light Warning light

1.3 GENERAL RULES The inspection, maintenance, troubleshooting and repair operations are essential to ensure that the tractor continues to operate correctly over time and to prevent malfunctions and breakdowns. The scope of this paragraph is to describe repair procedures and to help improve the quality of repairs. 1.3.1MODIFICATION 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 equipment or components. In particular, if it is discovered that the electrical system or a component has been modified without authorisation, the Manufacturer will accept no liability for any damage to the vehicle and the vehicle warranty will be invalidated. 1.3.2MAIN WIRING FAULTS a. Poor contact between connectors 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.

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84

b.

Welding or crimping of defective pins The pins of the male and female connectors make good contact in the crimped or welded area, but the wires are subjected to excessive tension, leading to breakage of the insulation or the wire itself and a poor connection.

c.

Disconnecting wiring If components are disconnected by pulling on the wires, or if components are removed with the wires still connected, or if the wiring is subject to a heavy impact this could damage the connections at the pins, breaking strands of wire.

d.

Penetration of water in connectors The connectors are designed to prevent penetration of liquids (water, oil etc.); however, it is possible that when the tractor is cleaned using high-pressure water or steam, water could penetrate or condense in the connectors. As the connectors are designed to prevent liquid penetration, any water that does get in will not be able to drain out, and thus may cause shortcircuits across the pins. For this reason it is good practice to dry the connectors with a low pressure jet of compressed air after washing the tractor.

e.

Oil or dirt on connectors Oil or grease on the connectors or pins can create a poor contact (oil and grease are nonconductors). 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. ★ ★

Take care not to bend the pins when cleaning them. Use dehydrated but not lubricated compressed air.

1.3.3REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING a.

Disconnection of connectors 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, cover them in a waterproof material to prevent dirt or moisture getting into the contacts.

b.

Connecting the connectors Check the condition of the connectors: • 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. • 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 as described in paragraph 1.3.2. ★ 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 any force. For connectors with clips, insert the two halves until they clip together.

c.

Cleaning and drying wiring 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 has to be cleaned with water, avoid directing the water or steam jet on the connectors; if water penetrates the connector, proceed as described in paragraph 1.3.2. ★ Check that the connector is not short circuited by humidity by testing the continuity across the pins.

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Electrical system ★ d.

After checking the connector is good condition, degrease the contacts using a deoxidising product.

Renewal of damaged electrical components. • 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 standards and in particular: - fuse F1 (100A) DIN 72581/2 - bayonet fuse (F2, F3, etc.) DIN 72581/3C The fitting of replacement fuses that do not comply with these standards will invalidate the warranty with immediate effect and release the manufacturer from any liability. • When replacing relays, make sure that the new relay conforms to the standards marked on the original relay.

1.4 DIAGNOSTIC INSTRUMENTS For the correct diagnosis of any faults in tne tractor’s electrical system, the following instruments are required: 1 - Digital multimeter with the following minimum characteristics: AC VOLT 0-600 DC VOLT 0-600 OHM 0-32M AC AMP 0-10 DC AMP 0-10 2 - All Round Tester 1.5 WIRE COLOUR CODES

268

COLOUR CODES

COLOUR CODES

A

Light blue

M

Brown

B

White

N

Black

C

Orange

R

Red

G

Yellow

S

Pink

H

Grey

V

Green

L

Dark blue

Z

Purple

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2. INDICES 2.1 COMPONENT DESCRIPTION INDEX Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

2.7099.770.0

X2

6-7-8

Alternator ISKRA 65A

2.9439.420.0

X65

2

Alternator ISKRA 85A

2.9439.460.0/10

X65

2

Heating alternator ISKRA 70A

2.9439.440.0/10

X109/B+/B-

14-15-16-17

RH speaker

X133

12-13

LH speaker

X132

12-13

X86-X131

12-13

2.8419.003.0

X61

3-4-5

Glowplug

01175757

X57

2

Preheating control unit

01178976

X43

2

0.011.2992.4/20

X71

6-7-8-20

2.8639.007.0

X40

3-4-5

0.010.8869.4/20

X72

19

Heater settings control unit

0.007.6766.4

X136

14-15-16-17

Fan speed selector switch

0.009.4743.1

X139

14-16

Fan speed selector switch

0.010.2528.1

X154

15-17

Air conditioning compressor

0.009.7660.4

X59

16-17

Compressor for driver’s seat air suspension

0.007.6273.4

X12

6-7-8

X42

6-7-8-20

Component description

Component code

Cigar lighter

Radio Horn

Rear lift control unit Hazard lights control unit HML control unit

Diagnostics connector Analogue instrument panel

2.8339.212.0/10

X3

2-3-4-5-1118-19-21

Digital instrument panel

2.8339.153.0/30

X3

2-3-4-5-1118-19-21

Lights selector switch

0.009.6491.4

39

X36

3-4-5-6-7-8

Diff lock control solenoid valve (DF)

2.3729.240.0/10

8

X16

19

4WD control solenoid valve

2.3729.240.0/10

9

X15

19

High range control solenoid valve (HI)

2.3729.240.0/10

11

H

19

Low range control solenoid valve (LO)

2.3729.240.0/10

12

L

19

Preheating control solenoid valve

01179366

X58

2

X17

21

Rear PTO control solenoid valve (PTO)

2.3729.240.0/10

10

Lift lowering solenoid valve

2.3729.460.0

EV DW

20

Front PTO solenoid valve

2.3729.400.0

X63

21

Lift raising solenoid valve

2.3729.460.0

EV UP

20

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Electrical system Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

2.8019.970.0

X13

3

Front left headlamp

2.8019.960.0

X27

3

Front right worklight

2.8029.730.0

X124

4-5

Front left worklight

2.8029.730.0

X121

4-5

Rear right worklight

2.8029.730.0

X123

4-5

Rear left worklight

2.8029.730.0

X122

4-5

Number plate light

2.8029.240.0/10

X28

3-4-5

Front right lights

2.8029.820.0/30

X64

3-4-5

Front left lights

2.8029.830.0/30

X62

3-4-5

Front right sidelight and direction indicator

04411920.4

X13

4-5

Front left sidelight and direction indicator

04411921.4

X27

4-5

Rear right light

2.8019.190.0

X14

3-4-5-18

Left rear light

2.8019.180.0

X29

3-4-5-18

Rear worklight (platform version)

2.8029.300.0

X22

3

X104

5-8-10

X32

2-3-4-5-6-7-8-910-11-14-15-1617-18-19-20-21

X158

17

Component description

Component code

Front right headlamp

Roof wiring fuse (40 Amp) Starter switch

2.7659.127.0

Air conditioning control switch

0.010.2560.1

Diff lock control switch

2.7659.163.0

32

X9

19

0.007.5945.0/20

34

X8

19

Rotating beacon control switch

2.7659.159.0

31

X96

8

Rotating beacon control switch

2.7659.126.0

X81

7

X100

5

X85

4

X99

5

X78

4

X80

10

X80

9

4WD control switch

Front worklights switch Front worklights switch Rear worklights switch

2.7659.154.0

30

2.7659.078.0 2.7659.155.0

Rear worklights switch

2.7659.079.0

Front screen washer switch

2.7659.223.0

Front screen washer switch

28

29

24

2.7659.091.0

Rear PTO control switch

2.7659.108.0/10

36

X10

2-21

Front PTO control switch

2.7659.108.0/10

35

X35

21

Front wiper control switch

2.7659.092.0

25

X84

9

270

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84

Component description

Component code

Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

Front wiper control switch

2.7659.224.0

38

X98

10

Rear wiper control switch

2.7659.146.0

26

X79

9

Rear wiper control switch

2.7659.192.0

37

X97

10

Start enable switch

2.7659.097.0

X31

2

Handbrake switch

2.7659.129.0

17

X24

18

Hazard warning lights switch

2.7659.110.0

27

X33

3-4-5

X34

3

X5

18

X127

7-8

Rear worklights switch (Not utilised) Brake pedal switch

2.7659.097.0

Flashing light Windscreen wiper motor

04413192

X130

9-10

Rear screen wiper motor

2.9019.100.0/20

X125

9

Rear screen wiper motor

2.9019.180.0

X125

10

01180928

X37-X38

2

Clock

2.9389.002.0

X83

7-8

Interior roof light

2.8339.032.0

X74

7-8

X41

2

Starter motor

Fuel pump Front screen washer pump

0.9241.566.1

X129

9-10

Rear screen washer pump

0.9241.566.1

X135

9-10

Max. lift height adjustment potentiometer

0.011.2990.0

3

H1

20

Lift position adjustment potentiometer

0.011.2990.0

4

P1

20

Potentiometer adjustment heading

0.98707.67.3

X138-X145

14-15-16-17

Draft/wheelslip adjustment potentiometer

0.011.2990.0

5

M1

20

Lift lowering speed adjustment potentiometer

0.011.2990.0

6

V

20

Outlet socket (in cab)

2.6039.017.0

X11

6-7-8

X26

3-4-5-18

Trailer socket (For lights and auxiliary power) Air conditioning pressure switch

0.010.2140.0

X118-X120

16

Air conditioning pressure switch

0.010.2262.0

X116

17

Trailer braking low pressure switch

2.7099.430.0

X25

18

X20

11

X19

11

Hydraulic oil low pressure switch

2.7099.660.0/10

15

Pressure switch - hydraulic oil filter clogging Engine oil pressure switch Engine governor reset button

01181549

16

X55

11

2.7659.139.0

18

X45

11

271

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Component description

Component code

Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

Rear lift "lower" control pushbutton

2.7659.182.0

22

DW

20

HML control pushbutton

0.010.5330.4

M

19

Preheating control pushbutton

2.7659.140.0

21

X67

2

Rear lift "raise" control pushbutton

2.7659.182.0

23

UP

20

0.011.7720.0/10

33

C-I

20

Selection pushbutton

2.7659.140.0

19

X52

11

Display pushbutton

2.7659.173.0

20

X44

11

Relay - cab roof wiring

X103

4-5-7-8-9-1014-15-16-17

Relay -1st heater fan and air conditioning on

X156

17

Relay - 3rd heater fan vspeed

X157

15-17

Relay - air conditioning

X143

16

Relay - alternator excitation

X142-X147

14-15-16-17

Relay - maximum fan speed

X146

15-17

Relay - heat exchanger fan

X115

16-17

Relay - supplementary heat exchanger fan

X114

17

Relay RL1

RL1

2

Relay RL2

RL2

2

Heater unit resistance

X106

14-15-16-17

Rear lift control pushbutton

Resistor - right heater fan

0.010.2555.0

X149

15-17

Resistor - heater fan

0.010.2122.0

X140

14-16

Resistor - left heater fan

0.010.2555.0

X148

15-17

Air cleaner clogged sensor Fuel level sensor

2.7099.320.0/10

14

X60

11

2.7059.998.0

13

X23

11

X66

18

Brake fluid level sensor Rear lift position sensor

0.009.2194.4

1

P2

20

0.011.2164.0/10

2

S1

20

0.010.2124.1

X137

14-15-16-17

Coolant temperature sensor

01177090

X54

11

Transmission speed sensor

0.008.1646.0

X50

11

PTO engagement sensor

2.7659.097.0

S

21

1000 rpm PTO engagement sensor

2.7659.131.0

1

21

540 rpm PTO engagement sensor

2.7659.131.0

5

21

750 (ECO) PTO engagement sensor

2.7659.131.0

E

21

Intermittent windscreen wiper interval timer

2.8639.008.0

X82

9-10

Lift draft sensor Heating air temperature sensor

272

7

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8

Electrical system

84

Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

0.009.4744.1

X144

16

Air conditioning thermostat

0.010.2522.0

X159

17

Right heater fan

0.011.2047.4

X153

15

Right heater fan

0.011.8858.4

X153

17

Heater fan

0.010.2121.1

X141

14-16

Air conditioning heat exchanger fan

0.010.0618.4

X119

16

Air conditioning heat exchanger fan

0.010.2545.2

X117a

17

Left heater fan

0.011.2047.4

X151

15

Left heater fan

0.011.8858.4

X151

17

Supplementary air conditioning heat exchanger fan

0.010.2545.2

X117b

17

Component description

Component code

Antifrost thermostat

273

8

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84

Electrical system

2.2 COMPONENT CODE INDEX

Code

0.007.5945.0/20

Description

4WD control switch

Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

34

X8

19

0.007.6273.4

Compressor for driver’s seat air suspension

X12

6-7-8

0.007.6766.4

Heater settings control unit

X136

14-15-16-17

0.008.1646.0

Transmission speed sensor

7

X50

11

0.009.2194.4

Rear lift position sensor

1

P2

20

0.009.4743.1

Fan speed selector switch

X139

14-16

0.009.4744.1

Antifrost thermostat

X144

16

0.009.6491.4

Lights selector switch

X36

3-4-5-6-7-8

0.009.7660.4

Air conditioning compressor

X59

16-17

0.010.0618.4

Air conditioning heat exchanger fan

X119

16

0.010.2121.1

Heater fan

X141

14-16

0.010.2122.0

Resistor - heater fan

X140

14-16

0.010.2124.1

Heating air temperature sensor

X137

14-15-16-17

0.010.2140.0

Air conditioning pressure switch

X118-X120

16

0.010.2262.0

Air conditioning pressure switch

X116

17

0.010.2522.0

Air conditioning thermostat

X159

17

0.010.2528.1

Fan speed selector switch

X154

15-17

0.010.2545.2

Air conditioning heat exchanger fan

X117a

17

0.010.2545.2

Supplementary air conditioning heat exchanger fan

X117b

17

0.010.2555.0

Resistor - right heater fan

X149

15-17

0.010.2555.0

Resistor - left heater fan

X148

15-17

0.010.2560.1

Air conditioning control switch

X158

17

0.010.5330.4

HML control pushbutton

M

19

39

0.010.8869.4/20

HML control unit

X72

19

0.011.2047.4

Right heater fan

X153

15

0.011.2047.4

Left heater fan

X151

15

0.011.2164.0/10

Lift draft sensor

2

S1

20

0.011.2990.0

Max. lift height adjustment potentiometer

3

H1

20

0.011.2990.0

Lift position adjustment potentiometer

4

P1

20

274

Code

Description

Systems

8

Electrical system

84

Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

0.011.2990.0

Draft/wheelslip adjustment potentiometer

5

M1

20

0.011.2990.0

Lift lowering speed adjustment potentiometer

6

V

20

X71

6-7-8-20

C-I

20

0.011.2992.4/20

Rear lift control unit

0.011.7720.0/10

Rear lift control pushbutton

33

0.011.8858.4

Right heater fan

X153

17

0.011.8858.4

Left heater fan

X151

17

0.9241.566.1

Front screen washer pump

X129

9-10

0.9241.566.1

Rear screen washer pump

X135

9-10

0.98707.67.3

Potentiometer adjustment heading

X138-X145

14-15-16-17

01175757

Glowplug

X57

2

01177090

Coolant temperature sensor

X54

11

01178976

Preheating control unit

X43

2

01179366

Preheating control solenoid valve

X58

2

01180928

Starter motor

X37-X38

2

01181549

Engine oil pressure switch

X55

11

16

04411920.4

Front right sidelight and direction indicator

X13

4-5

04411921.4

Front left sidelight and direction indicator

X27

4-5

Windscreen wiper motor

X130

9-10

04413192 2.3729.240.0/10

Diff lock control solenoid valve (DF)

8

X16

19

2.3729.240.0/10

4WD control solenoid valve

9

X15

19

2.3729.240.0/10

Rear PTO control solenoid valve (PTO)

10

X17

21

2.3729.240.0/10

High range control solenoid valve (HI)

11

H

19

2.3729.240.0/10

Low range control solenoid valve (LO)

12

L

19

X63

21

2.3729.400.0

Front PTO solenoid valve

2.3729.460.0

Lift lowering solenoid valve

EV DW

20

2.3729.460.0

Lift raising solenoid valve

EV UP

20

2.6039.017.0

Outlet socket (in cab)

X11

6-7-8

2.7059.998.0

Fuel level sensor

13

X23

11

14

X60

11

2.7099.320.0/10

Air cleaner clogged sensor

275

8

Systems

84

Electrical system

Code

2.7099.430.0 2.7099.660.0/10

Description

Tech. descr. (Chap. 3.2.x)

Trailer braking low pressure switch Hydraulic oil low pressure switch

15

Connector

System (Chap. 4.xx)

X25

18

X20

11

2.7099.770.0

Cigar lighter

X2

6-7-8

2.7659.078.0

Front worklights control switch

X85

4

2.7659.079.0

Rear worklights control switch

X78

4

X80

9

X84

9

2.7659.091.0

Front screen washer control switch

2.7659.092.0

Front wiper control switch

2.7659.097.0

Start enable switch

X31

2

2.7659.097.0

Brake pedal switch

X5

18

2.7659.097.0

PTO engagement sensor

S

21

2.7659.108.0/10

Front PTO control switch

35

X35

21

2.7659.108.0/10

Rear PTO control switch

36

X10

2-21

2.7659.110.0

Hazard warning lights switch

27

X33

3-4-5

2.7659.126.0

Rotating beacon control switch

X81

7

2.7659.127.0

Starter switch

28

X32

2-3-4-5-6-7-8-910-11-14-15-16 17-18-19-20-21

2.7659.129.0

Handbrake switch

17

X24

18

2.7659.131.0

1000 rpm PTO engagement sensor

1

21

2.7659.131.0

540 rpm PTO engagement sensor

5

21

2.7659.131.0

750 (ECO) PTO engagement sensor

E

21

2.7659.139.0

Engine governor reset button

18

X45

11

2.7659.140.0

Selection pushbutton

19

X52

11

2.7659.140.0

Preheating control pushbutton

21

X67

2

2.7659.146.0

Rear wiper control switch

26

X79

9

2.7659.154.0

Front worklights control switch

30

X100

5

2.7659.155.0

Rear worklights control switch

29

X99

5

2.7659.159.0

Rotating beacon control switch

31

X96

8

2.7659.163.0

Diff lock control switch

32

X9

19

2.7659.173.0

Display pushbutton

20

X44

11

2.7659.182.0

Rear lift "lower" control pushbutton

22

DW

20

276

25

Code

Description

Systems

8

Electrical system

84

Tech. descr. (Chap. 3.2.x)

Connector

System (Chap. 4.xx)

2.7659.182.0

Rear lift "raise" control pushbutton

23

UP

20

2.7659.192.0

Rear wiper control switch

37

X97

10

2.7659.223.0

Front screen washer control switch

24

X80

10

2.7659.224.0

Front wiper control switch

38

X98

10

2.8019.180.0

Rear left light

X29

3-4-5-18

2.8019.190.0

Rear right light

X14

3-4-5-18

2.8019.960.0

Front left light

X27

3

2.8019.970.0

Front right light

X13

3

2.8029.240.0/10

Number plate light

X28

3-4-5

2.8029.300.0

Rear worklight (platform version)

X22

3

2.8029.730.0

Front right worklight

X124

4-5

2.8029.730.0

Front left worklight

X121

4-5

2.8029.730.0

Rear right worklight

X123

4-5

2.8029.730.0

Rear left worklight

X122

4-5

2.8029.820.0/30

Front right light

X64

3-4-5

2.8029.830.0/30

Front left light

X62

3-4-5

Interior roof light

X74

7-8

2.8339.153.0/30

Digital instrument panel

X3

2-3-4-5-1118-19-21

2.8339.212.0/10

Analogue instrument panel

X3

2-3-4-5-1118-19-21

2.8419.003.0

Horn

X61

3-4-5

2.8639.007.0

Hazard lights control unit

X40

3-4-5

2.8639.008.0

Intermittent windscreen wiper interval timer

X82

9-10

2.9019.100.0/20

Rear screen wiper motor

X125

9

2.9019.180.0

Rear screen wiper motor

X125

10

2.9389.002.0

Clock

X83

7-8

2.9439.420.0

Alternator ISKRA 65A

X65

2

X109/B+/B-

14-15-16-17

X65

2

2.8339.032.0

2.9439.440.0/10

Heating alternator ISKRA 70A

2.9439.460.0/10

Alternator ISKRA 65A

277

8

Systems

84

Electrical system

2.3 CONNECTOR INDEX Wiring code

Connection wiring or component code

1

0.010.5303.4

2.7659.131.0

1000 rpm PTO engagement sensor

5

0.010.5303.4

2.7659.131.0

540 rpm PTO engagement sensor

Connector

Type

Component description

0.009.7852.3 B-

2.9439.440.0/10

Heating alternator ISKRA 70A

2.9439.440.0/10

Heating alternator ISKRA 70A

0.011.6943.4

0.011.7720.0/10

Rear lift control pushbutton

0.011.6943.4

2.7659.182.0

Rear lift "lower" control pushbutton

0.010.5303.4

2.7659.131.0

750 (ECO) PTO engagement sensor

0.011.3761.3 0.009.7852.3 B+ 0.011.3761.3 C DW

3

E EV DW

2

0.011.6943.4

2.3729.460.0

Lift lowering solenoid valve

EV UP

2

0.011.6943.4

2.3729.460.0

Lift raising solenoid valve

H1

3

0.011.6943.4

0.011.2990.0

Max. lift height adjustment potentiometer

H

2

0.011.7972.4

2.3729.240.0/10

High range control solenoid valve (HI

0.011.6943.4

0.011.7720.0/10

Rear lift control pushbutton Low range control solenoid valve (LO)

