Deutz-Fahr Tractors AGROTRON 80 MK3, AGROTRON 85 MK3, AGROTRON 90 MK3, AGROTRON 100 MK3, AGROTRON 105 MK3 Repair Service Manual
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Model:
Complete service manual for Deutz-Fahr AGROTRON 80 MK3, AGROTRON 85 MK3, AGROTRON 90 MK3, AGROTRON 100 MK3, AGROTRON 105 MK3, with workshop information to maintain, diagnose, repair, and service like professional mechanics.
Deutz-Fahr Tractors AGROTRON 80 MK3, AGROTRON 85 MK3, AGROTRON 90 MK3, AGROTRON 100 MK3, AGROTRON 105 MK3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
AGROTRON 80 MK3 –> 6001
AGROTRON 90 MK3 –> 6001
AGROTRON 100 MK3 –> 6001
AGROTRON 105 MK3 –> 6001
AGROTRON 80 MK3
AGROTRON 85 MK3
AGROTRON 90 MK3
AGROTRON 100 MK3
AGROTRON 105 MK3
Deutz-Fahr AGROTRON 80 MK3->6001, AGROTRON 90 MK3->6001, AGROTRON 100 MK3->6001, AGROTRON 105 MK3->6001 Workshop Manual.pdf
Deutz-Fahr AGROTRON 80 MK3, AGROTRON 85 MK3, AGROTRON 90 MK3, AGROTRON 100 MK3, AGROTRON 105 MK3 Workshop Manual.pdf
Total Pages: 784 + 590 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
HOW THE MANUAL IS STRUCTURED
Section 00 Contains the general safety rules, information on how to use and update the manual, the symbols used, the products required, the standard tightening torques and a conversion table for units of measurement.
Section 10 Contains technical descriptions and information regarding the mechanical and hydraulic operation of machine components, the designations of the various components, hydraulic diagrams and general technical data.
Section 20 Contains a guide to the use of the necessary software for machine and engine configuration and for diagnostic.
Section 30 Contains the methods, checks and adjustments regarding the external components; the operations dealt with in this section do not require removal of the various assemblies that form the tractor frame and cab.
Section 40 Contains information and diagrams regarding the machine's electrical and electronic systems.
Deutz-Fahr AGROTRON 80 MK3, AGROTRON 85 MK3, AGROTRON 90 MK3, AGROTRON 100 MK3, AGROTRON 105 MK3 Workshop Manual...2
307.1100.3.6 AGROTRON 80-85-90-100-105 MK3...2
INTRODUCTION...4
SAFETY NOTES...6
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS...9
LIFTING INSTRUCTIONS...11
HOW THE MANUAL IS STRUCTURED...12
HOW TO CONSULT THE MANUAL...13
HOW TO USE AND UPDATE THE MANUAL...14
STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS...15
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS...16
SPECIAL TOOLS...18
CONVERSION FACTORS...19
SECTION 10...20
1. TRANSMISSION...22
INTRODUCTION...22
1.1 TRANSMISSION...23
1.1.1 MAIN COMPONENTS...23
1.1.2 TRANSMISSION HYDRAULIC SYSTEM...26
1.1.3 GEARBOX...27
GEARBOX COMPONENTS...28
1.1.4 MAIN CLUTCH...29
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE...30
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC...33
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC...34
1.2 REAR AXLE...36
1.3 REAR PTO...38
2. BRAKING SYSTEM...40
2.1 BRAKE MASTER CYLINDER...41
2.2 BRAKE...42
2.3 TRAILER BRAKING SYSTEM...43
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)...43
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)...45
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)...46