I L

2

0.011.7972.4

2.3729.240.0/10

M1

3

0.011.6943.4

0.011.2990.0

Draft/wheelslip adjustment potentiometer

M

3

0.011.7972.4

0.010.5330.4

HML control pushbutton

P1

3

0.011.6943.4

0.011.2990.0

Lift position adjustment potentiometer

P2

3

0.011.6943.4

0.009.2194.4

Rear lift position sensor

RL1

0.010.5303.4

Relay RL1

RL2

0.010.5303.4

Relay RL2

S1

3

S

0.011.2164.0/10

Lift draft sensor

0.010.5303.4

2.7659.097.0

PTO engagement sensor

UP

3

0.011.6943.4

2.7659.182.0

Rear lift "raise" control pushbutton

V

3

0.011.6943.4

0.011.2990.0

Lift lowering speed adjustment potentiometer

X1

1

0.010.5302.4

0.010.5303.4

0.010.5303.4

2.7099.770.0

X2

278

0.011.6943.4

Cigar lighter

Systems

8

Electrical system

84

Connector

Type

Wiring code

Connection wiring or component code

X3

7

0.010.5303.4

2.8339.153.0/30

X4

9

0.010.5303.4

0.010.5582.3

0.010.5303.4

2.7659.097.0

X5

Component description Digital instrument panel

Brake pedal switch

X6

8

0.010.5303.4

0.011.7972.4

X7

4

0.010.5303.4

0.011.6943.4

X8

6

0.010.5303.4

0.007.5945.0/20

X9

6

0.010.5303.4

2.7659.163.0

X10

6

0.010.5303.4

2.7659.108.0/10

X11

0.010.5303.4

2.6039.017.0

Outlet socket (in cab)

X12

0.010.5303.4

0.007.6766.4

Compressor for driver’s seat air suspension

0.010.5582.3

04411920.4

Front right sidelight and direction indicator

0.010.5303.4

2.8019.970.0

Front right headlamp

0.010.5303.4

2.8019.190.0

Rear right light

X13

X14

Four-wheel drive control switch Diff lock control switch PTO control switch

X15

2

0.010.5303.4

2.3729.240.0/10

4WD control solenoid valve

X16

2

0.010.5303.4

2.3729.240.0/10

Diff lock control solenoid valve (DF)

X17

2

0.010.5303.4

2.3729.240.0/10

Rear PTO control solenoid valve (PTO)

X18

0.010.5303.4

Connector for joint

X19

0.010.5303.4

Pressure switch hydraulic oil filter clogging

X20

0.010.5303.4

X21

0.010.5303.4

X22

0.010.5303.4

2.8029.300.0

Rear worklight (platform version

0.010.5303.4

2.7059.998.0

Fuel level sensor

0.010.5303.4

2.7659.129.0

Handbrake switch

0.010.5303.4

2.7099.430.0

Trailer braking low pressure switch

X23

4

X24 X25 X26

2

2.7099.660.0/10

Hydraulic oil low pressure switch Connector for joint

Trailer socket (For lights and auxiliary power)

0.010.5303.4 0.010.5582.3

04411921.4

Front left sidelight and direction indicator

0.010.5303.4

2.8019.960.0

Front left headlamp

X27

279

8

Systems

84

Electrical system

Wiring code

Connection wiring or component code

X28

0.010.5303.4

2.8029.240.0/10

X29

0.010.5303.4

2.8019.180.0

Left rear light

X31

0.010.5303.4

2.7659.097.0

Start enable switch

X32

0.010.5303.4

2.7659.127.0

Starter switch

2.7659.110.0

Hazard warning lights switch

Connector

Type

Component description Number plate light

X33

6

0.010.5303.4

X34

6

0.010.5303.4

X35

6

0.010.5303.4

2.7659.108.0/10

X36

5

0.010.5303.4

0.009.6491.4

X37

0.010.5302.4 0.009.7852.3 0.011.3761.3 0.010.5303.4

01180928

Starter motor

X38

0.010.5302.4 0.010.5303.4

01180928

Starter motor

Rear worklights switch (Not utilised) Front PTO control switch Lights selector switch

0.009.7852.3 X39

2

0.010.5303.4 0.011.3761.3

X40

0.010.5303.4

X41

0.010.5302.4

Fuel pump

Hazard lights control unit

Diagnostics connector

X42

3

0.010.5303.4

X43

10

0.010.5303.4

01178976

X44

6

0.010.5303.4

2.7659.173.0

Display pushbutton

X45

6

0.010.5303.4

2.7659.139.0

Engine governor reset button

X50

11

0.010.5303.4

0.008.1646.0

Transmission speed sensor

X52

3

0.010.5303.4

2.7659.140.0

Selection pushbutton

X54

0.010.5302.4

01177090

Coolant temperature sensor

X55

0.010.5302.4

01181549

Engine oil pressure switch

X57

0.010.5302.4

01175757

Glowplug

X58

0.010.5302.4

01179366

Preheating control solenoid valve

X59

0.010.5302.4

0.007.7660.4

Air conditioning compressor

X60

0.010.5302.4

2.7099.320.0/10

Air cleaner clogged sensor

X61

0.010.5302.4

2.8419.003.0

X62

0.010.5302.4

2.8029.830.0/30

0.010.5302.4

2.3729.400.0

X63

280

2.8639.007.0

2

Preheating control unit

Horn Front left lights Front PTO solenoid valve

Systems

8

Electrical system

84

Wiring code

Connection wiring or component code

X64

0.010.5302.4

2.8029.820.0/30

X65

0.010.5302.4

Connector

Type

X66 X67 X71 X72

14

Front right lights

2.9439.420.0

Alternator ISKRA 65A

2.9439.460.0/10

Alternator ISKRA 85A

0.010.5302.4 3

Component description

Brake fluid level sensor

0.010.5303.4

2.7659.140.0

Preheating control pushbutton

0.011.6943.4

0.011.2992.4/20

Rear lift control unit

0.011.7972.4

0.010.8869.4/20

HML control unit

2.8339.032.0

Interior roof light

0.009.7850.4 X74 0.011.3606.4 0.009.7850.4

0.009.7854.3

0.011.3606.4

0.011.3743.3

X76

0.009.7850.4

0.009.7853.3

X77

0.009.7850.4

0.009.7851.4

X78

0.009.7850.4

2.7659.079.0

Rear worklights switch

X79

0.009.7850.4

2.7659.146.0

Rear screen washer switch

0.009.7850.4

2.7659.091.0

Front screen washer switch

0.011.3606.4

2.7659.223.0

0.009.7850.4

2.7659.126.0

Rotating beacon control switch

2.8639.008.0

Intermittent windscreen wiper interval timer

2.9389.002.0

Clock

X75

X80 X81

0.009.7850.4 X82 0.011.3606.4 0.009.7850.4 X83 0.011.3596.3 X84

0.009.7850.4

2.7659.092.0

X85

0.009.7850.4

2.7659.078.0

Front screen washer switch Rear worklights switch

0.009.7850.4 X86

Radio 0.011.3596.3

X87

0.009.7850.4

0.009.7852.3

X88

0.009.7850.4

0.010.4516.3

281

Connector

8

Systems

84

Electrical system

Type

Wiring code

Connection wiring or component code

Component description

0.010.2123.2 X89

0.009.7850.4 0.010.2130.1

X90

0.009.7850.4

0.010.2130.1

X91

0.011.3761.3

0.011.3606.4

0.011.3606.4

0.011.3597.3

X92

12

0.010.2558.1 X93

0.011.3606.4 0.010.2562.1

X94

0.011.3606.4

0.010.2562.1

X95

0.011.3606.4

0.011.3595.3

X96

0.011.3606.4

2.7659.159.0

X97

0.011.3606.4

2.7659.192.0

X98

0.011.3606.4

2.7659.224.0

X99

0.011.3606.4

2.7659.155.0

X100

0.011.3606.4

2.7659.154.0

X101

0.011.3606.4

0.011.3596.3

X102

0.011.3606.4

0.011.3610.3

Rotating beacon control switch Rear wiper control switch Winscreen wiper control switch Rear worklights control switch Front worklights control switch

0.009.7850.4 X103

Relay - cab roof wiring 0.011.3606.4 0.009.7852.3

0.009.7850.4

0.011.3761.3

0.011.3606.4

X103-30

X104

Roof wiring fuse (40 Amp)

0.011.3606.4 0.009.7852.3

X106

Heater unit resistance 0.011.3761.3 0.010.2123.2

X107

0.009.7852.3 0.010.2130.1 0.009.7852.3

X108

2

Connector for joint 0.011.3761.3 0.009.7852.3

X109

2.9439.440.0/10 0.011.3761.3

282

Heating alternator ISKRA 70A

Connector

Type

Wiring code

Systems

8

Electrical system

84

Connection wiring or component code

Component description

0.009.7852.3 X111

Connector for joint 0.011.3761.3 0.010.2558.1

X113

4

0.011.3761.3 0.010.2562.1

X114

Relay - supplementary heat exchanger fan

0.011.3610.3 0.009.7853.3

X115

Relay - heat exchanger fan 0.011.3610.3

X116

13

0.011.3610.3

0.010.2262.0

Air conditioning pressure switch

X117a

15

0.011.3610.3

0.010.2545.2

Air conditioning heat exchanger fan

X117b

15

0.011.3610.3

0.010.2545.2

Supplementary air conditioning heat exchanger fan

X118

3

0.009.7853.3

0.010.2140.0

Air conditioning pressure switch

X119

0.009.7853.3

0.010.0618.4

Air conditioning heat exchanger fan

X120

0.009.7853.3

0.010.2140.0

Air conditioning pressure switch

2.8029.730.0

Front left worklight

2.8029.730.0

Rear left worklight

2.8029.730.0

Rear right worklight

2.8029.730.0

Front right worklight

0.009.7851.4 X121 0.011.3595.3 0.009.7851.4 X122 0.011.3595.3 0.009.7851.4 X123 0.011.3595.3 0.009.7851.4 X124 0.011.3595.3 0.009.7851.4

2.9019.100.0/20

0.011.3596.3

2.9019.180.0

X125

Rear screen wiper motor 0.009.7851.4

X126

Connector for joint 0.011.3596.3 0.009.7851.4

X127

Flashing light 0.011.3596.3 0.009.7854.3

X129

0.9241.566.1

Front screen washer pump

0.011.3743.3 0.010.4516.3 X130

04413192

Front screen wiper motor

0.011.3597.3

283

Connector

8

Systems

84

Electrical system

Type

Wiring code

Connection wiring or component code

Component description

0.011.0729.4 X131

Radio 0.011.3596.3 0.011.0729.4

X132

Left speaker 0.011.3596.3 0.011.0729.4

X133

Right speaker 0.011.3596.3 0.009.7854.3

X135

0.9241.566.1

Rear screen washer pump

0.007.6766.4

Heater settings control unit

0.010.2124.1

Heating air temperature sensor

0.98707.67.3

Potentiometer adjustment heading

0.009.4743.1

Fan speed selector switch

0.010.2122.0

Resistor - heater fan

0.010.2121.1

Heater fan

0.011.3743.3 0.010.2123.2 0.010.2130.1 X136 010.2558.1 0.010.2562.1 0.010.2123.2 0.010.2130.1 X137 010.2558.1 0.010.2562.1 0.010.2123.2 X138 0.010.2130.1 0.010.2123.2 X139 0.010.2130.1 0.010.2123.2 X140 0.010.2130.1 0.010.2123.2 X141 0.010.2130.1 0.010.2123.2 X142

Relay - alternator excitation 0.010.2130.1

X143

0.010.2130.1

X144

0.010.2130.1

Relay - air conditioning 0.009.4744.0

Antifrost thermostat

0.98707.67.3

Potentiometer adjustment heading

010.2558.1 X145 0.010.2562.1 010.2558.1 X146

Relay - maximum fan speed 0.010.2562.1

284

Connector

Type

Wiring code

Systems

8

Electrical system

84

Connection wiring or component code

Component description

010.2558.1 X147

Relay - alternator excitation 0.010.2562.1 010.2558.1

X148

0.010.2555.0

Resistor - left heater fan

0.010.2555.0

Resistor - right heater fan

0.010.2562.1 010.2558.1 X149 0.010.2562.1 010.2558.1 X150

Connector for joint 0.010.2562.1 010.2558.1

0.011.2047.4

0.010.2562.1

0.011.8858.4

X151

Left heater fan 010.2558.1

X152

Connector for joint 0.010.2562.1 010.2558.1

0.011.2047.4

0.010.2562.1

0.011.8858.4

X153

Right heater fan 010.2558.1

X154

0.010.2528.1

Fan speed selector switch

0.010.2562.1 X156

Relay -1st heater fan and air conditioning on

0.010.2562.1 010.2558.1

Relay - 3rd heater fan speed

X157 0.010.2562.1 X158

0.010.2562.1

0.010.2560.1

Air conditioning control switch

X159

0.010.2562.1

0.010.2522.0

Air conditioning thermostat

285

8

Systems

84

Electrical system

3. COMPONENTS This chapter contains: 1 - Connectors table: the shapes and pinouts of the connectors 2 - Components table: technical and functional description of the components 3 - Pinouts of the electronic control units 3.1 CONNECTOR LAYOUTS

1

2

3

1 4

8

9

1

15

14

3

4

8

9

14

15

20

20 21

25 26

29

26

1

3

6

2

1

3

2

5

2

4

1

2

3

3

2

1

4

5

6

6

5

4

7

8

9

9

8

7

1

7

7

1

2

6

3

5 4

286

2

29

3

4

1

25

21

4

3

8

36

28

27

19

18

10

9

8

3

7 6 5

2

1

4

1

1

4 5

5

7 3

8

3

8

12

4

1 2

10

10

Electrical system

84

11

1

7

6

2

8

3

6

6

2

2

1

7 8

8

4

5

1

4 5 6

3

9

Systems

7

17

4

13

1

6 3

2

1

4 4

2

3

1

9

14

2

6

2

3

7

3

1 1

12

15

A A

B B

287

8

Systems

84

Electrical system

3.2 COMPONENT TECHNICAL DATA N° Description

1

Rear lift position sensor

Code

Characteristics

Notes

Connector

0.009.2194.4

Pin1 = earth Pin2 = output signal Pin3 = 10Vdc power 0.2Vdc output (sensor not engaged) 8.3 Vdc (Sensor fully pressed)

P2

0.011.2164.0

Pin1 = earth Pin2 = analogue signal Pin3 = 10V power Signal with sensor disconnected from the tractor between pins 1 and 2: ~5 V

S1

H1

2

Lift draft sensor

3

Max. lift height adjustment potentiometer

0.011.2990.0

Resistance between pin1 and pin 3: ~4.7 kOhm Resistance between pin1 and pin 2: 0÷4.7 kOhm

4

Lift position adjustment potentiometer

0.011.2990.0

Resistance between pin1 and pin 3: ~4.7 kOhm Resistance between pin1 and pin 2: 0÷4.7 kOhm

P1

5

Draft/wheelslip adjustment potentiometer

0.011.2990.0

Resistance between pin1 and pin 3: ~4.7 kOhm Resistance between pin1 and pin 2: 0÷4.7 kOhm

M1

6

Max. lift height adjustment potentiometer

0.011.2990.0

Resistance between pin1 and pin 3: ~4.7 kOhm Resistance between pin1 and pin 2: 0÷4.7 kOhm

V

7

Transmission speed sensor

008.1646.0

Resistance between pin1 and pin 2: ~1000 Ohm at 20°C

X50

8

Diff lock control solenoid valve (DF)

2.3729.240.0

Resistance between pin1 and pin 2: ~ 8 Ohm at 20°C

X16

9

4WD control solenoid valve

2.3729.240.0

Resistance between pin1 and pin 2: ~ 8 Ohm at 20°C

X15

10

Rear PTO control solenoid valve (PTO)

2.3729.240.0

Resistance between pin1 and pin 2: ~ 8 Ohm at 20°C

X17

High range control 11 solenoid valve (HI)

2.3729.240.0

Resistance between pin1 and pin 2: ~ 8 Ohm at 20°C

H

12 L o w r a n g e c o n t r o l solenoid valve (LO)

2.3729.240.0

Resistance between pin1 and pin 2: ~ 8 Ohm at 20°C

L

13 Fuel level sensor

2.7059.998.0

Air cleaner clogging 14 sensor

2.7099.320.0

288

Resistance between pin 2 and pin 3: ___ Ohm (Tank full ___ mm) ___ Ohm (Tank half full ___ mm) ___ Ohm (Tank empty ___ mm) Illumination reserve warning light (Closes contact between pins 1 and 3): at _____ mm from tank empty signal Normally open contact

X23

X60

N° Description Hydraulic oil 15 pressure switch

Code low

8

Electrical system

84

Characteristics

Notes

Connector

Normally open contact

X20

01181549

Normally closed contact

X55

17 Handbrake switch

2.7659.129.0

Normally closed contact (Handbrake on)

X24

Engine governor reset 18 button

2.7659.139.0

Normally open contact

X45

19 T y r e s i z e s e l e c t i o n pushbutton

2.7659.140.0

Normally open contact

X52

Engine governor display pushbutton

2.7659.173.0

Normally open contact

X73

21 Preheating control pushbutton

2.7659.177.0

Normally open contact (NO) resistance with contact closed 3.9 Ohm

X67

Rear lift "lower" control 22 pushbutton

2.7659.182.0

Normally open contact (NO) resistance with contact closed 3.9 Ohm

DW

Rear lift "raise" 23 control pushbutton

2.7659.182.0

Normally open contact (NO) resistance with contact closed 3.9 Ohm

UP

2.7659.223.0

Normally open contact between contacts 2 and 3.

32

16 Engine oil pressure switch

20

24

Front screen washer control switch

2.7099.660.0

Systems

289

8

Systems

84

Electrical system

N° Description

Code

Characteristics

Connector

0 1 2

25

Winscreen wiper control switch

1

2

3

4

5

6

7

8

2.7659.092.0

X84 Pin

1

Pos

2

3

4

5

6

7

8

0 1 2

0 1 2

26 Rear wiper control switch

1

2

3

4

5

6

7

8

2.7659.146.0

X79 Pin

1

Pos

2

3

4

5

6

7

8

0 1 2

1

0

b 30

30 49a

15

49

L

Hazard warning lights 27 switch

X33 Pin Pos

0 1

290

R

2.7659.110.0 15

49

30

L

49a

R

Code

8

Electrical system

84 Connector

Characteristics

0

P

1 15

2

30

N° Description

Systems

50

30/1

17 19

28 Starter switch

2.7659.127.0

Pin Pos

15 30/1 50

19

30

X32

17

P 0 1 2 0 1

7

Rear worklights control 29 switch

4

5

3

6

2

1

8

2.7659.155.0

X99 Pin

1

Pos

2

3

4

5

6

7

8

0 1

0 1

7

30

Front worklights control switch

4

5

3

6

2

1

8

2.7659.154.0

X100 Pin Pos

1

2

3

4

5

6

7

8

0 1

291

8

Systems

84

Electrical system

N° Description

Code

Connector

Characteristics

0 1

7

Rotating beacon control 31 switch

4

5

3

6

2

1

8

2.7659.159.0

X96 Pin Pos

1

2

3

4

5

6

7

8

0 1

1

0 3 5

1

2

4

6

32 Diff lock control switch

7

2.7659.163.0

X9

Pin Pos

1

2

3

4

6

7

0 1

Rear lift 33 pushbutton

control

1 2 3 4 5

2 0 1

0.011.7720.0

Pin Pos

1 0 2

292

C-I 1

2

3

4

5

N° Description

Code

Systems

8

Electrical system

84

Characteristics

1

Connector

0

b

30 49a

15

30

49

L

34 4WD control switch

R

007.5945.0

X8 Pin Pos

15

49

30 30b

L

R

0 1

1

0

b

30 49a

15

30

49

L

35 Rear PTO control switch

R

2.7659.108.0

X10 Pin Pos

15

49

30 30b

L

R

0 1

1

0

b 30

30 49a

15

49

L

36 Front PTO control switch

R

2.7659.108.0

X35 Pin Pos

15

49

30 30b

L

R

0 1

293

8

Systems

84

Electrical system

N° Description

Code

Characteristics

1 2

0

7

37 Rear wiper control switch

Connector

4

5

3

6

2

1

8

2.7659.192.0

X97 Pin

1

Pos

2

3

5

6

0 1 2

1 2

0

7

38 Winscreen wiper control switch

4

5

3

6

2

1

8

2.7659.224.0

X98 Pin

1

Pos

2

3

5

6

0 1 2

Pin Pos

39 Lights selector switch

0.009.6491.4

Freccia sx Freccia dx Clacson Lampeggio Luci di posizione Luci anabbagl. Luci abbagl.

294

1

2

3

4

5

6

7

8

9

X36

N° Description

Code

Systems

8

Electrical system

84

Characteristics

1

Connector

0 C 1

S

31

PTO engagement 40 pushbutton

S1

2.7659.142.0

X10

Pos

Pin S1

S

31

C

0 1

295

8

Systems

84

Electrical system

3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS 3.3.1 HML CONTROL UNIT CONNECTOR X72

1

6

1

2

3

4

5

6

12 11 10 9

8

7

12 Pin

Volts.

1

0V

2

Abbreviation

Description Battery negative "M" warning light output

3

+12V

4

0V

Power (+) commmon for "H-M-L" solenoid valves Configuration pin

5

Not utilised

6

Digital signal - range downshift pushbutton

7

Digital signal - range upshift pushbutton

8

0V

Range switch common

9

Power for "L" solenoid valve

10

Power for "M" solenoid valve

11

Power for "H" solenoid valve

12

296

7

+12V

Battery positive

Systems

8

Electrical system

84

3.3.2 POWER LIFT CONTROL UNIT CONNECTOR X71

1

6

1

2

3

4

5

6

12 11 10 9

8

7

12 Pin

Volts.

1

+12V

Abbreviation

Description Battery positive

2

Power for "UP" solenoid valve

3

Power for "DOWN" solenoid valve

4

0V

5

+10V

7

Battery negative Power (+) common for solenoid valves and sensors

6

Analogue input - lift position sensor

7

Analogue input - lift draft sensor

8

Analogue input - lift lowering speed adjustment trimmer

9

Analogue input - max. lift height adjustment trimmer

10

Analogue input - lift draft-wheelslip adjustment trimmer

11

Analogue input - lift position adjustment trimmer

12

ISO 9141 serial interface (Diagnostics connector)

297

8

Systems

84

Electrical system

3.3.4 ANALOGUE INSTRUMENT PANEL

27

9

7

8

16

17

18

26

25 15

23

REF.SAME-10S-10N ANALOGICO

4

5

2200RPM=567A-473W HZ 12V REF.AST/Rev. DATE........ AST MADE IN SPAIN

W A

1

2

3

11 10

6

14

13

29

21

12

20

19

28

22

30

31

24

32

33

34

35

36

CONNECTOR X3

Pin

Volts.

Abbreviation

Description

1

Warning light - "Memorising selected gear"

2

Analogue input - "W" (Alternator rotation)

3

Not utilised

4

Input - engine temperature sensor

5

Input - fuel level sensor resistance

6

Warning light - "High beam"

7

Warning light - "Preheating"

8

"Clogged air cleaner" warning light

9

Warning light - "Low engine oil pressure"

10

Warning light - "Handbrake - Low fluid level"

11

Warning light - "Low gear" (L)

12

Warning light - "Fuel reserve"

13

Warning light - "Low trailer braking pressure"

14

Warning light - "Battery charging"

15

Warning light - "Hydraulic oil filter clogged - Low oil presure"

16

Warning light - "Front PTO engaged"

17

Warning light - "Rear PTO engaged"

18

Warning light - "Broken belt alarm"

19

Instrument panel lighting

20

Warning light - "Diff lock"

21

Warning light - "4wd engaged"

22

Warning light - "Direction indicators"

23

Warning light - "1st trailer direction indicators"

24

Warning light - "2nd trailer direction indicators"

298

Systems

8

Electrical system

84

25

Warning light - "Rear PTO Groundspeed"

26

Warning light - "High gear" (H)

27

Warning light - "Medium gear" (M)

28

Warning light - "Rear PTO at 540 rpm"

29

Warning light - "Rear PTO at 1000 rpm"

30

Warning light - "Rear PTO ECO"

31

0V

32

+12V

Common earth fore warning lights (pins 1,6,16,18,19,22,23,24) Power common for warning lights (Pins 7,8,9,10,11,12,13,14,15,17,20,21,25,26,27,28,29,30)

33

Power for "External alarm" warning light

34

Not utilised

35

Not utilised

36

Not utilised

299

8

Systems

84

Electrical system

3.3.5 DIGITAL INSTRUMENT PANEL

27

9

7

8

16

17

18

26

25 15

23

SWITCH SELEZIONE ACQUA/ARIA

4

5

REF.SAME-10S-10N DIGITALE 2200RPM=1760 Hz12V REF.AST/Rev. DATE........ AST MADE IN SPAIN

1

2

3

11 10

6

14

13

29

21

12

20

19

28

22

30

31

24

32

33

34

35

36

CONNECTOR X3

Pin

Volts.

Abbreviation Description

1

Warning light - "Memorising selected gear"

2

Input - engine speed signal (from engine control unit - Pin 22)

3

Digital input - transmission speed sensor

4

Input - engine temperature sensor

5

Input - fuel level sensor resistance

6

Warning light - "High beam"

7

Warning light - "Preheating"

8

Spia "Intasamento filtro aria"

9

Warning light - "Low engine oil pressure"

10

Warning light - "Handbrake - Low fluid level"

11

Warning light - "Low gear" (L)

12

Warning light - "Fuel reserve"

13

Warning light - "Low trailer braking pressure"

14

Warning light - "Battery charging"

15

Warning light - "Hydraulic oil filter clogged - Low oil presure"

16

Warning light - "Front PTO engaged"

17

Warning light - "Rear PTO engaged"

18

Warning light - "Broken belt alarm"

19

Instrument panel lighting

20

Warning light - "Diff lock"

21

Warning light - "4wd engaged"

22

Warning light - "Direction indicators"

23

Warning light - "1st trailer direction indicators"

24

Warning light - "2nd trailer direction indicators"

300

Systems

8

Electrical system

84

25

Warning light - "Rear PTO Groundspeed"

26

Warning light - "High gear" (H)

27

Warning light - "Medium gear" (M)

28

Warning light - "Rear PTO at 540 rpm"

29

Warning light - "Rear PTO at 1000 rpm"

30

Warning light - "Rear PTO ECO"

31

0V

32

+12V

Common earth fore warning lights (pins 1,6,16,18,19,22,23,24) Power common for warning lights (Pins 7,8,9,10,11,12,13,14,15,17,20,21,25,26,27,28,29,30)

33

Power for "External alarm" warning light

34

Input - "Display" pushbutton

35

Input - "Reset" pushbutton

36

Input - "Select" pushbutton

301

8

Systems

84

Electrical system

4. SYSTEMS N°

Systems

1

Platform

Standard cab

High Visib. Cab

Earths

X

X

X

2

Starting and preheating

X

X

X

3

Lights - steering column switch unit

X

4

Lights - steering column switch unit

5

Lights - steering column switch unit

6

Accessories - Diagnostics

7

Accessories - Diagnostics

8

Accessories - Diagnostics

9

Wipers

10

Wipers

11

Front instrument panel

12

Radio

13

Radio

14

Heating

15

Heating

16

Heating and air conditioning

17

Heating and air conditioning

18

Braking system - Trailer braking

X

X

X

19

HML transmission

X

X

X

20

Electronic lift

X

X

X

21

Rear and front PTO

X

X

X

302

X X X X X X X X

X

X

X X X X X X

Systems

8

Electrical system

84

4.1 EARTHING POINTS GND5

GND4

F0028100

F0028140

GND9 GND5 GND1

GND2

F0028120

GND8 GND3

F0026980

F0028560

D0007220

303

8

Systems

84

Electrical system

GND6

F0027370

GND7

F0027210

D0007860

304

Systems

8

Electrical system

84

4.2 STARTING AND PREHEATING 4 2

3

1

2

30 86 85 87

X67

ON

13

87a

87 85 86 30

30 50

30/1

15

X32

RL1

RL2

0.010.5303.4

1

210

X10 R

7

30b

2

Fmax

31 14

+12 VOLT

32

W (ROTAZIONE ALTERNATORE)

2

PRERISCALDO

7

X3

X43

X31 5

1

6

3

4

2

4

3

2

X38

X1

1

29 5

12 11 13

X37

4

GND4

+30

CARICA BATTERIA

12

20A

3

+50

-VCC

F6

6

L

40A

1

30

F1

OFF

4 15

40A

49

M

11

+

10

5

-

BATTERY

0.010.5302.4

GND3

X41 X57 1

X65

X58

2

D+

B+

W +

G

7 9

-

6 1 2 3 4 5 6

Preheating push button Relay RL2 Relay RL1 Starter switch Starter motor Alternator

7 8 9 10 11 12 13

8 Preheating control solenoid valve Glowplug Fuel pump Start enable switch Preheating control unit Instrument panel Rear PTO control switch

D0008840

305

8

Systems

84

Electrical system

4.3 LIGHTS - STEERING COLUMN SWITCH UNIT (PLATFORM)

5

7

4

1

X3

3

1

4

2

3

49

49a

32 19 22 24 23 18 31

X33

11

C

-VCC

G

-31

4

9 ABBAGLIANTI

7

IND. DIR. 1° RIMORCHIO

5

IND. DIREZIONE

6

+12 VOLT

1 3

49

R

30 50

49a

30/1

L

15

X32

+30

+15

0.010.5303.4

ILL. CRUSCOTTO

ON

2 1 0

1 2 3 4 5 6 7 8 9

10

8 IND. DIR. 2° RIMORCHIO

OFF

C2 C3

7

6

5

6

1

2

1

2

X40

X26

X22 X21 GND5

X4 5

5

4

3

7 6

GND4

1

X13

4

1

5

2

6

X34 7

3

6

4

3

X14

3

10 11 12 13 14 15 16

2

2

1 2

X28 9

2

8 7

X27

6

1

4 3

12

X36

5

+1

X29

30 5 FS

9

L

7

FD

F12 10A

F11 10A

F10 10A

F9 10A

F8 10A

F4 20A

F3 15A

F2 20A

Fmax 40A

F6 20A

8

57/58

2

56b

3

56a

4

H

6

X38

X37

X1 7

9 10 6

1

3

+30

+50

8

M

-

16

BATTERY

2

X61

X62

X64 1

3

2

2

1

GND3

15

D0008850

306

14

13

0.010.5302.4

+

Rear left light Front left headlamp Number plate light Rear right light Front right headlamp Starter switch Hazard warning lights switch Instrument panel Trailer socket (For lights and auxiliary power) Hazard warning control unit Rear worklight Lights selector switch Horn Front left lights Front right lights Starter motor

Systems

8

Electrical system

84

4.4 LIGHTS - STEERING COLUMN SWITCH UNIT (STANDARD CAB)

15

10 9

32 19 22 24 23 18 31

X33

49

49a

-31

7 5

C C2 C3

G

-VCC

ABBAGLIANTI

+12 VOLT

49

R

L

1 3 6 5 7 4

30 50

30/1

X32

49a

0.010.5303.4

+30

0.010.5582.3

+15

2 10

IND. DIREZIONE

ON

IND. DIR. 1° RIMORCHIO

OFF

ILL. CRUSCOTTO

6

IND. DIR. 2° RIMORCHIO

8 7

1 4 2 3 5 6

4 1 3

X40

X26

X3

5 5 7 6

9 8 7

X13

GND5 3 1 2 4 5 6

X27

X4 GND4

11

12

1 3 4 2

1 3 4 2

4 3

1 2 3 4

X78

X85

1 2

1 2

2 1

15

16

X121 X124

1 2

X122

2 1

X123

F8

X28

1

14

GND6 X14

2

13

10A

6 4 5 3

F7 10A

X87

X39

X29 10A

F12

10A

F11

10A

10A

F10

F9

10A

F8

20A

F6

F3

15A

F2

20A

40A

Fmax

F7

10A

X77

3 1 2

1 2

F

X111

5 6 1 2

X103-30

50A

BATTERY

22

30

FS

L

FD

56b

57/58

H

6 4 3 2 8 7 9 5 1 56a

0.010.5302.4

+30

+50

-

X36

8 7 9 10 6

+

M +

X1

X37

X38

X103

0.009.7852.3

30 86 85 87

0.009.7850.4

0.009.7851.4

17 X62

X64 2 1 3

X61

2 1 3

2 1

GND6

18 21 1 2 3 4 5 6 7 8 9

Rear left light Number plate light Rear right light Front left sidelight and direction indicator Front right sidelight and direction indicator Starter switch Hazard warning lights switch Instrument panel Trailer socket (For lights and auxiliary power)

10 11 12 13 14 15 16 17 18 19

20

19

Hazard warning control unit Front worklights control switch Rear worklights control switch Front left worklight Front right worklight Rear left worklight Rear right worklight Roof wiring power relay Lights selector switch Horn

20 21 22

Front left lights Front right lights Starter motor

D0008860

307

8

Systems

84

Electrical system

4.5 LIGHTS - STEERING COLUMN SWITCH UNIT (HIGH-VISIBILITY CAB)

15

30 50

30/1

X32

5

1 3 6 5 7 4

10 9

7 5 4 1 3

49

49a

-31

32 19 22 24 23 18 31

X33

C C2 C3

G

-VCC

ABBAGLIANTI

IND. DIREZIONE

49

I+12 VOLT

R

L

+30

0.010.5303.4

49a

0.010.5582.3

+15

2 10

ILL. CRUSCOTTO

ON

IND. DIR. 1° RIMORCHIO

OFF

IND. DIR. 2° RIMORCHIO

8

7

6

1 4 2 3 5 6

X40

X26

X3

X13 5 7 6

GND5

X4 3 1 2 4 5 6

X27 9 8 7

GND4

4

11 3

1 2 3 4

1 2

1

6 4 5 3

13

14

15

16

1 2

2 1

GND7

X14

7 2 3 1 5 6 4 8

2

12

7 2 3 1 5 6 4 8

1 2

X99

X100

X121

1 2

X124

X122

X123

X28 F8 10A

F7 10A

X29

X91

X39

2

10A

F12

10A

F11

F10

10A

10A

F9

F8

10A

20A

F6

15A

F2

F3

20A

40A

F7

10A

Fmax

2

X95

F

X111

4 3 2 1

X103-30

50A

23

30

L

FS

FD

56b

57/58

0.010.5302.4

BATTERY

X104

X103 6 4 3 2 8 7 9 5 1 H

+30

+50

-

X36

8 7 9 10 6

+

M +

X1

X37

56a

X38

30 86 85 87

0.011.3761.3 40A

18 X64

X62

2 1 3

1 2

17

X61

2 1 3

2 1

GND6

19 22

1 2 3 4 5 6 7 8 9

D0008870

308

Rear left light Number plate light Rear right light Front left sidelight and direction indicator Front right sidelight and direction indicator Starter switch Hazard warning lights switch Instrument panel Trailer socket (For lights and auxiliary power)

10 11 12 13 14 15 16 17 18 19

21

20

Hazard warning control unit Front worklights control switch Rear worklights control switch Front left worklight Front right worklight Rear left worklight Rear right worklight Roof wiring power fuse (40 Amp) Roof wiring power relay Lights selector switch

20 21 22 23

Horn Front left lights Front right lights Starter motor

0.011.3606.4

GND7

0.011.3595.3

Systems

8

Electrical system

84

4.6 ACCESSORIES - DIAGNOSTICS (PLATFORM)

2 3

4

5

2 1 0

15

1

30 50

30/1

1

3

X2

10A

X7

F10

3

X71

F2

1

20A

2

+12 VCC

F4

1

4

2

X11

20A

12

GND

40A

ISO 9141

Fmax

3

F13

2

7

15A

1

F5

1

10A

8

2

X42

2

1

1

X12

X32 PRESA DIAGNOSTICA

2

0.010.5303.4

GND5

0.011.6986.4

0.011.6943.4 X38

X36

X37

1 +30

5

+50

9

30

L

7

FS

8 FD

56b

2 57/58

3

+

H

4 56a

6

M

6

+

-

BATTERY

7 1 2 3 4 5 6 7 8

Diagnostics connector Starter switch Compressor for driver’s seat air suspension Outlet socket (in cab) Cigar lighter Starter motor Lights selector switch Rear lift control unit

D0008880

309

8

Systems

84

Electrical system

4.7 ACCESSORIES - DIAGNOSTICS (STANDARD CAB)

7

0.009.7851.4

2 1

X127

2

3

4

1 2

1 2

15

30 50

30/1

X32

PRESA DIAGNOSTICA

1

2 1

GND5

0.011.6986.4

2 1 3

X11

X12

X42

30 86 85 87

8 7 6 5 4

X103

X2 X103-30

1 2 3

2 1 7

X126

6

5

2 10

X39 2

2 3

F

0.011.6943.4 0.010.5303.4

+30

L

FS

30

FD

56b

57/58

H

X83

X37

X38

+

56a

6 4 3 2 8 7 9 5 1

+50

X36

M

11

+

1 2 3 4 5 6 7 8 9 10 11 12 13

D0008900

310

Diagnostics connector Starter switch Compressor for driver’s seat air suspension Outlet socket (in cab) Cigar lighter Roof wiring power relay Flashing light Rotating beacon control switch Interior roof light Clock Starter motor Lights selector switch Rear lift control unit

GND6

X74 4 3 2 1 15 30 58

-

BATTERY

12

0.009.7852.3

10

1 2

9

2 4 3 1

8

X81

0.009.7850.4

F1

10A

F6 10A

20A

F10

F4

F2

20A

40A

15A

Fmax

F5

F13

X111

X7

50A

X71

10A

1 2 3

12 4 1

F7

GND +12 VCC

10A

ISO 9141

13

10A

X87

Systems

8

Electrical system

84

4.8 ACCESSORIES - DIAGNOSTICS (HIGH-VISIBILITY CAB)

3

4

1 2

1 2

5

2 10

15

30 50

30/1

X12

X32

PRESA DIAGNOSTICA

1

2 1 3

X11

2 1

7 2 3 1 8

X96

X74

X2

X42 1 2 3

X91

X39 2

2 3

X104 2 1

X36

X38

9

F1

X103 X101

X37

0.010.5303.4

+30

+50

30

L

FS

FD

56b

+

57/58

6 4 3 2 8 7 9 5 1

8

10A

5A

F2

F6 F

0.011.6943.4

H

10A

10A

20A

F10

F4

20A

40A

15A

F13

Fmax

F5

X7

56a

87 85 86 30

X111 50A

X71

10A

1 2 3

GND

F7

12 4 +12 VCC 1 ISO 9141

14

10A

X103-30

40A

2 1 7

GND7

GND5

0.011.6986.4

7

6

0.011.3606.4

2

4 2 3 1

0.011.3761.3

M

GND6 1 2

X126

BATTERY

13 X83

1 3 2 4 15 30 58

11 1 2 3 4 5 6 7

Diagnostics connector Starter switch Compressor for driver’s seat air suspension Outlet socket (in cab) Cigar lighter Interior roof light Rotating beacon control switch

8 9 10 11 12 13 14

1 2

X127

0.011.3596.3

12

+

10

Roof wiring power fuse (40 Amp) Roof wiring power relay Flashing light Clock Starter motor Lights selector switch Rear lift control unit

D0008890

311

8

Systems

84

Electrical system

4.9 WIPERS (STANDARD CAB)

X82

2 1

X80

X75 3

0.010.4516.3

2 1

2 3 6 1

X135 F5

2

F6

1

X130

X88 2 3 6

X129

1

1 2

10

T 31 15 53S 53M

3 7 6 5 8

0.009.7854.3 M

I

X84

7.5A

M

5 6 7 8 4 3 2 1

7.5A

11

1 2

5 6 7 8 4 3 2 1

4

X79

X77

X125

2

0.009.7850.4

0.009.7851.4

3

1

M

9

GND6 X87

30 86 85 87

F 30/1

30 50

6

2

F7

40A

Fmax

X37 +30

+50

X38

10A

X39

X32

0.010.5303.4

50A

2 10

0.009.7852.3

X111

8

15

X103

X103-30

2

M

7

+

-

BATTERY

1 2 3 4 5 6

D0008910

312

Rear wiper control switch Front windscreen wiper control switch Intermittent wipe timer for windscreen wiper Windscreen washer pump control switch Windscreen wiper motor Roof wiring power relay

7 8 9 10 11

Starter motor Starter switch Rear screen washer pump Front windscreen washer pump Rear screen wiper motor

5

Systems

8

Electrical system

84

4.10 WIPERS (HIGH VISIBILITY CAB)

1 3 2 6 5

1 3 2 6 5

GND6 X97

X101

2 1

4 I

T 31 15 53S 53M

X98

X82

2 3

X80

2

X125

0.011.3597.3

7.5A

2 3 1 4

0.011.3743.3

F6

X129

7.5A

11

X75

3 2 1

F5

1 2

M

X92

2 3 1 4

12

2

0.011.3606.4

0.011.3596.3

3

1

5

X130

X135 1

2

X103-30

X91

X104

X103

2

M

30 86 85 87

1 2

GND7

10 9

F 30/1

30 50

6

2

X39

X37 +30

+50

X38

F7

40A

Fmax

X32

0.010.5303.4

7

10A

15

50A

2 10

40A

0.009.7852.3

X111

M

8

+

-

BATTERY

1 2 3 4 5 6

Rear wiper control switch Front windscreen wiper control switch Intermittent wipe timer for windscreen wiper Windscreen washer pump control switch Windscreen wiper motor Roof wiring power fuse (40 Amp)

7 8 9 10 11 12

Roof wiring power relay Starter motor Starter switch Rear screen washer pump Front windscreen washer pump Rear screen wiper motor

D0008920

313

8

Systems

84

Electrical system

4.11 FRONT INSTRUMENT PANEL

Digital instrument panel

Analogue instrument panel

OLIO IDRAULICO

7

6

5

36 35 34

3

32 31

9

8

4

15 12

LIVELLA CARBURANTE

-VCC

2

5 33

1

15

30 50

30/1

X32

X3

X1 2 3 1

40A

20A

Fmax

GND4

0.010.5302.4

40A

Fmax

20A

F6

1

F6

X32

X3

+12 VOLT

30 50

30/1

2 1 0

0.010.5303.4

TEMP. MOTORE

15

RISERVA CARBURANTE

INT. FILTRO ARIA

1

GND4

0.010.5302.4

BASSA PRESS. OLIO MOTORE

-VCC

LIVELLA CARBURANTE

5 33

4

-VCC

15 12

+12 VOLT

4

+12 VOLT

8

0.010.5303.4

9

RISERVA CARBURANTE

32 31

2 1 0

+12 VOLT

3

+12 VOLT

DISPALY

AZZERAMENTO

36 35 34

OLIO IDRAULICO

6

TEMP. MOTORE

5

INT. FILTRO ARIA

7

X45

BASSA PRESS. OLIO MOTORE

2

3

4

-VCC

1

X52

SELEZIONE

2 +12 VOLT

1

SENS. VEL. TRASMISSIONE

3

X1 2 3 1

X18 X18

7

2

5

t

4

3

GND5

Fn

X60

X55

X37

1

1

X20

X54

2

2

3

7

X19

X23

X38 2

5

GND3

4

3

GND5

t

X37

1 +30

3

X38

+50

2

X23

+30

2

X19

+50

1

GND3

X20

X44

X54 X50

X60

X55

M

P

M

P

13

12

11

10

9

8

7

6

5

+

13

-

12

11

8

7

6

5

+

-

BATTERY BATTERY

1 2 3 4 5 6 7 D0009010

314

Selection pushbutton (only digital panel) Reset button (only digital panel) Instrument panel Starter switch Starter motor Fuel level sensor Hydraulic oil filter clogging pressure switch

8 9 10 11 12 13

Hydraulic oil low pressure switch Display pushbutton (only digital panel) Transmission speed sensor (only digital panel) Coolant temperature sensor Air cleaner clogged sensor Engine oil pressure switch