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)...47
COMPRESSOR...48
PRESSURE LIMITING VALVE...49
TRAILER BRAKING VALVE (2-WAY)...50
TRAILER BRAKING VALVE (1-WAY)...51
3. HYDRAULIC FRONT AXLE SUSPENSION...52
3.1 SOLENOID VALVE - SUPPLY TO FRONT SUSPENSION CONTROL VALVE...53
3.2 FRONT SUSPENSION CONTROL VALVE...54
4. FRONT AXLE...58
5. HYDRAULIC SYSTEM...59
5.1 HYDRAULIC SYSTEM...60
5.2 GEAR PUMP FOR TRANSMISSION ZF 7100...62
5.3 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING...63
5.4 POWER STEERING...64
5.5 AUXILIARY SERVICES CONTROL VALVE...65
5.5.1 TYPES OF CONTROL VALVE...66
5.5.2 SERVICES CONTROL SECTION...68
5.5.3 DESCRIPTIONS OF COMPONENTS...69
5.5.4 INLET MANIFOLD...70
5.5.5 LIFT CONTROL VALVE SECTION...71
SECTION 20...72
OPERATOR’S MANUAL SERDIA (LEVEL III)...74
1. ENTRY AND COMMUNICATION...75
1.1 OVERVIEW...75
1.2 ORDERING...76
1.3 SWITCH ON NOTEBOOK AND INSTALL SOFTWARE...77
1.4 USER LEVEL, ACCESS AUTHORIZATION...78
1.5 MAKING A CONNECTION BETWEEN ECU (ENGINE) AND NOTEBOOK...79
1.6 PROGRAM START...79
1.7 OFFLINE MODE...80
1.8 WORKING WITH THE PROGRAM...82
1.9 PRINT (OUTPUT)...84
1.10 PROTOCOL (PROTOKOLL)...85
1.11 END COMMUNICATION...85
2. ECU SELECTION...86
2.1 GENERAL...86
2.2 RECOGNITION OF ECUS...86
2.3 IDENTIFICATION DATA...86
3 MEASURED VALUES...87
3.1 ACTUAL MEASURED VALUES (GENERAL)...87
3.2 RAM VALUES...91
3.3 DATA LOGGER (ONLY EMS)...91
3.4 INPUT/OUTPUT ASSIGNMENT...91
3.5 CAN-Status...91
3.6 EXAMPLE OF A DISPLAYED ERROR INFORMATION:...93
4. PARAMETERS...93
4.1 CONFIGURATION...93
4.2 OVERALL PROGRAMMING...105
4.3 CALIBRATION...105
5. ERROR MEMORY...107
5.1 GENERAL...107
6. FUNCTION TEST...112
6.1 GENERAL...112
7. EXTRAS...113
7.1 MAXIMUM VEHICLE SPEED...113
7.2 LOGISTIC DATA...113
7.3 LOAD SPECTRUM (ONLY EMS)...114
7.4 MAINTENANCE INTERVAL EXCEEDED (ONLY EMS)...114
7.5 OVERRIDE MEMORY (ONLY EMS)...114
8 WHAT SHOULD YOU DO IF ...?...115
8.1 SERDIA IN GENERAL...115
8.2 EMR...118
9. SERDIA UPGRADE FROM VERSION 2.5 TO VERSION 3.1...130
9.1 IMPROVEMENTS AND HELP WITH PROBLEMS IN COMMUNICATING WITH NOTEBOOKS/WIN 98...130
9.2 NEW ENTRY MASK WITH MEASURED VALUES AND COLOURED-CODED INDICATION OF CONNECTION STATUS...131
9.3 NEW SWITCH “JOBS“ FOR PERFORMING SELECTED SERVICING OPERATIONS, E.G. ADJUSTING CONTROLLER OR ADJUSTING OFFSET...132
9.4 IN- AND OUTPUT ASSIGNMENT IS NOW ADDITIONALLY CONFIGURABLE USING PLAIN TEXT (PREVIOUSLY ONLY CODE NUMBERS)...133
9.5 UPGRADES IN "PARAMETER SETTING/CONFIGURATION“...133
OPERATOR’S MANUAL EDS (Electronic Diagnosis System)...134
1. GENERAL INTRODUCTION...135
1.1 FUNCTIONAL SCOPE...135
1.2 HARDWARE REQUIREMENTS...136
1.3 STARTING THE EDS PROGRAM...138
2. TRANSMISSION DIAGNOSIS...139
2.1 THE MAIN MENU...139
2.2 ONLINE HELP...142
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45...144
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45...144
3.2 DEST 45 PROGRAM DESCRIPTION...145
3.3 ERROR CODES POWER-SHUTTLE /DEST 45...160
3.4 DISPLAY POWERSHUTTLE...161
3.5 ERROR CODE LIST WITH DESCRIPTION...162
3.6 OTHER INFORMATIONS...173
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100...174
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100...175
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200...176
3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300...177