D0009110

4.12 RADIO (VERSION WITH STANDARD CAB)

Systems

8

Electrical system

84

4.13 RADIO (VERSION WITH HIGH-VISIBILITY CAB)

1

1

2 4 1 3

0.011.3596.3

5A

0.009.7850.4

X86

F2

X132

4

X131

2 1

X86 X101 3

X132

2 1

4 X87

X133 2 1

F2 5A

0.011.0729.4

X131

1 2

2 1

X133

3

0.011.3606.4

GND6 2 4 1 3

X91 2 1

3

GND6

3

F 50A

X37 +50

+30

+50

X37

X111

M

2

M +

-

2

BATTERY

1 2 3 4

D0007500

+30

F

50A

X111

0.009.7852.3

0.009.7852.3

3

+

-

BATTERY

Radio Starter motor RH speaker LH speake

1 2 3 4

Radio Starter motor RH speaker LH speake

D0007510

315

8

Systems

84

Electrical system

4.14 HEATER (STANDARD CAB)

X142

12

1

2

1 2 3

1 2

010.2123.2 X137

X138

87 85

X139

86 30 11 3 10 6 3 8 9 4 5 7 2 1

H

3

3 0

2

M

1

L

2 3

4

X140

10

2

5

M

1

X141 2 1

1 2

X106

F4

X89

X103-30

2 1

X108

20A

X107

X103 30 86 2

6

85

X87

87

X111

7

GND6

F

2 10

X109

B+

X39

1 2 B-

+

B+

15

2

DF D+

30/1

30 50

X32

0.010.5303.4

B-

50A

0.009.7852.3

B

4

3 1 2 4

40A

F7

10A

Fmax

G -

9 X37 +30

+50

X38

M

8

+

-

BATTERY

316

C

2 3 4 5 1

X136

D0008930

1

0.009.7850.4

11

1 2 3 4 5 6 7 8 9 10 11 12

Potentiometer adjustment heading Heating air temperature sensor Fan speed selector switch Resistor for heater fan Heater fan Roof wiring power relay Starter switch Starter motor Heating alternator Heater unit resistance Heater settings control unit Relay - alternator excitation

Systems

8

Electrical system

84

4.15 HEATER (HIGH-VISIBILITY ROOF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

010.2558.1 X153

5

X150

X152

2 1

M

2 1

X149

4

II

3

III IV C

2 1

6

M

X148

1

1

2 3 4

2 3 4

X154 I

X151

2 1

7

X146

1

87b

2 3 4 5

87 86 85 30

8

X145 1 2 3 4 5

X147

X137 1 2

87b

8 9

30 85 86 87

12 6 10 3 4 5 1 2 7 11

87b

X157

1 2

2 1

X93

X106 F 40A

X113

X103-30

2 1

11

X136

12 3 1 2 4

X103 30 86 85 87

X108 2

X91

13

GND6

X111

F

2 10

B+

B-

X109 1 2

B- +

B+

14

50A

0.011.3761.3

10

X39 2

15

DF D+

X32

G

F7 10A

Fmax 40A

-

16 X37

30 50

+30

+50

X38

30/1

0.010.5303.4

1

9

0.011.3606.4

2

30 85 86 87

Control relay for 3rd heater fan speed Relay - alternator excitatione Fan speed selector switch Resistor for right heater fan Right heater fan Left heater fan Resistor for left heater fan Control relay for maximum fan speed Potentiometer adjustment heading Heating air temperature sensor Heater settings control unit Heater unit resistance Roof wiring power relay Starter switch Starter motor Heating alternator

M

15

+

-

BATTERY

D0008940

317

8

Systems

84

Electrical system

4.16 HEATING AND AIR CONDITIONING (STANDARD CAB)

4

1 2 3

1 2

X138

0.010.2130.1

30 85 86 87

X137

X143

X144

X142

1 2

87

6

85

X139

86 30

1

C

2

B

11

3

H

3

4 5

M

10 6 12

1

8

2

1

9

3

4

4

5

7

3 0

2 1

L

8

X140

7

10

2

1

1

X141 1

2

4

1 2

2

3

2

4

1

X106

F3 30A

X107

X108 2

X141

X89

1

F4 20A

3

0.009.7850.4

X136

X103-30

1

X87

9

M

2

12

30 86 2

85

1

87

11

30 86 85 87

X115

4 2 3 1

B+

X109 1

+

B+

2

X76 1

2

DF D+

G

Fmax 40A

F7 10A

-

18 X1

X38

X32

X37

318

30 50

M

16 X59

17

D0008950

30/1

+30

15 +50

0.009.7624.4

15

+

2 10

-

BATTERY

15

0.010.5303.4

B-

X39

2

3 2

1

X119

1

1

X118 X120

0.009.7853.3

GND6

X111

F 50A

0.010.5303.4

3

B-

14

13

X103 M

2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

5

3

Heater control unit Control relay for alternator excitation Heater control potentiometer Heater air temperature sensor Control relay for air conditioning Demister thermostat Fan speed selector switch Resistor for heater fan Heater fan Heater resistance Roof wiring power relay Control relay for air conditioning fan Air conditioning fan Air conditioning pressure switch Starter switch Starter motor Air conditioning compressor Heating alternator

Systems

8

Electrical system

84

4.17 HEATING AND AIR CONDITIONING (HIGH-VISIBILITY ROOF) 1 2

X153

X152 X158

2 1

X150

X159

2 1

X151

2 1

2 1

X149

1 2 3 4

X154

4

III IV C

3

2

X146

1

87b

2 3 4 5

87 86 85 30

30 85 86 87 30 85 86 87

X156

X145 1 2 3 4 5

12

1 2

13

X147 X137

87b

30 85 86 87

8 9 12 6 10 3 4 5 1 2 7 11

87b

X157

15

X136

F

40A

X93

7.5A

F3

X108

F4

X94

X106

X113

2 1

3 2 1

1 2

304

3 1 2 4

X103-30

2 1

30 86 85 87

1 3

F 50A

0.011.3761.3

B+

X109

X102

X39

1 2 B+

18

20

19

21

16

2 1

X117a

30 86 85 87 87a

X115

30 86 85 87 87a

X114

1 2 3 4 5 6

1 2

X116

X117b

GND6

X111

B-+

17

X103

X91 2

B-

14

0.011.3606.4

1

11

1 2 4 5 7 8 6 3

0.011.3610.3

II

10

Control relay for 3rd heater fan speed Control relay for alternator excitation12 Control relay for 1st fan speed and air conditioning on Fan speed selector switch Resistor for right heater fan Right heater fan Air conditioning control switch Air conditioning thermostat Left heater fan Resistor for left heater fan Control relay for maximum fan speed Heater control potentiometer Heater air temperature sensor Heater control unit Heater resistance Roof wiring power relay Air conditioning fan Control relay for air conditioning fan Control relay for supplementary air conditioning fan Air conditioning pressure switch Supplementary air conditioning fan Starter switch Starter motor Air conditioning compressor Heating alternator

M

I

9

X148

1 2 3 4

5

M

M

M

0.010.2562.1

1 2

1 2

DF D+

0.010.5303.4

6

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

8

7

40A

F7

10A

Fmax

G

-

25 X38

X32

X37

15

30/1

30 50

+30

+50

0.010.5302.4

X1 15

M

-

+

X59

210

BATTERY

23

22

24 D0008960

319

8

Systems

84

Electrical system

4.18 BRAKING SYSTEM - TRAILER BRAKING 4

5

4

6

4

3

2

6

1

X14

X29

15

3

30/1

30 50

X26

-VCC

+12 VOLT

2 10

FRENO A MANO

3

13 10 32 31

0.010.5303.4

3

2

PRESS. RIMORCHIO

1

5

X3

X32

40A

Fmax

X5

F6 20A

F7 10A

GND4

1

10

2

X25

9

1 P

2

X24

8

1 2

X38

X37 +30

+50

20

GND5

X1 M +

7

-

0.010.5302.4

BATTERY

X66 1

2

GND3

6 1 2 3 4 5 6 D0008970

320

Rear left light Rear right light Trailer socket (For lights and auxiliary power) Starter switch Instrument panel Brake fluid level sensor

7 8 9 10

Starter motor Handbrake switch Trailer braking low pressure switch Brake pedal switch

Systems

8

Electrical system

84

4.19 HML TRANSMISSION

4

4

3

2 1

M

5

L

3

2

6

1

1

GND

1

2

CONFIG

4

3

EV HI 11

4

SPIA M

2

5

EV LO

9

6

COM EV

3

7

LEVA LO

6

8

LEVA COM.

8

LEVA HI

4

2

2

1

X16

1

2

6

3

1

X15

4

2

R

49

30 15

L

7

30b

2 10

R

49

1

X9

X72 +12 Vcc 12

1

3

X73

ON

7

15

30/1

30 50

X8

0.010.5303.4

H

4

2

7

X32

X6

Fmax 40A

1

6

ON

OFF

F6 20A

2

L

GND5 1

9

8

30b

3

30 15

2

OFF

7 10 5

X38

X3

X37

HML control unit Solenoid valve for High range control (HI) Solenoid valve for Low range control (LO) HML control pushbutton DF control switch Differential lock control solenoid valve (DF)

7 8 9 10 11

M

10

+

-

BATTERY

11

1 2 3 4 5 6

+30

GND4

+50

-VCC

+12 VOLT

BLOCC. DIFF.

DOPPIA TRAZIONE

MARCIA VELOCE (H)

MARCIA LENTA (L)

0.010.7972.3

MARCIA MEDIA (M)

11 27 26 20 21 32 31

4WD control solenoid valve (DT) 4WD control switch Starter switch Starter motor Instrument panel

D0008980

321

8

Systems

84

Electrical system

4.20 ELECTRONIC LIFT 14

ISO 9141 +10 VCC MAX ALZATA MIX POSIZIONE VEL. DISCESA SFORZO EV DW EV UP GND +12 VCC POSIZIONE

13

9 10 11 8

7

3

2

4

1

6

15

30 50

30/1

X71

0.010.5303.4

12 5

UP

2 10

X32

2

12

3

11

40A

F5

DW

Fmax

2

10A

1

3 1

7

2

3

4 3

8

4.7 Khom 4.7 Khom 4.7 Khom 4.7 Khom

6

5

X7 I

4 3

1

2

7

2

1

3

4

1

3

9

7

5

3 1 Khom

P1

2

X42

1

3 1 Khom

H1

3

X38 1

GND5

2

M

1 3 1 Khom

V

15

16

3 1 Khom

M1

2

3

S1

2

F U

1 3

3

P2

2

S

1 1

2

2

1

2

1

EV DW EV UP

0.011.6943.4 Lift UP solenoid valve Lift lowering solenoid valve Rear lift position sensor Lift draft sensor Draft/wheelslip control potentiometer Lift lowering speed potentiometer Maximum lift height potentiometer Lift position adjustment potentiometer

D0008990

322

-

BATTERY

1

4

+

2 1

U

1 2 3 4 5 6 7 8

X37

2 +30

2

C

1

1

10

8

5

+50

2 8

9 10 11 12 13 14 15 16

Rear lift control pushbutton Rear lift control pushbutton Rear lift “down” control pushbutton Rear lift “Up” control pushbutton Rear lift control unit Starter switch Starter motor Diagnostics connector

Systems

8

Electrical system

84

4.21 REAR AND FRONT PTO

3

4

2

7

GND5 15

14

30 50

30/1

0.010.5303.4

49

1

X32

X10

40A

6

F6 20A

X1

3

Fmax

X17

2

30 15

L

1

ON

2 10

+12 VOLT

PTO POST.

PTO 540 rpm

PTO 1000 rpm

31 16 25 30 29 28 17 32

X3

X35

X63

PTO ECO

6

PTO ANT.

3

-VCC

4

4

30b

1

30b

2

R

7

49

2

ON

6

5 OFF

R

0.010.5302.4

L

GND4 1

30 15

1

PTO POST. SYNCRO

2 OFF

GND3

E

S 2

1

5

X38

X37

1 +30

3

+50

4

M

11

10

9

8

7

+

-

BATTERY

1 2 3 4 5 6 7 8 9 10 11

Front PTO solenoid valve Front PTO control switch Instrument panel Rear PTO control solenoid valve (PTO) Rear PTO control switch Starter switch Starter motor 540 PTO engagement sensor 1000 PTO engagement sensor 750 (ECO) PTO engagement sensor PTO engagement sensor

D0009000

323

PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

ENGINE WIRING (1/2) X61

X58

X60

X59 X57 X37 X62

X55

X54

X1 TO 0.010.5303.4

1

3 8

4

14

9

X63

20

15 21 26

25 29

X64

X66 X41

X65

X1 X37 X41 X54 X55 X57 D0008300

To central wiring Starter motor Fuel pomp Cooling engine sensor Engine oil pressure switch Glowplug

X58 X59 X60 X61 X62 X63

Preheating control solenoid valve Air conditioning compressor Air cleaner clogged sensor Horn Front left lights Front PTO solenoid valve

X64 X65 X66

GND3

Front right lights Alternator Brake fluid level sensor

0.010.5302.4 325

8

Systems

84

Electrical system

ENGINE WIRING (2/2) X55 X37

BN 1

RN 1.5

M1

RN 1.5

N 16

R1

X58

X59

N1

VN 1.5

X57

X54

X60

B1

N1 N1

X61

Z1

R1 TEMPERATURE

1

ENGINE OIL PRESS.

P. OLIO MOT.

2

AIR FILTER

FILTRO ARIA

3

RPM INDICATOR

W CONTAGIRI

4

GENERATOR

GENERATORE

5

M1 N1

1

TEMPERAT.

2

B1 BR 1

HN 1

3

V1

L1

X62

Z1 AVV. ACUSTICO

6

DIPPED HEAD LIGHTS

ANABBAGL.

7

H1

N1

1

HORN

ANABBAGL.

8

FULL BEAM HEAD LIGHTS

ABBAGLIANTI

9

FULL BEAM HEAD LIGHTS

ABBAGLIANTI

10

PLUG

CANDELATTA

11

PLUG

CANDELATTA

12

ELECKTROVALVE

ELETTROVALVOLA

13

FRONT PTO

PTO ANT.

14

COMPRESSOR

COMPRESS.

15

2

DIPPED HEAD LIGHTS

HN 1 H1

V1

3

V1

X64

V1 RN 1.5 RN 1.5 BN 1 N1 N1

MN 1

N1 VN 1.5

N1

BRAKES OIL

OLIO FRENI

20

+12 VOLT

+12 VOLT

29

GND3

N1

ZN 1

N1

N1

MB 1

MN 1

N1

BR 1

8

9

L1

N 16

3

4

N1

1

ZN 1

MB 1

14 20 25 26

1

21

2

15

29 AMP

X41 X1

X66

X63

X65 D0008310

326

0.010.5302.4

Systems

8

Electrical system

84

POSITION OF ENGINE WIRING CONNECTORS

1 X66 X1

X54

F0028460

2

X55

F0028480

3 X58

F0028450

327

8

Systems

84

Electrical system

4 X60

F0028420

5

X62

X64

F0028430

6

X61

X63

F0028440

328

Systems

8

Electrical system

84

7 GND3

X67: conector for engine cooling fan speed with air conditioning system

F0026980

8 X41

F0028490

9 X59

F0028520

329

PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

ENGINE WIRING

10

1 2 3 X65

4 5

F0028410

6

11 X37

7

8

9

10

11

F0028390

0.010.5302.4 331

PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

CENTRAL WIRING (1/2)

D0008360

GND5

TO 0.011.6943.4

X3 X40

X8

X9

X10

X11

X7

X2

TO 0.010.5302.4

X43

4 3

X1

2

1

X52 X12 X45

X13

X42

C

X5

X14

X15 3

X67

2

1

X16 X4

TO 0.011.7972.4

X6 X17

GND4 TO 0.009.7852.3 0.011.3761.3

X21

1

X20

X21 X22

S S

X44

10 A

10 A

10 A

10 A

10 A

20 A

10 A

10 A

STOP

ELECT.2

20 A

X50

X24

X36 15 A

RL1

E

1

5

X32

15 A

2

SERVIZI

X39

X19

X18

20 A

X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X20 X21 X22 X23 X24 X25 X26 X27 X28 X29 X31 X32 X33 X34 X35 X36 X37 X38 X39 X40 X41 X42 X43 X44 X45 X50 X52 X67

1000 rpm PTO engagement sensor 540 PTO engagement sensor 750 PTO (ECO) engagement sensor PTO engagement sensor To engine wiring Cigar lighter Analogue instrument panel Connector (Platform version) To front light wiring (Version with cab) Brake pedal switch To HML wiring To electronic lift wiring Four-wheel drive control switch Diff lock control switch PTO control switch Outlet socket (in cab) Compressor for driver’s seat air suspension Front right headlamp Rear right light Four-wheel drive control solenoid valve Differential lock control solenoid valve (DF) Rear PTO control solenoid valve (PTO) Connector Pressure switch for hydraulic oil filter clogging Hydraulic oil low pressure switch Connector Rear worklight (platform version) Fuel level sensor Handbrake switch Trailer braking low pressure switch Trailer socket Front left headlamp Number plate light Rear left light Start enable switch Starter switch Hazard warning lights switch Rear worklights switch (Not utilised) Front PTO control switch Lights selector switch Starter motor (+12V) Starter motor (Start) To cab wiring Hazard warning lights control unit Alarms control unit Diagnostics connector Preheating control unit Display pushbutto Engine governor reset button Transmission speed sensor Selection pushbutton Preheating control pushbutton

40 A

1 5 E S X1 X2 X3 X4

X23 5

1

E

S

RL2 FM1

X38

X37 X25 X31 X26

X35

X34

X33

X29

X28

X27

0.010.5303.4 333

84

Electrical system AN1

AN1

AMP

1

CENTRAL WIRING (2/2)

AMP

AN1

X19

AMP

1

Systems

1

8

N1

1

1 6

AN1

X20

1

AMP

7

2

6 5

3

4

3

CB1

4

X44

N1

Z0.5

AR0.5

X45

5

2

MG 0.5

X52

7

MN 0.8

N1

N1

X18

8

26 20 13

14

14 15

17

M1 B1 S1 MB1 C1 R1 GV1 BR1 N1

18

MN1

BN1

MN0.8

VN1.5

MG0.5 CB1

1

RN0,5 AR0,5 Z0,5 HG1 ZB1 ZV1

1

7

2

X10

5

X9

4

6 3

RV1 MB1 1

7

2

6 3

X3

36 35 34 33 32 31 30 29 28

RN1,5

AR1

MB1

4

5

AR1

MB1

ZB1

5

2

4

1

N1 MB1

6

*ZN1 ZV1

7

2

3

8 7

6 3

5 4

X8

AR1

N1

3

HR1

2

7 13

MV1

HR1

N1

19

GN1

19 20 21 22 23 24 25 26 27

10 11 12 13 14 15 16 17 18

HR1

6 18 12

24

HV1 ZN1 HN1 CN1 L1 AN1 MN1 GR1 V1

HR1

23 29

12

1

17 11

27 28

RN 1.5

5

GR1

10

MB1

16 22

X6

9 8 7 6 5 4 3 2 1

VM1

4

GR1

N1

2

26

MB1

29 28 27 26 25 24 23 22 21 20 19

9

N1

1

15 21

MB1

RN 1.5

1 2 3 4 5 6 7 8 9 10 11

R1 M1 B1 BR1 L1 Z1 H1 H1 V1 V1 RN1,5

MB

3 4

R1

X1

X40

MB

M4

6

MB

S1

3

5

BM1 N1 B1 N1 AG1

5 6

2

4

B1.5

BN1

1

RN0.5 SG1.5

X43

MB1 MB1

1

1

X36

H1.5 G1.5 R1.5

3

9

AN1.5

2

8

A1.5

1

7 6

B1.5 Z1

R1.5

X37

5 4

X35

3

2

NM1

6 5

4

3

GV1.5

N1 7

M1

M1

5

1 2

6 3

N1

VM1 VB1

7

4

MN1

MN1

RV1

MB1

X11

X12

MN1

N1 AN1.5 A1.5

V1.5

X2

X39

5

1

N1 A 1.5

N1.5 N1.5 N1.5 N1.5 N1.5 N1.5 N1.5

N1

N1

N1

N1 N1

N1

N1

N1

N1

N1

CN1

X22

N1

GN1 N1 RN1 G1 AN1 N1

1 2

X28

3 4 5

X29

6 7 8

X27

9

N1

RN1

2

X5

X25

GND5

2

N1 A1

X31

GN 1

1 6

X26

3

5

4 7

GN1

7 8

8

G1

2

6

X4

7

X32

4

4 5

1

6

2

2

1

M1 1

3

X50 X4

N1 A 1.5

X13

7

AN1

MV1

2

N1

30

3

L4

RL 2

1

AN 1.5

2

M4

50

3

17

VN1.5 LB1

19

RN1.5

M1

30

M4

L4

86

M1

LB1.5

M

MV1 N1

H2,5

X38

85

86

AR4

15

87

GV0.8

87

6

1

GN1 AN1.5 N1

H2,5 N1.5

5

2

2 1

X14

4

MV1

F13

15A

G1

AR1.5

H1

G1

H1.5

G1.5

AR4

VN1.5

F12

10A

H1

H1 F11

10A

GN1.5

G1.5 10A

F10

MN 1.5

L4

L4

F9

10A

F8

10A

F7

BN1.5

BM1.5

LB1.5

G1.5

10A

BM1.5 F6

20A

M0.5 M1.5 F5

10A

F4

20A

GV1.5

GV1.5

VB1.5 F3

15A

R1.5 20A

R4

M4 40A

F2

GN1.5

GN 1.5

40A

F1 F1

R1.5

GN 1

3

X21

VN1.5

R6

2

M1

A1.5 AN1.5

1

G1 A1.5 N1

2 1

N1

HG 1

B1.5

1

2

M1

MB1

S

X34

B1.5

MB1.5

VB1.5 SG1.5

GND4

MB1

4

GV1.5

3

MB1

B1.5

5

MB1 MB1

FM1

6

N1

X24

1

RN1 GN1 A1 N1

A1.5 A1.5

MB1

2

M4

X33

7

A1

1

2

X15

X16

4

1

A1

N1 30

X17

MV 1

BN1.5

AN1

MB1

85

N1 N1 N1 N1 N1

N1

N1 N1 N1

87

2

N1 HV1

M4

RL1

1

2

5

GV1.5

E

1

2

G1

X23

MB1

AG1

4

GV1.5

3

MB1.5

2

VN1

MB1 1

VB1

C1

HN1

N1

X67

MB1

MB1

R1

MB1

G1 AN 1.5 GN 1 N1

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

HG 0.5 N1

AMP

X42

2

Arancio/Orange

M 0.5 1

C

4

Marrone/Brown

M 1.5

3

M

3

TABELLA COLORI / COLOURS TABLE

HG 0.5

D0008330

334

AMP

X7

1

2

N1

0.010.5303.4

Systems

8

Electrical system

84

FRONT LIGHT WIRING (VERSION WITH CAB)

X4 TO 0.010.5303.4

X13

X4 X13 X27

D0009120

X27

To central wiring Front right sidelight and direction indicator Front left sidelight and direction indicator

0.010.5582.3 335

PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

CONNECTOR POSITIONS

1 X1

GND4 X43

X67

F0028510

2 X45 X2

X67 X32

F0028750

3

X40

F0027610

337

8

Systems

84

Electrical system

4

X52

X33

F0028730

5

X5

F0027680

6

X42

X36

RL2

X44 RL1

FM1

F0028740

338

Systems

8

Electrical system

84

7 X31

F0027670

8 X38

X37

F0027820

339

8

Systems

84

Electrical system

9

X39

F0027550

10

X17 X16 X18

X15

F0027790

11

X20

F0027750

340

Systems

8

Electrical system

84

12 X19

F0027810

13 X50

F0027930

14

X24

F0027710

341

8

Systems

84

Electrical system

15 X23

S

F0027780

16

5 1 E

F0027760

17 X25

F0027770

342

18

Systems

8

Electrical system

84

X26

F0027740

19

X14-X29

F0027720

20

X28

F0027730

343

8

Systems

84

Electrical system

21 X11

X12

F0027700

22

GND5

X7

F0027800

23

X8 X10

X9

F0027690

344

Systems

8

Electrical system

84

24

X4

F0027580

25

X3

F0027620

26

X13-X27

F0027590

345

PAGE INTENTIONALLY LEFT BLANK

CENTRAL WIRING CAB 1

27

25

24

23

Systems

8

Electrical system

84

22

20

21

19

19

X21

26

18

2 17

3 4 F0028540

5 6 7

8

9

10

11

12

13

PLATAFORM

14

16 26

X22 26 19

19

27

0.010.5303.4 0.010.5582.3 347

PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

POWERSHIFT WIRING (1/2)

X6 TO 0.010.5303.4

L

2

1

2

L

3

H

1

2

1

H

M

X72

H L M X6 X72

D0008340

Solenoid valve for High range (HI) control Solenoid valve for Low range (LO) control To HML lever wiring To central wiring HML control unit

0.011.7972.4 349

8

Systems

84

Electrical system

POWERSHIFT WIRING (2/2) M

4

X6

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

1

2

1

ZB 1

M1

N1

ZN 1

8

ZB 1

ZN 1

ZV 1

MB 1

TABELLA COLORI / COLOURS TABLE M

2

M1

7

B1

6

H1

5

1

3

Z1

4

2

H1

1

2

3

H

L

1

N1

2

ZV 1

N1

5

4

3

M 1.5

6

Z1

B1

7

X72

ZN 1

10

9

8

H1

12

11

ZB 1

D0008350

350

MB 1

0.011.7972.4

CONNECTOR POSITIONS

Systems

8

Electrical system

84

POWERSHIFT WIRING

1 M

3 H

L

2

F0027830

2 X72

F0028530

3 1

X6

F0028550

0.011.7972.4 351

PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

1

ELECTRONIC LIFT WIRING (1/2)

5

4

I

3

2

I

2

1

P

3

P1

3

H1

2

1

H

3

V

2

1

V

2

1

M

1

S

3

M1

3

2

C

5

4

C

2

3

UP

3 2

S1

1

2

3

1

2

P

DW

UP

X7

1

TO 0.011.6955.4 0.011.6958.4

DW

4

1

3 1

2

1

2

1

2

3

X71 UP

C Rear lift control pushbutton DW Rear lift “Down” control pushbutton EV DWLift DOWN solenoid valve EV UPLift UP solenoid valve H1 Maximum height adjustment potentiometer

D0006640

I M1 P1 P2 S1 UP

DW

Rear lift control pushbutton Draft/wheelslip control adjustment potentiometer Lift position adjustment potentiometer Rear lift position sensor Lift draft sensor Rear lift “Up” control pushbutton

EV UP

V X7 X71

EV DW

P2

Lift lowering speed potentiometer To central wiring Rear lift control unit

0.011.6943.4/10 353

8

Systems

84

Electrical system

ELECTRONIC LIFT WIRING (2/2)

H1

V

M1

P1

+12 VCC

ISO 9141

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

I

1

2

3

4

5

C

1

2

UP

3

1

MB1

1

H05

2

MB1

3

V05

4

MB1

5

V05

4

H05

3

HR1

MB1

HR1 2

MB1

1

N1

3

M1

VO5 2

M05

N05 1

BN 1

3

MB1

2

M05

S05 1

S05

3

1

HR1

11

L05

2

N05

H05

1

M05

3

N05

L05

M05

L05 N05

2

12

V05

10

S05

8

1

POSIZIONE

MIX

VEL.DISCESA

9

H05

6

BN1

7

B1

5

MAX ALZATA

POSIZIONE

+10VCC

SFORZO

EV DW AN1

AB1

3

M1

4

N1

2

GND

EV UP

TABELLA COLORI / COLOURS TABLE

X71

2

3

DW

1

AN1

2

N1

1 1

1

M1

N1

B1

M1

N1

BN1

N1

AB1

X7

2

2

3

3

S1

2

P2

EV UP EV DW

D0006650

354

0.011.6943.4/10

Systems

8

Electrical system

84

POSITION OF ELECTRONIC LIFT CONNECTORS

1

P1

V

H1

M1

I F0027440

2 C

X71

F0027420

3 X71

X7 F0027430

355

8

Systems

84

Electrical system

4 UP

DW

F0027410

5 P2

F0027400

6

EV DW EV UP F0027380

356

Systems

8

Electrical system

84

ELECTRONIC LIFT WIRING

7 3

S1

4

2 5

F0027390

1

7

6

0.011.6943.4/10 357

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

ROOF WIRING (STANDARD CAB) (1/2)

X 79

6

4 3

7

2 3

1

X 76

4 8

X 80

X 81

2 2

X 75

1

TO 0.009.7854.3

7

3

TO 0.009.7853.3

4

1

X 77

3

6

5

TO 0.009.7851.4

2

5 8

X 78

1

X 82

X 74 30

A

H 85

1

86 87

8

X 103

1 2 3 4

D0006890

3

4

5

6

7

8

X 83

X 84

X 86

1

1

2

X 85

3

2

TO 010.2153.2

4

X 90

X 87

3 2

5 4

1

TO 0.010.1359.3

2

X 88

6

X 89 TO 0.010.4516.3

GND4

1

2

TO 010.2147.2 010.2153.2

1

Interior roof light To screenwash pumps wiring To air conditioning fans wiring To worklights wiring Rear worklights switch Rear screen wiper control switch Windscreen washer pump control switch Rotating beacon control switch Intermittent wipe timer for windscreen wiper Clock Front windscreen wiper control switch Front worklights switch Radio To heater power supply wiring To windscreen wiper wiring To heater or air conditioning wiring To air conditioning wiring Relay for roof wiring power

2

3

X74 X75 X76 X77 X78 X79 X80 X81 X82 X83 X84 X85 X86 X87 X88 X89 X90 X103

1

0.009.7850.4/50 359

8

Systems

84

Electrical system

ROOF WIRING (STANDARD CAB) (2/2) X85

X78

X81

X84

X79

A-N 1 A-N 1

X80

X83 4 43 32 21

3 4 7 8

1

1 2 5 6

3 4 7 8

H-N 1

A1 H-N 1 C1

A1

N1

R1

A1

AR1

AR1

AN1

A-N 1

G-R 1

V1

V-N 1

R-N 1 M 1.5

N1

M 1.5

R1.5

N1

G-N 1.5

G-N 1.5

G-V 1.5

G1

N1

G1

M-G 1.5

V1

1 2 5 6

H-N 1 M 1.5

3

7

2

6

1

5

X77

8

4

N 1.5

N 2.5 G-N 1.5 G 1.5

RN1 GR1

I

53N

AR1 V1

N 2.5

AN1

V1 N1

V1

3

N 1.5 N1

2

1

X75

X82

15 31

1

3

2

4

X76

A-N 2.5

T 53S

A-R 1

2

R4 N4

1 4 3

N1 V1 V-N 1.5 V1

1

C1

2

X90 X89

G-R 1

3

6

2

N1

1 4

X88

5

AN 1

V-N 1

2 3

L-B 1

R 2.5

X87

1

V-N 1.5

30

2

A

H

1

8

X86 GND6

X103 85

LB 1

M-G 1.5

A1 G-V 1.5

A-N 1 A1

R4

A-N-2.5

R1

R1.5

R1

N1

R1

R1 1

N1

R1

N1 N4 N1 N 2.5 N 2.5 N1 N1 N1 N1 N1

A-N 1

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

86 87

X74

M 2.5

R 2.5

D0006900

360

10 A

10 A

7.5 A

7.5 A

30 A

20 A

5 A RADIO

10 A

M 2.5

0.009.7850.4/50

Systems

8

Electrical system

84

POSITION OF ROOF WIRING CONNECTORS (STANDARD CAB)

1 X86

F0027290

2

X88

F0027300

3 X74

F0027310

361

8

Systems

84

Electrical system

4 X77

X75

X87

F0027320

5

X83

X103 F0027330

6 X76

F0027340

362

Systems

8

Electrical system

84

7 X89

X90

F0027350

8

X82

F0028180

9

GND

F0027370

363

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

ROOF WIRING (STANDARD CAB)

10

X84

X79 X81

1 10

7

9 8

6

X78 X85 X80

2

5

F0028170

3 4

0.009.7850.4/50 365

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

WORKLIGHTS WIRING (STANDARD CAB) (1/2) X124

X121

TO 0.009.7850.4

X77

X126

X122

X127

X123

1

2

X125

X77 X121 X122 X123 D0006770

To roof wiring Front left worklight Rear left worklight Rear right worklight

X124 X125 X126 X127

Front right worklight Rear screen wiper motor Connector Rotating beacon

0.009.7851.4/40 367

8

Systems

84

Electrical system

WORKLIGHTS WIRING (STANDARD CAB) (2/2)

GN 1.5

X122 N 1.5

GN 1.5 1

5

N 1.5 GN 1.5

X123

2

G 1.5 6

N 1.5 N 1.5

HN 1 3

7

N 1.5 G 1.5

M 1.5

4

8

N 1.5

X124 N 1.5

X77

G 1.5

X121 N 1.5

M 1.5

M 1.5

X127 N 1.5

N 1.5

N 1.5

1

X125 2

HN 1

X126

TABELLA COLORI / COLOURS TABLE

D0006780

368

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

0.009.7851.4/40

Systems

8

Electrical system

84

POSITION OF WORKLIGHTS CONNECTORS (STANDARD CAB)

1

X121-X122 X123-X124

F0027200

2

X77

F0027270

3 X126

F0027180

369

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

WORKLIGHTS WIRING (STANDARD CAB)

4

5 X127

1

4 3 F0027170

5

2

X125

F0027280

0.009.7851.4/40 371

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

SCREENWASH PUMPS WIRING (STANDARD CAB)

X135

X129

1

2

2

2

TO 0.009.7850.4

1

1

X75 3

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

2 1

X75

C 1.5

X135

1 AR 1.5

2 N 1.5

3

N1

1 2

X129

X75 To roof wiring X129 Front windscreen washer pump X135 Rear screen washer pump

D0006750

0.009.7854.3/10 373

8

Systems

84

Electrical system

WINDSCREEN WIPER WIRING (STANDARD CAB)

G-R 1

M-N 1

R-N 1

G-R 1

(+AZZ)

(+MOT)

(AZZ.)

V-N 1

(+MOT)

(AZZ.)

R-N 1

TO 0.009.7850.4

X130 V-N 1

G-R 1

(+AZZ)

X88

3

2

1

6

5

4

M-N 1 (GND)

V-N 1 M-N 1 (GND) R-N 1

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

X88 To roof wiring X130 Windscreen wiper motor

D0006740

374

0.010.4516.3/1

Systems

8

Electrical system

84

SPEAKER WIRING (STANDARD CAB)

R X131

L

X132

X133

X131 Radio X132 Left speaker X133 Right speaker

D0006760

0.011.0729.4/10 375

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

CONNECTOR POSITIONS

1

X130

F0027120

2 X88

F0027240

3

X131

F0027250

377

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

WIRING FOR SCREENWASH PUMP - WINDSCREEN WIPER - SPEAKERS (STANDARD CAB)

4

4

4

X132-X133

F0027260

5

3 X135 X129

2 6

X129 F0027130

5

6

1

X75

F0028060

0.009.7854.3/10 0.010.4516.3/1 0.011.0729.4/10 379

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

HEATER POWER SUPPLY WIRING (STANDARD CAB) (1/2)

X108

1

1

1

TO 010.2123.2 010.2130.1

X109 2

2

X108

2

SOLO PER 65A

X107

B+ X106

BX106

3

TO 0.009.7850.4

X87

1

X111

2

X37

X111 50A

TO 0.009.7850.4

(X103)

R6

1 2

X39

X103-30

B+ Heater alternator (+) B– Heater alternator (–) X37 Starter motor X39 To central wiring X87 To roof wiring X103-30 To roof wiring (X103) X106 Heater resistance X107 To heater or air conditioning power wiring X108 Connector X109 Heater alternator X111 Connector

D0006800

0.009.7852.3/40 381

8

Systems

84

Electrical system

POSITION OF HEATER POWER CONNECTORS (STANDARD CAB)

X108

AMP

1

B1

2

B1

G-R 1

G-R 1

1

N-L 1

2

2

G-R 1

3

X107

4

1

X108 L1

B1

1

2

X109 L1 N 16

X106

N 16

B+

TABELLA COLORI / COLOURS TABLE N-L 1 N 16

X106

N 16

B-

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

R 2.5 3

1

2

2 1

V-N 1.5

X87

LB1

L-B 1

X39

V-N 1.5

X111

X103-30

D0006790

382

R6

X111

X37

R 2.5

0.009.7852.3/40

Systems

8

Electrical system

84

POSITION OF HEATING CONNECTORS (STANDARD CAB)

1 X106

F0028150

2 X106

F0027050

3 X107

X103-30

F0028160

383

8

Systems

84

Electrical system

4 X87

F0027070

5 X111 X37

X39 F0026880

6

X108 X109

F0028720

384

Systems

8

Electrical system

84

HEATER POWER SUPPLY WIRING (STANDARD CAB)

1

7

2

3

4

B+ B-

X108

F0026890

7

6

5

0.009.7852.3/40 385

PAGE INTENTIONALLY LEFT BLANK PAGINA INTENZIONALMENTE LASCIATA BIANCA

Systems

8

Electrical system

84

HEATER WIRING (STANDARD CAB) (1/2) X141

X140

X136

4

12 11 10 9 8 7 6 5 4 3 2 1

3

85 2

X107

30 86

1

TO 0.009.7852.3

87

1

X142

2

TO 0.009.7850.4

2 1

X138

1 2 3

X89

X137

X139

X89 X107 X136 X137 X138 D0007780

To roof wiring To heater power wiring Heater control unit Heater air temperature sensor Heater control potentiometer

X139 X140 X141 X142

Fan speed selector switch Heater fan resistor Heater fan Relay for alternator excitation

0.010.2123.2 387

8

Systems

84

Electrical system

HEATER WIRING (STANDARD CAB) (2/2)

X136

8

9

12

6

10

3

4

5

1

2

7

11

L1

X137

N 0.5

GR 1

N 0.5

NL 1 B1

N4 C4

1 2 3

X107

4

1

X89 2

H 0.5 C 0.5

X138

V 0.5

N4

X141

M

R4

B1 Z 0.5 C 0.5 R1

87 86

X142

85 30

M 2.5

C4

R4

B 0.5

R 2.5

LR 1.5

TABELLA COLORI / COLOURS TABLE

3 2

1

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

X140 0

D0007770

388

X139

0.010.2123.2

Systems

8

Electrical system

84

POSITION OF HEATING CONNECTORS (STANDARD CAB)

1 X107

X89

F0028260

2

X141

X140

F0028230

3

X138

X137 X139

F0028240

533

PAGE INTENTIONALLY LEFT BLANK PAGINA INTENZIONALMENTE LASCIATA BIANCA

Systems

8

Electrical system

84

HEATER WIRING (STANDARD CAB)

4

2 X136

X142

1

F0028250

3

4

0.010.2123.2 391

PAGE INTENTIONALLY LEFT BLANK PAGINA INTENZIONALMENTE LASCIATA BIANCA

Systems

8

Electrical system

84

AIR CONDITIONING WIRING (STANDARD CAB) (1/2) X90 TO 0.009.7850.4

X141

X136

X140

12 11 10 9 8 7 6 5 4 3 2 1 2

3

4

4

1

85

X107

2

86

1

3

30

TO 0.009.7852.3

87

1

X143

2

TO 0.009.7850.4

X89

2 1

X138

1 2 3

30 85 86 87

X137 X142

X144

X139

X89 X90 X107 X136 X137 X138 D0007750

To roof wiring To roof wiring To heater power wiring Heater control unit Heater air temperature sensor Heater control potentiometer

X139 X140 X141 X142 X143 X144

Fan speed selector switch Heater fan resistor Heater fan Relay for alternator excitation Air conditioner control relay Demister thermostat

0.010.2130.1 393

8

Systems

84

Electrical system

AIR CONDITIONING WIRING (STANDARD CAB) (2/2)

X136

8

9

12

6

10

3

4

5

1

2

7

11

L1

X137

1

N 0.5

GR 1

N 0.5

NL 1 B1

2 3

X107

4

N4

1

X89

C4

2

H 0.5

X138

C 0.5

BV 0.5

V 0.5

NZ 0.5 CR 1 B 0.5

1 2 3

X90

4

B 0.5

X144

B 0.5

N4

X141

M

R4

B1 Z 0.5 C 0.5 R1

CR 1 NZ 0.5 M 2.5

BV 0.5 C1

86

X142

85 30

87 86

X143 85 30

C4

R4

B 0.5

R 2.5

LR 1.5

87

TABELLA COLORI / COLOURS TABLE

3 2

1

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

X140 0

D0007760

394

X139

0.010.2130.1

Systems

8

Electrical system

84

AIR CONDITIONING WIRING (STANDARD CAB)

1 X107

X89

X90

F0028270

2

X141

X140

F0028230

3 X137 X138

X144

X139

F0028290

395

PAGE INTENTIONALLY LEFT BLANK PAGINA INTENZIONALMENTE LASCIATA BIANCA

Systems

8

Electrical system

84

AIR CONDITIONING WIRING (STANDARD CAB)

4

2 X136

X142

1 X143 F0028280

3

4

0.010.2130.1 397

PAGE INTENTIONALLY LEFT BLANK PAGINA INTENZIONALMENTE LASCIATA BIANCA

Systems

8

Electrical system

84

AIR CONDITIONING FAN WIRING (STANDARD CAB) (1/2)

X120

X118 X115

X119 TO 0.009.7850.4

85

86

87

3

87

2

1

WHITE

1

BIANCO

X76

30

ITALAMEC 037

X76 X115 X118 X119 X120 D0006620

To roof wiring Relay - heat exchanger fan Air conditioning pressure switch Air conditioning heat exchanger fan Air conditioning pressure switch

0.009.7853.3/21 399

8

Systems

84

Electrical system

AIR CONDITIONING FAN WIRING (STANDARD CAB) (2/2)

X120

X118

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

BIANCO

Marrone/Brown

X115

3

2

1

WHITE

X119

TABELLA COLORI / COLOURS TABLE M

1

AN 1

AN 2.5

87

86

VN 1

N1

87

CB 1

V1

CB 1

N 2.5

85

A 2.5

30

A 2.5

V1 N 2.5 N1

2

1

4

3

X76 AN 2.5

VN 1

D0006630

400

0.009.7853.3/21

Systems

8

Electrical system

84

AIR CONDITIONING FAN WIRING (STANDARD CAB)

1

2 1

X118

X120 F0028210

2 3

X115

X119 F0028220

3 X76

F0027340

0.009.7853.3/21 401

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

ROOF WIRING (HIGH VISIBILITY CAB) (1/2) TO 0.011.3595.3

X74

X95

TO 0.010.2560.0

X94

TO 0.010.2554.2 0.010.2560.0

X93 X80

GND7 X82

X96

TO 0.011.3597.3

X92 X97

TO 0.011.3743.3

X75

X98

TO 0.011.3754.3

X91

Interior roof light To screenwash pumps wiring Windscreen washer pump control switch Intermittent wipe timer PTO To heater power supply wiring To windscreen wiper wiring To heater wiring To heater or air conditioning wiring To worklights wiring Rotating beacon control switch Rear screen wiper control switch Windscreen wiper control switch Rear worklights control switch Front worklights control switch To speaker and radio wiring To air conditioning fan wiring Relay for roof wiring power Roof wiring power fuse (40 Amp)

X100

10A

5A

30A

7.5A

7.5A

7.5A

10A

10A

TO 0.011.3596.3

X101

RADIO

FREON

X74 X75 X80 X82 X91 X92 X93 X94 X95 X96 X97 X98 X99 X100 X101 X102 X103 X104

X99

TO 0.011.3610.3

X102

X103

X104 D0008810

0.011.3606.4/51 403

8

Systems

84

Electrical system

ROOF WIRING (HIGH VISIBILITY CAB) (2/2)