3.11 ERROR ANALYSIS...178
4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER...180
4.1 PROGRAM DESCRIPTION...181
4.2 CONSTANT VALUES FOR INFOCENTER...191
ALL ROUND TESTER MANUAL - MK3 80-105 SERIES...196
1. MONITOR...198
1.1 LIFT...198
1.2 CONSOLE...200
1.3 ASM...200
1.4 POWER...201
1.5 SENSORS...202
2. PARAMETERS...202
2.1 SPEED CONSTANTS...203
2.2 OPTIONS...203
3. CALIBRATIONS...204
3.1 MINIMUM HEIGHT...205
3.2 MAXIMUM HEIGHT...205
3.3 LOCK SPEED...206
3.4 WHEELSLIP...206
3.5 TRANSPORT...207
3.6 STOP...207
3.7 CONTROL...208
3.8 FLOAT...208
4. ALARMS LIST...209
SECTION 30...212
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING...216
TOP VIEW OF WIRING AND PIPES...217
VIEW OF UPPER WIRING AND PIPES...218
PIPES ON RIGHT-HAND SIDE...219
TOP VIEW OF REAR PIPES...220
DETAIL OF AIR TRAILER BRAKING SYSTEM...221
ENGINE HOOD AND LAMP ASSEMBLIES...222
REMOVAL AND ADJUSTMENT...222
REFITTING AND ADJUSTMENT...224
BATTERY...225
REMOVAL...225
REFITTING...226
CAB ACCESS STEPS...227
REMOVAL...227
REFITTING...227
BATTERY SUPPORT...228
REMOVAL...228
REFITTING...228
STARTER MOTOR...229
REMOVAL...229
REFITTING...229
ALTERNATOR...230
REMOVAL...230
REFITTING...230
ALTERNATOR DRIVEBELT...231
RENEWAL AND TENSIONING...231
FAN...234
REMOVAL...234
REFITTING...236
COMPRESSOR DRIVEBELT...237
RENEWAL...237
AIR COMPRESSOR (for air trailer braking)...239
REMOVAL...239
REFITTING...241
AIR RESERVOIRS (for version with air trailer braking only)...242
REMOVAL...242
REFITTING...242
AIR BRAKING SYSTEM VALVES...243
REMOVAL...243
REFITTING...245
TRAILER AIR BRAKES COUPLING HEADS...246
REMOVAL...246
REFITTING...246
HYDRAULIC TRAILER BRAKING VALVES...247
REMOVAL...247
REFITTING...248
AIR CONDITIONING SYSTEM...249
TECHNICAL SPECIFICATIONS...249
OPERATION...250
MAINTENANCE...251
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT...251
DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM...252
AIR CONDITIONING COMPRESSOR...254
REMOVAL...254
REFITTING...255
RECEIVER-DRIER...256
REMOVAL...256
REFITTING...256
CONDENSER ASSEMBLY (The figures depict models with 6-cylinder engines)...257
REMOVAL...257
REFITTING...257
GEARBOX OIL/FUEL COOLERS...258
REMOVAL...258
REFITTING...259
RADIATOR...260
REMOVAL...260
REFITTING...261
EXPANSION TANK...262
REMOVAL...262
REFITTING...262
INTERCOOLER (4-cylinder models)...263
REMOVAL...263
REFITTING...264
COMPLETE RADIATOR/COOLERS ASSEMBLY...265
REMOVAL...265
REFITTING...268
FLEXIBLE COUPLING OF THE FRONT PTO...269
RENEWAL...269
REFITTING...271
TURBOCHARGER...272
REMOVAL...272
REFITTING...272
AIR INLET PIPE...273
REMOVAL...273
REFITTING...273
AIR CLEANER...274
REMOVAL...274
REFITTING...275
EXHAUST PIPE...276
REMOVAL...276
REFITTING...276
SILENCER...277
REMOVAL...277
REFITTING...277
4WD PROPELLER SHAFT (Version without front suspension)...278
REMOVAL...278
REFITTING...279
4WD PROPELLER SHAFT (Version with front suspension)...280
REMOVAL...280
REFITTING...282
BRAKE MASTER CYLINDERS...283
REMOVAL...283
REFITTING...284
BLEEDING THE BRAKING SYSTEM...285
BRAKE LIGHT SWITCHES...287
ADJUSTMENT...287
POWER STEERING UNIT...288
1. Testing...288
2. Adjustment...288
REMOVAL...289
REFITTING...289
DISMANTLING...290
ASSEMBLY...297
FRONT WHEELS...307
REMOVAL...307
REFITTING...307
FRONT FENDERS...308
REMOVAL...308
REFITTING...308