4 1

3 2

HN 1 M 1.5

3

2

AR 1

6

AR 1

2

AN 1

5

A1

3

C1

2

A1

3

HN 1

5

VN 1

6

X80

X97

V1

1

RN 1

M 1.5

7

AN 1

8

AN 1

3

N1

R 1.5

GN 1.5

2

M 1.5

7

8

N1

GV 1.5

G1

3

X98

G1

2

3

G1 GN 1

1

X95

2

X96

A1 R1

4

X101

7

8

N1

3

MG 1.5 G1

2

X99

GN 1

X100

GN 1

4 2 A

LAMPEGGIANTE

TERGI

POSTERIORE

N1

TERGI

VN 1.5

ANTERIORE

2

V1 V1

3

AN1

POSTERIRI

X82 FARI LAVORO

31

POMPA TERGI

15

ANTERIORI

53S

FARI LAVORO

V1

I

53N T

ANTERIORE

7

8

3

6

1

2 1

N1 N1

3

AR1

RADIO

FREON

C1

1

5A

10A

30A

AR 1

X93

7.5A

RN1 GR1

X94

7.5A

N 1.5 AN 1.5 V1

X75

7.5A

N 1.5

10A

X102

10A

V1

5

R1 R1 AN 1.5

R6

B

N6 VN 1 GR 1 53

X92 N1

R6

AN 1

TABELLA COLORI / COLOURS TABLE

X91

1

2

LB 1

3

LB 1

MG 1.5

GV 1.5

AN 1 A1 A1

R 1.5

X103

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

N1 N1

5

R1

A

N1

N1 N1

N 1.5 N 1.5

N1 N6

R1

VN 1.5

R1 AN 1.5 AN 1.5 VN 1.5

R4

M

1

40A

2

1

H

3

X104

8

M 10 R4

M4

VN 1.5

GND7 D0006880

404

X74

0.011.3606.4/51

Systems

8

Electrical system

84

POSITION OF ROOF WIRING CONNECTORS (HIGH VISIBILITY CAB)

1

X75 GND7 X103

X91 F0026770

2 X99

X80

X97

X96 X100

X98

F0026780

3 X82

X104 F0026790

405

8

Systems

84

Electrical system

4

X93 X94

X95 F0026800

5 X101

X102 F0026820

6

X74

F0026810

406

Systems

8

Electrical system

84

ROOF WIRING (HIGH VISIBILITY CAB)

4

7

3 1 2

5

1

3 6 X92

7 F0026830

0.011.3606.4/51 407

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

WORKLIGHTS WIRING (HIGH VISIBILITY CAB)

2

TO 0.011.3606.4

X95

4

X123

3

1

X124

GND7

X122

TABELLA COLORI / COLOURS TABLE

GN 1.5

X123

N 1.5

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

X121

X95 4

3

N 1.5

2

1

GN 1.5

X122

G 1.5

X124

N 1.5

GND7 G 1.5

X121

X95 X121 X122 X123 X124 D0006840

N 1.5

To roof wiring Front left worklight Rear left worklight Rear right worklight Front right worklight

0.011.3595.3/10 409

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

WORKLIGHTS WIRING (HIGH VISIBILITY CAB)

1

3

X121-X122 X123-X124

2 1

F0027200

2 GND7

F0027210

3

X95

F0027220

0.011.3595.3/10 411

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

SCREENWASH PUMP WIRING (HIGH VISIBILITY CAB)

X129

X75

1

2

1

TABELLA COLORI / COLOURS TABLE 3

TO 0.011.3606.4

2

2

1

X135

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

2 1

X75

C 1.5

X135

1 AR 1.5

2 N 1.5

3

N1

1 2

X129

X75 To roof wiring X129 Front windscreen washer pump X135 Rear screen washer pum

D0006820

0.011.3743.3 413

8

Systems

84

Electrical system

WINDSCREEN WIPER WIRING (HIGH VISIBILITY CAB)

G-R 1

G-R 1 M-N 1

R-N 1

G-R 1

(+AZZ)

(+MOT)

V-N 1

TO 0.011.3606.4

X130 V-N 1

M-N 1

(AZZ.)

(GND)

X92 V-N 1 R-N 1 M-N 1 R-N 1

CORRISPONDENZA TRA CAVI CABLAGGIO E CAVI TERGI ANTERIORE

CABLAGGIO

G-R

(+MOT)

G

M-N

(GND)

M

R-N

(+AZZ)

V-N

V-N

(AZZ.)

N

WIRES

MOTORINO TERGI Wiper

X92 To roof wiring X130 Windscreen wiper motor

D0006830

414

0.011.3597.3/33

CONNECTOR POSITIONS

Systems

8

Electrical system

84

WIRING FOR SCREENWASH PUMP & WINDSCREEN WIPER (HIGH VISIBILITY CAB)

1 X75

1

X92

F0027110

2

X130

F0027120

3

2

3

X135 X129

X129 F0027130

0.011.3743.3 0.011.3597.3/33 415

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

2

X101

3

TO 0.011.3606.4

3

1

SPEAKER AND RADIO WIRING (HIGH VISIBILITY CAB)

GND7

X83 2

1

N1

3

R1

A1

4

X101 1

M 1.5

R1

3

A1

4

2

HN 1

N1

X126

X83

N 1.5 N 1.5 N1

3

4

1

2

X86

3

4

1

2

1

2

X131

X132 X126

C1

CN 1

B1

BN 1

N1

2xR 1

BN 1

B1

CN 1

C1

HN 1

N 1.5

X125

M 1.5

2

N 1.5

1

GND7

X133

X132

X133

X125 X86 X131

X127 M 1.5

N 1.5

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

X127

X83 Clock X86 Radio X101 To roof wiring X125 Rear screen wiper motor X126 Connector D0006810

X127 Rotating beacon X131 Radio X132 Left speaker X133 Right speaker

0.011.3596.3/30 417

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

SPEAKER AND RADIO WIRING CONNECTORS (HIGH VISIBILITY CAB)

1 GND7

X101 F0027140

2 X132-X133

F0027150

3

X125

F0027160

419

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

SPEAKER AND RADIO WIRING (HIGH VISIBILITY CAB)

2

4

3

X127

1 2

1

F0027170

4

5 5 6 X126

F0027180

6 X131 X83

X86

F0027190

0.011.3596.3/30 421

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

HEATER POWER SUPPLY WIRING (HIGH VISIBILITY CAB) (1/2)

2

X109 1

2

2

3

1

TO 010.2558.1 010.2562.1

X108 1

4

2

X108

1

X113

B+

X106

B-

3

TO 0.011.3606.4

X91

1

X111

2

X37

X111 50A

TO 0.011.3606.4

R 10

X103-30

1 2

X39

B+ Heater alternator (+) B– Heater alternator (–) X37 Starter motor X39 To central wiring X91 To heater power supply wiring X103-30 To roof wiring (X103) X106 Heater resistance X108 Connector X111 Connector X113 To heater or air conditioning wiring

D0007210

0.011.3761.3/30 423

8

Systems

84

Electrical system

GR 1

L1

B1

X108 1

2

X108 2

3 2

GR 1

G-R 1

1

4

B1 NL 1

1

HEATER POWER SUPPLY WIRING (HIGH VISIBILITY CAB) (2/2)

B1 1

2

X113

X109 L1 N 16

N 16

B+

X106 NL 1 N 16

B-

N 16

R4 3

VN 1.5 LB 1

1

2 1

X91

LB 1

2

X39

VN 1.5

X111 X103-30

R 10

X37

X111

R4 R 10

TABELLA COLORI / COLOURS TABLE

D0006710

424

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

0.011.3761.3/30

Systems

8

Electrical system

84

SPEAKER AND RADIO WIRING (HIGH VISIBILITY CAB)

1 X103-30 X91

F0026840

2 X113

F0026850

3

X106

F0026860

425

8

Systems

84

Electrical system

4 X106

F0026870

5 X111 X37

X39 F0026880

6

B+ B-

X108

F0026890

426

Systems

8

Electrical system

84

HEATER POWER SUPPLY WIRING (HIGH VISIBILITY CAB)

1

7

2

3

4

X108 X109

F0028720

6

7

5

0.011.3761.3/30 427

PAGE INTENTIONALLY LEFT BLANK PAGINA INTENZIONALMENTE LASCIATA BIANCA

Systems

8

Electrical system

84

HEATER WIRING (HIGH VISIBILITY CAB) (1/2) TO 0.011.3606.4 TO 0.011.3761.3

X157

X147

X146

X93

X113

4

3 2

X145

1 85 86 30 87 87a

85 86 30 87 87b

85 86 30 87 87B

A

B

2 3 4

4

X154

5

2 1

X148

3

5

1

1 2 3 4 5 6

5 4 3 B

A

1

2

2

1

X137

X149

B

A

7

6

5

4

3

2

1

X150

10

9

8

X152

X136

12

11

X150

X152

B

A

A

X151 B

A

B

A

B

X93 X113 X136 X137 X145

D0007850

To heater power supply wiring To roof wiring Heater control unit Heater air temperature sensor Heater control potentiometer

X146 X147 X148 X149 X150

Control relay for maximum fan speed Control relay for alternator excitation Resistor for left heater fan Resistor for right heater fan Connector

X151 X152 X153 X154 X157

X153

Left heater fan Connector Right heater fan Fan speed selector switch Relay for 3rd fan speed and air conditioning on

0.010.2558.1 429

8

Systems

84

Electrical system

HEATER WIRING (HIGH VISIBILITY CAB) (2/2)

X136 X146

X145

X137

M

8

9

12

6

10

3

4

5

1

2

7

11

30

X93 C6

N6

L 0.5

Z B0.5

GR 0.5

GR 0.5

LN 0.5

LN 0.5

A 0.5

V 0.5

H 0.5

Z 0.5

Z 0.5

Z 0.5

A 0.5

C 0.5

H 0.5

V 0.5

CB 0.5

C6

85

B 1.5

86

N 0.5

R 2.5

87

A1

V 1.5

AR 2

BR 2

N 2.5

B 2.5

BR 2.5

87b

CB 0.5

X148

Z 0.5

X151

BR 2.5

X150

L 0.5 GR 1 LN 1

X113

N 2.5

R 1.5

B1

TABELLA COLORI / COLOURS T

30

I

II

III

IV

85

86

87

87b

30

85

AR 2

GL 2

N 0.5

S 1.5

C4

B1

B1

ZB 0.5

C 1.5

R1

C 2.5

B 1.5

S 1.5

LR 2

A 1.5

A 1

V 1.5

GL 2

R2

R 1.5

N 2.5

X152

86

87

87b

ABLE

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/V iolet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

C

M X153

D0007840

430

X149

X154

X147

X157

0.010.2558.1

Systems

8

Electrical system

84

POSITIONOF HEATER CONNECTORS (HIGH VISIBILITY CAB

1 X154 X145

F0028300

2 X146

X147 X157 F0028570

3 X113

X93

F0028330

431

8

Systems

84

Electrical system

4 X148-X149

X151-X153

F0028340

5

X150-152

F0028350

6 X137

F0028360

432

Systems

8

Electrical system

84

HEATER WIRING (HIGH VISIBILITY CAB)

7

5

3 4 2

6 7

1

X136

F0028370

0.010.2558.1 433

PAGE INTENTIONALLY LEFT BLANK PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

AIR CONDITIONING WIRING (HIGH VISIBILITY CAB) (1/2) TO 0.011.3606.4

X93

X157

X147

X146

X156 TO 0.011.3606.4

X94 X137 A

2

85 86 30 87 87a

B

85 86 30 87 87b

85 86 30 87 87b

1 2 3

85 86 30 87 87a

1

X158 2 2 3

X154

1

5

2

4

4 3

5

1

1

X148

1 2 3

2

4 5

4

1

3

6

B

X145

TO 0.011.3761.3

A

X113

5

X159

4

3

2

1

B

A

4

3

2

1

X150

7

6

5

X149 10

9

8

X152

X136

12

11

X150

X152

B

A

A

X151 B

A

B

A

B

X93 X94 X113 X136 X137 X145 X146 D0007820

To heater power supply wiring To roof wiring To roof wiring Heater control unit Heater air temperature sensor Heater control potentiometer Control relay for maximum fan speed

X147 X148 X149 X150 X151 X152 X153

Control relay for alternator excitation Resistor for left heater fan Resistor for right heater fan Connector Left heater fan Connector Right heater fan

X154 X156 X157 X158 X159

X153

Fan speed selector switch Relay for1st fan speed and air conditioning on Relay for 3rd fan speed and air conditioning on Air conditioning control switch Air conditioning thermostat

0.010.2562.1 435

8

Systems

84

Electrical system

AIR CONDITIONING WIRING (HIGH VISIBILITY CAB) (2/2)

X136 X146

X145

X137

M

8

9

12

6

10

3

4

5

1

2

7

11

30

X93 C6

N6

L 0.5

Z B0.5

GR 0.5

GR 0.5

LN 0.5

LN 0.5

A 0.5

V 0.5

H 0.5

Z 0.5

Z 0.5

Z 0.5

A 0.5

C 0.5

H 0.5

V 0.5

CB 0.5

C6

85

B 1.5

86

N 0.5

R 2.5

87

A1

V 1.5

AR 2

BR 2

N 2.5

B 2.5

BR 2.5

87b

CB 0.5

X148

Z 0.5

X151

BR 2.5

X150

L 0.5 GR 1

X113

LN 1

GB 1

N 2.5

R 1.5

B1

V 0.5

X94

B 0.5

30

85

86

87

87b

30

85

86

87

87b

30

85

86

B 0.5

VN 0.5

VN 0.5

A 0.5

GB 1

V 0.5

N 0.5

C 1.5

AR 2

GL 2

N 0.5

S 1.5

C4

B1

B1

ZB 0.5

C 1.5

R1

C 2.5

B 1.5

S 1.5

LR 2

A 1.5

A 1

V 1.5

GL 2

R2

R 1.5

N 2.5

X152

87

TABELLA COLORI / COLOURS T I

II

III

IV

C

M X153

D0007810

436

X149

X154

X147

X157

X156

X158

ABLE

M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/V iolet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Y ellow

R

Rosso/Red

H

Grigio/Gray

X159

0.010.2562.1

Systems

8

Electrical system

84

POSITION OF AIR CONDITIONING CONNECTORS (HIGH VISIBILITY CAB)

1 X158

F0028310

2 X154 X145

F0028300

3 X156 X157 X146 X147

F0028320

437

8

Systems

84

Electrical system

4 X113

X93

F0028330

5 X148-X149

X151-X153

F0028340

6

X150-152

F0028350

438

Systems

8

Electrical system

84

AIR CONDITIONING WIRING (HIGH VISIBILITY CAB)

7

6

4 5 3

7 8

2 1

X137

F0028360

8 9

X136

F0028370

9

X159

F0028380

0.010.2562.1 439

PAGE INTENTIONALLY LEFT BLANK PAGE INTENTIONALLY LEFT BLANK

Systems

8

Electrical system

84

AIR CONDITIONING FAN WIRING (HIGH VISIBILITY CAB) (1/2)

X116 TO 0.011.3606.4

X102 1

2

3

4

5

6

7

8

3

2

6

1

4

A

B

X117a

87

86 ITALAMEC 037

B

X117b

X115

X114

85

A

87

30

85

87

86

87

30

ITALAMEC 037

X102 To roof wiring X114 Relay for supplementary air conditioning fan X115 Relay for air conditioning fan X116 Air conditioning pressure switch X117a Air conditioning fan X117b Supplementary air conditioning fan D0006860

0.011.3610.3/20 441

8

Systems

84

Electrical system

AIR CONDITIONING FAN WIRING (HIGH VISIBILITY CAB) (2/2)

X117a

X117b

X116

AN 1.5

AN 1.5

3

2

6 A

X114

1 30

B

4

86

VN 1

C1

CB 1

87

N 1.5

R1 A 1.5

87

87

CB 1

L 1.5

85

R1

N 2.5

86

C1

N1

87

A

30

V1

85

B

X115

A 1.5

L 1.5

V1 N 1.5

N 1.5 N1

N 1.5

N 1.5

X102

1

2

3

4

5

6

7

8

AN 1.5

AN 1.5

AN 1.5

VN 1

R1

R1

D0006870

442

TABELLA COLORI / COLOURS TABLE M

Marrone/Brown

C

Arancio/Orange

V

Verde/Green

A

Azzurro/Blue

Z

Viola/Violet

B

Bianco/White

N

Nero/Black

L

Blu/Dark Blue

S

Rosa/Pink

G

Giallo/Yellow

R

Rosso/Red

H

Grigio/Gray

0.011.3610.3/20

Systems

8

Electrical system

84

AIR CONDITIONING FAN WIRING (HIGH VISIBILITY CAB)

1

3 1

3

2

X114

X115 F0027080

2

X102 F0027090

3

X117b X117a

X116

F0028190

0.011.3610.3/20 443

PAGE INTENTIONALLY LEFY BLANK

Systems

8

Electrical system

84

Electrical system AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772) General specifications The electrical system is fully equipped for use on the road, with sidelights, main/dipped beam headlamps, direction indicators doubling as hazard warning lights, and work lights, all fully in compliance with legal requirements as embodied in the highway code. There are four essential components and assemblies: battery, alternator, starter motor, and auxiliaries. The system operates at a nominal 12 Volts (the maximum voltage in operation is 14,3÷0,5 V). The battery charge level is indicated by a relative meter on the instrument panel.

Specifications

battery type voltage discharge capacity over 20 hours rated current

starter motor voltage nominal rated power electromagnetic control

alternator RECHARGE SYSTEM code

HEATING SYSTEM code type nominal rated voltage pulley nut tightening torque

V Ah A

maintenance free 12 100 (470)

V 12 cv 4 (3 kW) electro-magnetic with translation and rotation of pinion

65A AA 125 R 14V 65A (MARELLI) K1-14V 65A 20 (BOSCH) AA K3563 14V 65A (ISKRA) 85A

AA K5114 14V 85A (ISKRA)

70A

AA5112 12V 70A (ISKRA) three-phase 12 5,5 (62 Nm)

V kgm

445

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

GENERAL SAFETY DIRECTIONS PRECAUTIONS AGAINST DAMAGE TO ELECTRICAL AND ELECTRONIC EQUIPMENT — Disconnect any electronic equipment from the system when the tractor is placed in any environment where temperatures are likely to exceed 80 °C. — Remove battery connections when carrying out servicing or repair operations on the electrical system. — Avoid overvoltages in the electrical system. Always remove battery and alternator connections before carrying out welding operations or when recharging the battery from the mains. — Never disconnect the battery while the engine is running. — In the event that the battery needs topping up, use only distilled or demineralized water; top up only when the battery is AT REST and at AMBIENT TEMPERATURE (allow time for cooling after operation and following recharge). — Never carry out servicing operations on the electric heating system with the engine running. — When washing the tractor, ensure that the alternator and starter motor are well protected. These components must not be sprayed or splashed directly with water.

PRECAUTIONS AGAINST ACCIDENT AND INJURY WHEN COMMENCING ANY KIND OF WORK: — Turn off the main ignition switch. — Disconnect the battery; remember that electric shocks discharged through the human body will damage pacemakers. — The battery generates powerful and inflammable gases when recharging, which if ignited can cause the battery itself to explode. — Do not make temporary or makeshift connections to the battery, as these can cause dangerous sparks. — The electrolyte in the battery is a solution of dilute sulphuric acid; if splashed on the skin, wash straight away with plenty of water and sodium bicoarbonate. — Seek attention immediately from a doctor if electrolyte is splashed into the eyes. — Never allow the battery near a naked flame. — Keep a safe distance from a recharging battery when testing or measuring, and always wear suitable eye protection. — Make certain that the electrical system and all its components are inspected and serviced periodically; any faults must be eliminated without delay, and parts subject to everyday wear replaced at the recommended intervals. — Ensure that trailers are fitted with regulation lights. IMPORTANT REMINDERS The maker declines all liability in respect of any damages resulting from operations performed other than in the recommended manner and/or by unskilled hands. — To ensure smooth operation of the machine, use only genuine replacement parts.

446

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

JUMP START UTILIZING ANOTHER BATTERY NB: Emergency starting with the aid of a battery charger is not recommended. PRECAUTIONS The battery may be that of another tractor, but must in any event have the same rated voltage (and therefore an identical number of cells). 1 - Make certain the two vehicles are not in contact with one another. 2 - Ensure that all auxiliary services are switched off. 3 - Make certain the flat battery is securely connected to earth, that the filler caps are properly tightened and that the electrolyte is up to the correct level. PROCEDURE: A - Connect the two batteries as indicated in figure 1 (part A). B - If the jump battery is that of another tractor, start the engine and run at approximately 1/4 of full throttle. C - Turn the ignition key to start the engine of the stranded tractor, following the procedure given in the operator’s handbook. D - Remove the jump leads following the sequence as indicated in figure 1 (part B). A - connection of leads to the 2 batteries

B - disconnection of leads from the 2 batteries

Separate Batteries

connected batter.

STEP 1

STEP 4

STEP 5

STEP 2

STEP 6 STEP 3 connected batteries

separate batteries

Fig. 1 - Diagram of battery connections and relative leads.

447

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

PRACTICAL HINTS Before installing a battery, and periodically thereafter: — Check over the electrical system, giving particular attention to connections; make certain there are no traces of oxidation and that there is no loss of current. — Check the alternator and the voltage regulator setting. If the charging voltage is inordinately high, distilled water will be consumed at a high rate, whereas a low voltage will not charge the battery sufficiently. — Check the charge level of a new battery with a density indicator or voltmeter; if the density is less than 1.25 kg/l or the no-load voltage after at least 3 - 4 hours at rest is lower than 12.5 V, proceed to recharge. Install the battery in the machine with care, utilizing the anchorages provided. When connecting the battery to the system: — secure the clamp. — before connecting the negative, make certain there is no sparking on contact with the corresponding terminal of the battery. Sparks are due to insulation defects that must be located and eliminated. — Tighten the clamps on the terminals, smearing with petroleum jelly.

TABLE OF WIRING COLOUR CODES BK =BLACK BL=BLUE BR=BROWN DK BL=BLACK/BLUE DK GN=BLACK/GREEN GN=GREEN GY=GREY OR=ORANGE PK=PINK RD=RED VL=VIOLET WH=WHITE YL=YELLOW

EXEMPLE: DK BL/WH 1 680 DK BL/WH

=

DARK BLUE WITH WHITE LINE

1 680

= =

CROSS SECTION OF WIRE (mm) LENGTH OF WIRE (mm)

EXAMPLE OF CONNECTORS (CAN BE 4-PIN, 6-PIN OR 8-PIN)

448

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

RECHARGE SYSTEM 65A ALTERNATOR ISKRA AAK3563 14V 65A

RECHARGE SYSTEM 65A ALTERNATOR BOSCH K1-14V 65A 20

RECHARGE SYSTEM 65A ALTERNATOR ISKRA AA 125R 14V 65A

449

8

Systems

84

Electrical system

RECHARGE SYSTEM 85A ALTERNATOR ISKRA AAK5114 14V 85A

HEATING SYSTEM

70A ALTERNATOR ISKRA AAK5112 12V 70A

STARTING SYSTEM

EV 12V 3.0 JF 12V 3.1 KWKW

450

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

Fig. 2 - Check panel with digital display

Ignition switch Electtrical system deenergized - key removable (On version with electronic RPM control, the engine shuts off automatically; On versio with machanical throttle linkage, the engine is stopped by pulling the knob on the right of the instrument panel). Active electric circyit: - Lamps indicating operation of the alternator and low engine oil pressure light up on the instrument panel. A lamp indicating pre-heating lights up when ambient temperature is below 10°C; wait until the lamp has gone out (approx. 55 seconds) before turning the key to the next position. If the ignition key is turned to the start position with the thermostart indicator still alight, the heater cuts out and power is supplied to the starter motor.

Engine starting

451

8

Systems

84

Electrical system

IGNITION KEY

VENTILATION CONTROL for tractors equipped with standard cab

PUSH BUTTON CONTROL

HAZARD WARNING LIGHTS

452

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

PUSH BUTTON CONTROL P.T.O. CLUTCH cod. 2.7659.108.0/10 DIFFERENTIAL LOCK cod. 008.1335.0 4WD COUPLER cod. 007.5945.0/20

PUSH BUTTON CONTROL cod. 2.7659.138.0 SWITCH DIGITAL DISPLAY

453

8

Systems

84

Electrical system

WARNING SWITCH cod. 2.7659.080.0

WORK LIGHTS FRONT cod. 2.7659.078.0 REAR cod. 2.7659.079.0

SCREEN WASHER SWITCH FRONT cod. 2.7659.145.0 REAR cod. 2.7659.146.0

BEACON PUSH BUTTON cod. 2.7659.126.0

454

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

RELAY cod. 2.7659.107.0

ELECTRONIC FLASHER UNIT cod. 2.8639.004.0

455

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

INTERIOR ROOF LIGHT COD. 2.8339.032.0

SWITCH CONTROLLING: differential lock - 4RM - 540 1000 rpm/min P.T.O. Economy P.T.O. - Live P.t.o. - electric starter system. cod. 2.7659.097.0

SWITCH FOR EMERGENCY BRAKE

456

cod. 2.7659.129.0

speed selector -

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

Fuse box

tractor fuse box F1 - Thermostart F2 - Side/tail lights - horn F3 - Hazard warning lights F4 - Work light - 12V socket F5 - Engine RPM control unit F6 - Thermostart/panel/HML F7 - Engine STOP F8 - Flashers F9 - Side/tail light F10 - Side/tail light F11 - Dipped beam F12 - Main beam

cab fuse box F1 - Flasher unit F2 - Radio F3 - Air conditioning F4 - Blower/heater F5 - Front wiper F6 - Rear wiper F7 - Front work lights F8 - Rear work lights

457

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Instrument panel with digital display

The basic panel is the same as described above, except that the dial is replaced by a 4-digit display showing: — — — —

Lapsed time (hours) Ground speed (speedometer) P.T.O. speed Trip meter (distance in metres)

There are also 4 high brightness Leds which indicate the function currently being displayed. Any specifications not individually listed below will be the same as for the basic panel. Operation The selection and content of the functions displayed are governed by pressing buttons, denoted P1, P2 and P3. Button P1 - Red - Positioned to right of panel. Button P2 - Red - Positioned to right of panel. Button P3 - Red - Positioned near fuse box (cover must be removed to gain access).

Auxiliary electrical systems on (turn the ignition key to position displayed. Then, turn the ignition key to position (speedometer).

) the current total of working hours lapsed will be

, when the engine is started, the display sets itself to indicate ground speed

To display a function other than ground speed, simply press P1 repeatedly to select the function required.

1 - Lapsed work time indicated by 4 digits, to the nearest hour. 2 - Ground speed indicated by 3 digits, one of which after the decimal point (XX.X), in km/h. In the event that bigger or smaller rear tyres are fitted, the new size must be entered (see directions point 5 page 373).

458

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

IMPORTANT: If a function other than speedometer is currently selected, the panel will revert automatically to displaying ground speed if 20 km/h is exceeded.

3 - P.T.O. speed is indicated by 4 digits (XXX0), in revolutions per minute. 4 - The trip meter uses 4 digits (XXXX), indicating the distance covered by the tractor in metres. The trip meter can be reset; this is done by selecting the function then pressing and holding P2 for at least 3 seconds, during which time the figures will blink before returning to zero. If P2 is released before the 3 seconds have passed, there will be no reset. 5 - Entering the speed constant according to the tyre size. This operation becomes necessary only if the rear tyres are replaced with others of a different size. With the engine at standstill and the ignition key in the off position

, press and hold button P3 while turning the key

to the auxiliary position (without starting the engine), then release the button only when the tyre code appears in the display. This code will correspond to the type of rear tyre currently fitted. Now press button P1 repeatedly to view the permissible tyre sizes, which will be displayed in sequence. When the size displayed matches that of the new tyres, press P3 again to memorize. If the key is returned to the off position without completing this last step, the tyre size code will not be updated. Listed below are the tyre options specified for the tractor. Each size has a relative display code which corresponds to the number of impulses per 100 metres picked up by the speedometer sensor.

Tyre

Impulses for 100 metres

480/65 x 28 14.9 x 32 14.9 x 28

1100

14.9 x 30 420/70/30 16.9 x 28 480/70/28 540/65 x 28 12.4 x 36 540/65 x 30 16.9 x 30 480/70/30 13.6 x 28 380/70/28 420/70/24 14.9 x 24 13.6. X 36

1058

1050 1020

A - Button P 1, used to select the function displayed - Colour red. The 3 available functions (speedometer, P.T.O. speed, trip meter) are displayed cyclically by pressing P1 repeatedly. The function selected is indicated by a relative Led on the instrument panel.

1050 1153 1192

B - Button P 2, used to reset the function selected - Colour red Press this to select another function.

984

1 Diagnostics socket (on version with electronic RPM control only) -

2 Tyre size selection button (on version with the Instrument panel with digital display) -

459

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Operation of the broken belts alarm control unit

IMPORTANT: (for tractors equipped with air conditioning) if the engine fan belt breaks: a safety device will activate the emergency warning light on the dashboard (red triangle) and a warning buzzer will sound; (on tractors also equipped with electronic governors) with the handbrake on, the engine will also stop. This control unit allows the operator to leave the tractor with the engine running. The control unit acquires signals from the sensors and generates alarm conditions and may also stop the engine when necessary. control unit connections INPUTS - engine oil pressure - alternator d+ - broken fanbelt sensor - auxiliary input handbrake

NOTE: the auxiliary input is optional. If it is not to be utilised, leave the relative contact on the control unit free. This input can be connected to a relay which connects the signal to earth in the event an alarm.

OUTPUTS - control signal for engine oil pressure warning light - engine stop control signal - buzzer Input and output operation Inputs Input D+ serves two functions: - alarms control enabling - alarms. When the engine is switched off, this signal is low to illuminate the alternator warning light. The control unit considers the signal status low when it is below 3 volts. On starting the engine, this signal goes to +12 volts. If the signal voltage remains high (+12V) for 7 seconds, the control unit is enabled to check for alarm conditions. Once the alarm check has started, this input becomes itself a potential cause of an alarm; an alarm will be generated if the +12V is absent for at least 2 seconds. If the alternator is faulty, the signal D+ will never be activated and consequently control unit operation will not be initiated. The broken fanbelt input is connected to a sensor on the cooling fan on air-cooled engines. The broken fanbelt alarm is activated when a frequency below 10 Hz ( 10 pulses/second) is detected on the input. The oil pressure input is considered activated when it is low (earth) for at least 2 seconds, and deactivated when it stays high (12V) for the same duration. The auxiliary input is considered activated when it remains low (earth) for at least 2 seconds, and deactivated when it stays high (12V) for the same duration. The handbrake input is used by the control unit to determine the type of output in the event of an alarm condition. Outputs The engine stop command output is activated when one off the alarm inputs is activated while the handbrake is on. The control unit is capable of determining if this output is connected or not. The engine oil pressure warning light is used to generate a diagnostic code if the alarm is activated when the handbrake is released. If the alarm is caused by the absence of engine pressure, the warning light will illuminate steadily.

460

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

The buzzer is used to alert the operator to the status of the control unit. The buzzer emits three different signals: - two short acoustic signals (0.3 seconds) each time the handbrake is released to indicate that the control unit is in alarm signalling condition (diagnostic code on oil pressure warning light) but without generating the engine stop output. - one long acoustic signal (1 second) each time the handbrake is applied to indicate that the control unit will activate the engine stop output in the event of an alarm. - intermittent signal ( 3 Hz) to signal that the control unit has activated the engine stop output.

OPERATION The control unit only operates after the engine has been started. The control unit uses the D+ signal of the alternator to determine whether the engine is running. This signal must stay at high voltage for a duration of 7 seconds before control unit operation is initiated. If there is an alternator fault (signalled by the alternator warning light staying on when the engine is started), control unit operation will not be initiated. The start of control unit operation is signalled by an acoustic signal which will depend on the handbrake status: - two short acoustic signals (approx. 0.3 sec) id the handbrake is released. - one long signal (1 sec.) if the handbrake is on. At this point, the control unit will monitor the status of the broken fanbelt input, the oil pressure input, the auxiliary input and the D+ input. If one of these inputs is activated, the control unit will signal an alarm. There are two levels of alarm: Level 1 alarm - handbrake released. Level 1 alarm monitoring is activated when the handbrake is released, and is signalled by two short acoustic signals (0.3 seconds). If the handbrake is not on: - and the fanbelt is broken, the engine oil pressure warning light will flash with diagnostic code 2. - and the auxiliary input is activated, the engine oil pressure warning light will flash with diagnostic code 4. - and the D+ input voltage is low (earth), the engine oil pressure warning light will flash with diagnostic code 3. - and the oil pressure is low, the engine oil pressure warning light will illuminate steadily (controlled by the pressure switch). The warning light will stop flashing the moment the alarm condition ceases to exist. Level 2 alarm 2 - handbrake on. Level 2 alarm monitoring is activated when the handbrake is applied, and is signalled by a long acoustic signal (1 second). If the handbrake is on: - and any alarm is activated, the control unit will generate the ENGINE STOP signal. Consequently the engine oil pressure warning light will be steadily illuminated (as when the engine is stopped, the oil pressure will fall and thus the warning light will come on) unless there is no connection between the control unit and the engine stop device. The control unit will signal the ENGINE STOP condition with an intermittent acoustic signal (approx. 3 signals per second). To deactivate the ENGINE STOP, switch off and then restart the engine.

461

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

ENGINE STOP DEVICES The alarm control unit can generate an output signal to control a device which stops the engine. The alarm control unit output can be connected to an engine control unit type 2MH (manufacturer’s code for control unit with 26 contact connector) and is also capable of operating a relay with currents up to 250mA.

ENGINE STOP OPERATION WITH A TYPE 2MH ENGINE CONTROL UNIT The operation of the engine control unit in the presence of a STOP signal is very simple. The control unit starts to monitor the STOP signal 2 seconds after the engine has been started, i.e. when it has attained idling speed. The control unit checks for a STOP signal which remains active for at least 1 second. On detection of a STOP signal, the control unit switches off the engine. The engine control unit signals operation of the engine stop by 7 flashes of the HOLD led on the keypad. The engine control unit will ignore the STOP signal if the engine is switched off. For example, if the engine stalls (under excessive load), a STOP signal may be generated but it will be ignored. Using the ALL ROUND TESTER it is possible to check that the STOP signal is connected correctly. One of the following messages will also appear on the monitor: 1) STOP NOT CONNECTED 2) STOP CONNECTED 3) STOP ACTIVE On models equipped with STOP control units, the valid messages are nos. 2 and 3. Should message no. 1 “STOP NOT CONNECTED” appear, check the connection between pin 5 of the alarm control unit and pin 11 of the engine control unit. If none of the above messages appears, this means that the engine control unit does not have the correct program.

DIAGNOSTICS To enable the operator to identify the problem which caused the intervention of the engine stop, the control unit provides a diagnostic code by means of the oil pressure warning light, but only when the handbrake is released. The diagnostic code is only given after the engine has been re-started and the control unit has given the first acoustic signal, typically 7 seconds after the alternator warning light goes out. The diagnostic code consists of a series of flashes each with a duration of 0.3 seconds at 1 second intervals. The oil pressure input does not provide a diagnostic code as the illumination of the warning light is forced by the pressure switch.

462

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

Diagnostic codes Below is a list of the diagnostic codes and their meanings: flashes WARNING LIGHT 2 3 4 5

Broken fanbelt sensor Alternator signal D+ Auxiliary input Engine STOP output

example of code 2 ON OFF

Description of faults This chapter provides useful information for fault tracing. Code 2 - Broken fanbelt sensor This fault is signalled when the input signal from the fanbelt sensor fails to arrive at the control unit. If this fault occurs : - Check that the battery voltage is present between pins 1 and 2 of the sensor connector. - Check that pin 3 of the sensor connector is connected to pin 6 of the alarm control unit. Code 3 - Alternator signal D+ This fault is signalled when the alternator signal D+ is no longer present after the alarm control unit has entered into operation. If this fault occurs: - Check the alternator warning light: if on, the problem concerns the alternator itself; if off, the wire carrying the signal to the control unit may have come disconnected. Code 4 - Auxiliary input This fault is signalled when the voltage on pin 8 of the control unit falls below 12V. This input is not currently utilised, consequently if this fault is signalled, check that pin 8 of the control unit is at +12V. If necessary, remove the contact from the connector and test again. Code 5 - Engine STOP output This fault is signalled when the control unit does not detect any connection to its STOP output. If this fault occurs: - Check that pin 5 of the alarm control unit is connected to pin 11of the engine control unit.

463

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Broken belt alarm system and diagnostic codes. (If the light stays on continuously this indicates low engine oil pressure). A - Alternator B - Engine oil pressure C - Fan pick-up D - Brake fluid level E - Handbrake F - Alarm control unit G - Engine control unit

464

H - Electro stop I - Connection for engines with electronic governor L - Diagnostic codes M - N* of flashes 2 - Broken belt sensor 3 - Alternator signal 5 - Engine stop output

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

Systems

8

Electrical system

84

ELECTRICAL WIRING

TRACTOR ELECTRICAL SYSTEM DIAGRAM KEY TO ELECTRICAL SYSTEM DIAGRAM

TAV.1 -

TRACTOR WIRING COMPLETE CENTRAL UNDERBODY WIRING

TAV. 2

COMPLETE FRONT WIRING

TAV. 3

GEARBOX WIRING

TAV. 4

BATTERY WIRING

TAV. 5

POWERSHIFT CONTROL WIRING

TAV. 6

CAB WIRING CAB WIRING DIAGRAM

TAV. 7

CENTRAL WIRING

TAV. 8

CLIMATE CONTROL SYSTEM WIRING

TAV. 9

WORK LIGHTS - SCREEN WIPER - ROTATING LIGHTWIRING

TAV. 10

AIR CONDITIONING SYSTEM WIRING

TAV. 11

AIR HEATING WIRING

TAV. 12

SCREENWASH PUMPS WIRING

TAV. 13

FRONT SCREEN WIPER WIRING

TAV. 14

CAB POWER SUPPLY WIRING

TAV. 15

FUEL LEVEL SENDER

TAV. 16

465

8

Systems

84

Electrical system

AGROPLUS 60 (under s.n. 1016) 70- (under s.n. 2772)

PAGE INTENTIONALLY LEFT BLANK

466

TAV. 1 - TRACTOR ELECTRICAL SYSTEM DIAGRAM - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

467

KEY TO FUNCTIONAL DIAGRAM OF TRACTOR ELECTRICAL SYSTEM

1 - PREHEATING SOLENOID VALVE 2 - STARTING ENABLING SENSOR 3 - STOP SENSOR 4 - STOP LIGHTS 5 - STOP LIGHTS 6 - GLOWPLUG 7 - GLOWPLUG WARNING LIGHT 17 - FUEL RESERVE WARNING LIGHT 18 - FUEL LEVEL INDICATOR 19 - SENSOR FOR FUEL LEVEL INDICATOR 20 - ENGINE OIL TEMPERATURE INDICATOR 21 - OIL TEMPERATURE SENSOR 22 - 540 RPM REAR P.T.O. INDICATOR LIGHT 23 - 540 RPM P.T.O. ENGAGEMENT SENSOR 24 - 1000 RPM REAR P.T.O. LIGHT 25 - 1000 RPM P.T.O. ENGAGEMENT SENSOR 30 - 4WD INDICATOR LIGHT 32 - TRAILER BRAKING INDICATOR LIGHT 33 - TRAILER BRAKING SENSOR 34 - CHRONOMETER-TACHOMETER 35 - ALTERNATOR WARNING LIGHT 36 - HYDRAULIC SERVICES OIL FILTER WARNING LIGHT 37 - HYDRAULIC SERVICES OIL FILTER SENSOR 40 - AIR FILTER WARNING LIGHT 41 - AIR FILTER SENSOR 42 - BRAKE OIL LEVEL WARNING LIGHT 43 - BRAKE OIL LEVEL SENSOR 44 - REAR P.T.O. IN OPERATION WARNING LIGHT 45 - SOLENOID VALVES OIL SENSOR 46 -SYNCHRONISED P.T.O. INDICATOR LIGHT 47 - SYNCHRONISED P.T.O. SENSOR 48 - ENGINE OIL LOW PRESSURE WARNING LIGHT 49 - ENGINE OIL LOW PRESSURE SENSOR 50 - DIFFERENTIAL LOCK INDICATOR LIGHT 51 - DIFFERENTIAL LOCK SWITCH 52 - DIFFERENTIAL LOCK SOLENOID VALVE 53 - 4WD ENGAGEMENT SWITCH 54 - 4WD ENGAGEMENT SOLENOID VALVE 55 - FRONT P.T.O. CONTROL SWITCH 56 - P.T.O. ENGAGEMENT INDICATOR LIGHT 57 - FRONT P.T.O. SOLENOID VALVE 59 - REAR P.T.O. SOLENOID VALVE 60 - REAR P.T.O. CONTROL SWITCH/ STARTING ENABLE

TRACTOR ELECTRICAL SYSTEM DIAGRAM - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

468

61 - ECONOMIC P.T.O. SELECTION INDICATOR LIGHT 62 - ECONOMIC P.T.O. SENSOR 63 - HANDBRAKE SENSOR 66 - SIDE LIGHTS INDICATOR LIGHT 67 - LEFT FRONT SIDE LIGHT 68 - RIGHT FRONT SIDE LIGHT 69 - RIGHT REAR SIDE LIGHT 70 - LEFT REAR SIDE LIGHT 71 - NUMBER PLATE LIGHT 72 - RIGHT LOW BEAM HEADLIGHT 73 - LEFT LOW BEAM HEADLIGHT 74 - LEFT MAIN BEAM HEADLIGHT 75 - RIGHT MAIN BEAM HEADLIGHT 76 - MAIN BEAM WARNING LIGHT 77 - HORN 83 - DIRECTION INDICATORS WARNING LIGHT 84 - DIRECTION INDICATORS WARNING LIGHT -1ST TRAILER 85 - DIRECTION INDICATORS WARNING LIGHT - 2ND TRAILER 86 - LEFT FRONT DIRECTION INDICATOR 87 - LEFT REAR DIRECTION INDICATOR 88- RIGHT FRONT DIRECTION INDICATOR 89 - RIGHT REAR DIRECTION INDICATOR 91 - WORK LIGHT 93 - REAR WORK LIGHTS 94 - FLASHER SOCKET A - IGNITION SWITCH B - STARTER MOTOR C - ELECTRONIC GOVERNOR D - FANBELT ALARM CONTROL UNIT E - 65A ALTERNATOR WITH SOCKET W F - LIGHTS, DIRECTION INDICATORS AND HORN CONTROL G - DIRECTION INDICATORS CONTROL UNIT H - DIRECTION INDICATORS CONTROLS I - TRAILER SOCKET N - PRE-HEATING CONTROL UNIT O - HIGH-MEAN-LOW CONTROL UNIT R1 - PRE-HEATING RELAY R2 - STARTING ENABLEMENT RELAY

TRACTOR WIRING

TAV. 2 - COMPLETE CENTRAL UNDERBODY WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

469

TRACTOR WIRING

470

TAV. 3 - COMPLETE FRONT WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

TRACTOR WIRING

TAV. 4 - GEARBOX WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

471

1200 3 CIL. 1300 4 CIL.

TRACTOR WIRING

472

TAV. 5 - BATTERY WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

TRACTOR WIRING

TAV. 6 - POWERSHIFT WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

473

KEY TO COMPONENTS 1 - FLASHING SWITCHES 2 - FLASHING 3 - COURTESY LIGHT 4 - 12V RADIO SOCKET 5 - CONDITIONER RELAY 6 - CONDENSER FAN 8 - PRESSURE SWITCH 9 - COMPRESSOR (R 132A) 10 - HEATING ALTERNATOR 11 - SCREEN WIPER SWITCH

12 - FRONT SCREEN WIPER MOTOR 13 - FRONT SCREEN WASH PUMP 14 - SCREEN WASH BUTTON 15 - SCREEN WIPER SWITCH 16 - REAR WIPER MOTOR 17 - REAR SCREEN WASH PUMP 18 - FRONT WORK LIGHTS SWITCH 19 - FRONT WORK LIGHTS 20 - REAR WORK LIGHTS SWITCH 21 - REAR WORK LIGHTS

7 - HEATING AND AIR CONDITIONING UNIT

A OPTIONAL CLIMATE CONTROL CONNECTOR B POWER SUPPLY CONNECTOR R OPTIONAL ELECTRIC HEATER CONNECTOR

CAB WIRING

474

TAV. 7 - CAB WIRING DIAGRAM - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

CAB WIRING

TAV. 8 - CAB WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

475

KEY TO CLIMATE CONTROL SYSTEM COMPONENTS E N P C RA RC A P F T CO S R B A

CAB WIRING

476

TAV. 9 - CLIMATE CONTROL SYSTEM WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

ELECTRONIC HEATING CONTROL UNIT NTC TEMPERATURE SENSOR FAN SPEED CONTROL RESISTOR FAN SPEED CONTROL SWITCH HEATING RELAY AIR CONDITIONING RELAY ELECTRIC HEATING ALTERNATOR HEATER ELEMENT POWER SUPPLY FUSE AIR CONDITIONER PRESSURE SWITCH COMPRESSOR THERMOSTAT OPTIONAL ELECTRIC HEATING CONNECTOR POWER SUPPLY CONNECTOR OPTIONAL CLIMATE CONTROL CONNECTOR

CAB WIRING

TAV. 10 - WORK LIGHTS - SCREEN WIPER - ROTATING LIGHTWIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

477

CAB WIRING

478

TAV. 11 - AIR CONDITIONING SYSTEM WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

CAB WIRING

TAV. 12 - AIR HEATING WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

479

CAB WIRING

480

TAV. 13 - SCREENWASH PUMPS WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

CAB WIRING

TAV. 14 - FRONT SCREEN WIPER WIRING

CAB WIRING

TAV. 15 - CAB POWER SUPPLY WIRING - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

481

CAB WIRING

482

TAV. 16 - FUEL LEVEL SENDER - AGROPLUS 60 (under serial number 1016) 70- (under serial number 2772)

APPENDIX

Appendix Power lift tester

Power Lift Electronic Control Unit TESTER manual

CONTENTS Functional diagram .............................................................................................................................III Presentation screen ...........................................................................................................................LV Initialisation menu................................................................................................................................V 1 Main menu .......................................................................................................................................VI 1 Calibrations menu..........................................................................................................................VII 2 Monitor menu...................................................................................................................................X 1 Lift menu......................................................................................................................................XI 2 Draft menu.................................................................................................................................XIII 3 Position menu ...........................................................................................................................XIV 3 Tests menu ...................................................................................................................................XV 1 Sensors menu ...........................................................................................................................XVI 2 Power supply menu .................................................................................................................XVII 3 Inputs menu ............................................................................................................................XVIII 4 Alarms menu .................................................................................................................................XX

Scope The scope of this document is: - to present the diagnostic information that can be accessed through the All Round Tester (ART®); - to list the alarm conditions that the electronic control unit is able to diagnose, along with the possible causes of the alarms and the relative actions of the electronic control unit.

II

Appendix Power lift tester

PIN OUT REAR LIFT ECU 5

11

10 Mix

Main Control

L. Speed

Draft

Position

9

+Vcc Sensors

8

7

Max H.

6

12 ISO 9141

Electrovalve DOWN

4 GND

3

2 Electrovalve UP

Vcc

1

1K2 Lock/Alarm

Extern up

Extern down

Down

1

2

1

1

2

3

V +

2

1

3

2

1

2

3

1

2

3

1

2

3

1

2

Up

3

V

EVup

A

EVdown

B

Tester In/Out

C

Position Sensor

D

Draft Sensor

E

Lowering Speed

F

Maximum Height

G

Mix Draft/Pos

H

Main Control

I

Down/Up Control lever

L

Functional diagram of the lift ECU. 1 - Vdc 2 - UP solenoid valve 3 - DOWN solenoid valve 4 - GND 5 - Sensor Vdc 6 - Position 7 - Draft 8 - Speed limit 9 - Maximum height 10 - Mix 11 - Main control 12 - ISO 9141

A - UP solenoid valve B - DOWN solenoid valve C - Tester IN/OUT D - Position sensor E - Draft sensor F - Lowering speed G - Maximum height H - DRAFT/POSITION MIX control I - Main control L - UP/DOWN control

III

Appendix Power lift tester Presentation screen

The presentation screen displays preliminary information about the electronic control unit: · Software version · Date of software issue The screen appears as follows:

Where: Version Date:

L

i

f

t =

=

=

=

=

=

=

=

=

=

=

=

=

=

S

o

f

t

w

a

r

e

D

a

t

e

d

d

P

a

r

a

m

e

t

e

T

R

A

C

T

O

R

=

=

=

=

=

=

=

=

=

=

=

=

=

[

C

]

C

H

[

E

]

C

X

.

x

x

x

/

m

m

/

y

y

r

s

f

o

r

x

x

x

=

=

=

=

=

=

=

=

=

=

=

=

A

N

G

E

P

A

O

N

T

I

U

E

software version date of software issue

The various functions are described below: Pressing "C" displays the initialisation menu for the tractor type: - lift for tractor 10N (Golden) - lift for tractor 10S (Dorado) As described on page V Pressing "E" displays the menu described on page vi

IV

N

=

=

=

=

=

=

=

=

=

R

A

M

.

Appendix Power lift tester Initialisation menu

From the Initialisation menu you can configure the lift in accordance wit the type of tractor.

The menu is displayed on the ART as follows: I

N

I

T

I

A

L

I

S

C

u

r

r

e

n

t

P

a

r

a

m

e

t

f

o

r

1

0

X

e

r

s

C

h

a

n

g

e

P

a

r

a

m

e

e

r

s

1

-

L

i

f

t

f

o

2

-

L

i

f

t

f

=

=

=

=

=

=

=

[

C

]

C

O

N

t

A

T

I

O

r

1

0

N

o

r

1

0

S

=

=

=

=

=

=

=

T

I

N

U

E

N

=

=

Where: Current parameters defines the configuration currently saved in memory To change and save the configuration, press "1" or "2". Press "1" to configure the lift for the 10N tractor. (Golden) Press "2" to configure the lift for the 10S tractor. (Dorado) Press "C" to pass to the main menu.

V

Appendix Power lift tester 1 - Main menu From this menu you can select the component on which diagnosis is to be performed or display the general list of alarms detected up until that point.

The menu displayed on the ART is as follows:

M

A

I

N

E

N

U

t

i

o

n

T

1

C

a

l

i

b

r

a

2

M

o

n

i

t

o

r

3

T

e

s

t

s

4

A

l

a

r

m

s

S

E

L

E

C

E

X

I

T

E

The various menus and submenus are described below.

VI

M

s

Appendix Power lift tester 1 - Calibrations menu From this menu you can calibrate the lift system. The menu displayed on the ART is as follows:

C

a

l

i

b

r

a

t

i

o

n

s

M

e

n

u

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1

-

M

a

x

.

h

e

i

g

h

t

P

e

r

s

o

n

a

l

i

s

a

t

i

o

n

L

i

f

t

i

n

g

s

p

e

e

d

2

-

L

i

f

t

i

n

g

s

p

e

e

d

[

E

]

E

X

I

T

These operations are to be performed with the lift lock released. The various calibration functions are described below.

VII

Appendix Power lift tester Maximum height calibration: On pressing "1" on the ART, the following screen is displayed:

1

-

M

a

x

.

-

-

-

-

-

-

C

u

r

r

e

n

N

e

w

H

e

i

g

h

t

-

-

-

-

-

-

-

-

-

-

t

:

x

x

x

x

:

x

x

x

x

[

A

]

C

a

n

c

e

l

[

C

]

C

O

N

F

I

R

M

Where: Current New

The position value between 0 and 1000 saved in memory. The position value between 0 and 1000 read by the position sensor.

Operation: To decontrol the lifter pressing for 3 second the key of command basculante on the position UP. With the keys of controls manual, to position the lifter to the maximum desired height. To press the key [E] on the tester and the key [C] to confirm the new value.

Press: · "A" to cancel the operation; · "C" to save the new value in the Eeprom.

VIII

Appendix Power lift tester Implement lifting speed This parameter regulates the speed at which the lift is raised when using the manual controls only. On pressing "2" on the ART, the following screen is displayed:

2

-

L

i

f

t

-

-

-

-

-

-

C

u

r

r

e

n

N

e

w

s

p

e

e

d

-

-

-

-

-

-

t

-

-

-

-

:

x

x

x

x

:

x

x

x

x

[

A

]

C

a

n

c

e

l

[

C

]

C

O

N

F

I

R

M

Where: Current New

The speed value between 300 and 400 saved in memory. The actual speed value between 300 and 400.

Press: · "A" to cancel the operation; · "C" to save the new value in the Eeprom.

IX

Appendix Power lift tester 2 - Monitor menu From this menu you can display the operating parameters of the lift system. The menu displayed on the ART is as follows:

M

o

n

i

1

L

i

f

t

2

D

r

a

f

t

3

P

o

s

i

[

E

]

The various functions are described below.

X

t

o

r

M

t

i

o

n

E

X

I

T

e

n

u

Appendix Power lift tester 2 - Monitor Menu 1 - Lift menu From this menu you can display the following values: Set Point Position Draft Maximum height

The menu displayed on the ART is as follows:

L

i

f

t

-

-

-

-

-

-

-

-

-

-

-

-

-

-

P

o

t

e

n

t

i

o

m

e

t

e

r

s

S

e

t

P

o

i

n

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.

.

.

.

x

M

a

x

.

h

e

i

g

h

t

.

L

o

w

.

s

p

e

e

d

.

M

i

x

.

.

.

.

.

.

.

S

E

N

S

O

R

S

-

-

x

x

x

.

.

x

X

.

.

.

x

X

.

.

x

x

x

X

P

o

s

i

t

i

o

n

.

.

.

.

.

x

x

X

D

r

a

f

t

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.

.

.

.

.

.

x

x

x

X

O

U

T

P

U

T

P

w

m

x

x

X

L

I

F

T

S

t

a

t

.

x

X

P W M

u E

S

T

A

T

U

S

.

.

s

.

.

.

.

.

.

.

E

X

I

T

POTENTIOMETERS Set Point Reference value for automatic control of the lift. On turning the potentiometer, the value displayed varies between 0 and 1000 (this operation must be performed with the lift lock released). The value modifies the positions of equilibrium during the operation in control. Max. height

Represents the maximum height to which the lift can be raised. On turning the potentiometer, the value displayed varies between 0 and 100.

Lowering speed

Represents the lowering speed as a percentage of the maximum speed. On turning the potentiometer, the value displayed varies between 0 and 100.

Mix

This parameter allows you to select the type of control, passing continuously from position to draft control. On turning the potentiometer, the value displayed varies between 0 and 1000.

XI

Appendix Power lift tester

· SENSORS Position Signal read by the position sensor; values range from 0 to 100. Draft Signal read by the draft sensor; values range from 0 to 1000. · PWM OUTPUT PWM Value that controls the current supplied to the proportional solenoid valves. Value ranges 290 to 600. when the lfting is in movement; 0 if the elettrovalvoles are not commanded. · LIFT STATUS Status Displays the operating status of the lift system. Press the control button to view the following status information LOCK lift locked STOP lift operative awaiting command CNTRL lift operating in automatic control mode FLOAT lift in float mode

XII

Appendix Power lift tester 2 - Monitor menu 2 - Draft menu From this menu you can display the following values: · Pwm Base Up · PWM Base Down · PWM Max Up · PWM Max Down · Gain Up · GainDown

The menu displayed on the ART is as follows: D

r

a

f

t

-

-

-

-

-

-

-

-

-

P W M

B

a

s

e

U

p

2

-

P W M

B

a

s

e

D

o

3

-

P W M M

a

x

U

p

4

-

P W M M

a

x

D

o

5

-

G

a

i

n

U

p

6

-

G

a

i

n

D

o

w

[

E

]

X

I

T

-

-

-

1

E

-

w w

-

n n

-

-

-

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

X

n

These are the characteristic values of the electronic lift control system. The default values are as follows: Values

10N

10S

PWM BaseUp

390

360

PWM BaseDown

400

420

PWM MaxUp

600

600

PWM MaxDown

600

600

Gain Up

25

18

Gain Down

45

35

XIII

Appendix Power lift tester 2 - Monitor Menu 3 - Position Menu From this menu you can display the following values: · Pwm Base Up · PWM Base Down · PWM Max Up · PWM Max Down · Gain Up · GainDown The menu displayed on the ART is as follows:

P

o

s

i

t

i

o

n

-

-

-

-

-

-

-

-

-

-

-

1

-

P W M

B

a

s

e

U

p

2

-

P W M

B

a

s

e

D

o

3

-

P

W M

M

a

x

U

p

4

-

P

W M

M

a

x

D

o

5

-

G

a

i

n

U

p

6

-

G

a

i

n

D

o

w

n

[

E

]

X

I

T

E

-

-

w

n

w

N

-

These are the characteristic values of the electronic lift control system. The default values are as follows:

XIV

Values

10N

10S

PWM BaseUp

315

315

PWM BaseDown

310

320

PWM MaxUp

600

600

PWM MaxDown

600

600

Gain Up

10

10

Gain Down

50

50

-

-

Appendix Power lift tester 3 - Tests Menu From this menu you can test the operation of the: 1 - sensors 2 - actuators connected to the ECU. 3 - inputs The menu displayed on the ART is as follows:

T

e

s

t

s

M

e

n

u

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1

-

S

e

n

s

o

r

s

2

-

P

o

w

e

r

s

u

p

p

l

y

3

-

I

n

p

u

t

s

[

E

]

E

X

I

T

-

-

The various functions are described.

XV

Appendix Power lift tester 3 - Tests Menu 1 - Sensors menu

In this menu you can check the operation of the sensors. The menu displayed on the ART is as follows: S

e

n

s

o

r

s

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

P

o

s

i

t

.

.

.

.

.

.

.

.

x

x

x

D

r

a

f

t

.

.

.

.

.

.

.

x

x

x

x

[

E

]

E

X

I

T

Where: Position Draft

XVI

Position sensor value ranging from 0 to 100 Draft sensor value ranging from 0 to 1000

Appendix Power lift tester 3 - Tests Menu 2 - Power supply

In this menu you check the power supply to the ECU.

The menu displayed on the ART is as follows:

P

o

w

e

r

S

u

p

p

l

y

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

+

1

0

v

o

u

t

m

V

x

x

x

x

[

E

E

X

I

T

]

Where: +10V

represents the output voltage value in the range 0 to 1000 mV.

XVII

Appendix Power lift tester 3 - Tests menu 3 - Inputs In this menu you can check the operation of the ECU inputs.

The menu displayed on the ART is as follows: n

p

u

t

s

-

-

-

-

-

-

-

-

-

-

-

P

u

s

h

b

u

t

t

o

n

s

U

P

/

D

W

E

x

t

U

P

/

D W

P

o

t

e

n

t

i

o

m

e

S

e

t

P

o

i

n

t

.

M

a

x

.

h

e

i

L

o

w

.

s

p

C

o

n

t

r

o

[

E

]

Where: Up/Down rocker switch on console

XVIII

I

-

-

-

-

-

t

e

r

s

.

.

.

x

x

x

x

g

h

t

.

x

x

x

x

e

e

d

.

.

x

x

x

x

l

t

y

p

e.

.

x

x

x

x

E

X

I

T

Appendix Power lift tester On pressing the UP side of the rocker switch with the lift lock released, the display will appear as follows: U

P

/

D W

U

P

On pressing the DOWN side of the rocker switch with the lift lock released, the display will appear as follows: U

P

/

D W

D

o

w

n

ExtUP/DW ground-operated pushbuttons

On pressing the button with the UP arrow when the lift lock is released, the display will appear as follows E

x

t

U

P

/

D W

U

P

On pressing the button with the DOWN arrow when the lift lock is released, the display will appear as follows E

x

t

U

P

/

D W

D

o

w

n

Set Point on turning the potentiometer, the value varies in the range 0 to 1000 Max. height on turning the potentiometer, the value varies in the range 0 to 100 Lowering speed on turning the potentiometer, the value varies in the range 0 to 100 CONTROL TYPE On pressing the control pushbutton, the following conditions are displayed C

o

n

t

r

o

l

t

y

p

e

L

O

C

K

C

o

n

t

r

o

l

t

y

p

e

S

T

O

P

C

o

n

t

r

o

l

t

y

p

e

C

O

N

T RL

C

o

n

t

r

o

l

t

y

p

e

F

L

O

A

T

XIX

Appendix Power lift tester 5 - Alarms menu

The screen displayed on the ART is as follows:

XX

A

L

A

R

M S

-

-

-

-

-

-

1

-

C

a

n

c

[

E

]

L

O G

-

-

-

e

l

E

X

I

-

-

-

l

o

g

T

-

-

-

-

Appendix Power lift tester Tester message

Possible cause of fault

ECU action

N° of flashes

UPSV DISCONN.

UP proportional solenoid valve disconnected. - Wiring error. Check electrical continuity -Solenoid faulty. Check solenoid -ECU faulty.

Loss of lift system function.

11

UPSV S.C.

Short circuit of UP proportional solenoid valve. - Wiring error. Check electrical continuity. - Solenoid faulty. Check solenoid. - ECU faulty.

Loss of lift system function.

12

DWSV DISCONN.

DOWN proportional solenoid valve disconnected. - Wiring error. Check electrical continuity. - Solenoid faulty. Check solenoid. - ECU faulty.

Loss of lift system function.

13

DWSV S.C.

Short circuit of DOWN proportional solenoid valve. - Wiring error. Check electrical continuity. - Solenoid faulty. Check solenoid. - ECU faulty.

Loss of lift system function.

14

EPROM CHECK

EPROM error. - ECU faulty.

Total lockup of lift system

15

POS.SENS.S.C.

Short circuit of position sensor. - Wiring error. Check electrical continuity. - Sensor faulty. Check sensor. - ECU faulty.

Loss of lift system function.

21

XXI

Appendix Power lift tester

XXII

Tester message

Possible cause of fault

ECU action

N° of flashes

POS.SENS. DIS.

Position sensor disconnected. - Wiring error. Check electrical continuity. - Sensor faulty. Check sensor. - ECU faulty.

Loss of lift system function.

22

GEN.FAIL.CPU

General failure of CPU. - ECU faulty.

Loss of lift system function.

23

DRAFT SENS. DIS.

Draft sensor not connected. - Wiring error. Check electrical continuity. - Sensor faulty. Check sensor. - ECU faulty.

Loss of draft control function.

41

DRAFT SENS. S.C.

Draft sensor short circuit. - Wiring error. Check electrical continuity. - Sensor faulty. Check sensor. - ECU faulty.

Loss of draft control function.

42

EEPROM CHECK

EEPROM error. - ECU faulty

Default values (for 10N) utilised

45

NO V. SENSOR

No voltage at sensor. - Wiring error. Check electrical continuity. - ECU faulty. Check using Tests menu on ART.

Loss of lift system function.

-

Der Nachdruck des Textes und der Abbildungen ist, auch auszugsweise, verboten. La reproduction du présent ouvrage, du texte et des ìllustratìons, mème partìelle est interdite. Text and illustrations herewith enclosed may not be reproduced, not even in part and by any means. E’ vietata la riproduzione, anche parziale, del testo e delle illustrazioni. Se prohibe la reproducciòn total o parcial del texto y de las ilustraciones. A proibida a reproduçào, até mesmo parcial, do texto e das ilustracòes.

Der zeitliche Unterschied zwischen der Aktualisierung der Druckschriften und der Durchführung technischer Veränderungen (die ständig vorgenommen werden, um immer hochwertigere Erzeugnisse auf den Markt zu bringen) erfordern aus Gründen der Korrektheit des Hinweises, dass die in dieser Ausgabe enthaltenen Daten jederzeit geändert werden können und deshalb unverbindlich sind. Le temps qui s’écoule entre la mise à jour en impression et les modifications techniques (ces dernières changeant continuellement afin d’offrir aux utilisateurs des produits toujours plus qualifiés) nous oblige a vous signaler que les données de la présente publication pourraient être susceptibles de variations. Elles sont données sans engagement de notre part. Because of the possible time lag between the introduction of technical modifications (an on-going process the aim of which is to offer products which are being continually improved) and the latest update of the manual, we must point out, for the sake of correctness,that the data contained in this edition are liable to change at any time and are therefore not binding. La differenza tra i tempi di aggiornamento in stampa e i tempi delle modifiche tecniche (variando queste ultime continuamente, ciò al fine di offrire prodotti sempre più qualificati) impongono di dichiarare, per correttezza, che i dati contenuti nella presente edizione sono suscettibili di variazione in qualsiasi momento e che quindi non sono impegnativi. La diferencia entre los tiempos necesarios para poner al dia la impresiòn y los tiempos de las modificaciones tècnicas (las que se verifican continuamente, con el objeto de ofrecer productos cada vez màs calificados) nos imponen declarar, por corrección, que los datos contenidos en la presente ediciòn estàn sujetos a variaciones en cualquier momento y que portanto no son obligativos. A diferença entre os tempos necessãrrios para actualizar a impressão e os tempos das modificacões técnicas (que se verificam continuamente, a fim de oferecer um produto cada vez mais qualificado), obrigam-nos a declarar, que os dados contidos neste manuel são susceptiveis de variacão em qualquer momento e que portanto não são vinculatórios.

NOTES

05 - 2003 By Personal computing

cod. 307.1064.3.6 Technical Publications Dep.

05 - 2003

307. 1064. 3. 6