REAR WHEELS...309
REMOVAL...309
REFITTING...309
LIFT VALVE BLOCK...310
REMOVAL...310
REFITTING...310
FRONT LIFT CYLINDERS...311
REMOVAL...311
REFITTING...312
FRONT LIFT ASSEMBLY...313
REMOVAL...313
REFITTING...315
FRONT PTO ASSEMBLY...316
REMOVAL...316
REFITTING...316
FRONT SUSPENSION CYLINDERS (Where fitted)...317
REMOVAL...317
REFITTING...319
DISASSEMBLY AND ASSEMBLY...320
FRONT AXLE AND SWINGING SUPPORT (Versions with front suspension)...322
REMOVAL...322
REFITTING...324
FRONT SUSPENSION VALVES...325
REMOVAL...325
REFITTING...325
FRONT SUSPENSION POSITION SENSOR...326
1. Removal...326
2. Positioning...326
3. Testing...327
REINFORCING SIDE MEMBERS (For versions with front lift only)...328
REMOVAL...328
REFITTING...328
FRONT CARRIER (Versions with front suspension)...329
REMOVAL...329
REFITTING...329
ACCELERATOR POTENTIOMETER...330
RENEWAL...330
REFITTING...330
FUEL TANK...331
REMOVAL...331
REFITTING...332
GEARBOX GEAR PUMP...333
REMOVAL...333
REFITTING...334
POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS...337
REMOVAL...337
REFITTING...339
SUPPLY VALVE FOR THE FRONT SUSPENSION CONTROL VALVE...340
REMOVAL...340
REFITTING...340
CONTROL VALVE ASSEMBLIES...341
REMOVAL...341
REFITTING...342
AUXILIARY CONTROL VALVE STACK...343
DISASSEMBLY...343
ASSEMBLY...344
LIFT CYLINDERS...345
REMOVAL...345
REFITTING...346
DISASSEMBLY AND ASSEMBLY...347
TESTING THE LIFT POSITION SENSOR...348
LIFT POSITION SENSOR...349
1. Removal of the position sensor...349
2. Renewal of the position sensor bush (only if necessary)...349
3. Refitting the position sensor...349
4. Position sensor adjustment...350
LIFT DRAFT SENSOR...352
REMOVAL...352
REFITTING...352
DRIVER'S SEAT...353
REMOVAL...353
REFITTING...353
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL...354
REMOVAL...354
REFITTING...355
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER...356
RENEWAL...356
ASSEMBLY...357
CENTRE CONSOLE AND SHROUD...358
REMOVAL...358
REFITTING...361
RIGHT-HAND CONSOLE...362
OPENING AND REMOVAL...362
REFITTING...368
LEFT-HAND CONSOLE...369
REMOVAL...369
REFITTING...370
LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS...371
REMOVAL...371
REFITTING...372
FUSE AND RELAY BOARD...373
REMOVAL...373
REFITTING...374
ENGINE ECU...375
REMOVAL...375
REFITTING...375
CLUTCH PEDAL AND RELATED DEVICES...376
1. Removal of the potentiometer...376
1.1. Refitting the potentiometer...376
2. Adjustment of the clutch pedal position and travel...377
3. Renewal of the proximity sensor...377
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO...378
REMOVAL...378
REFITTING...381
PTO ENGAGEMENT AND SELECTION CONTROL CABLES...382
REMOVAL (Figures refer to the speed selector)...382
REFITTING...383
AUXILIARY SERVICE VALVE CONTROL CABLES...385
RENEWAL...385
REFITTING...386
PARKING BRAKE SWITCH...387
ADJUSTMENT...387
CLIMATE CONTROL PANEL...388
REMOVAL...388
REFITTING...388
HEATER VALVE...389
1. Removal...389
2. Refitting and adjustment of the control cable...389
HEATER MATRIX...391
REMOVAL...391
REFITTING...393
AIR CONDITIONING EVAPORATOR...394
REMOVAL...394
REFITTING...395
RIGHT-HAND AIR CONDITIONING FAN...396
REMOVAL...396
REFITTING...396
LEFT-HAND AIR CONDITIONING FAN...397
REMOVAL...397
REFITTING...397
PARKING BRAKES...398
ADJUSTMENT...398
CAB DOOR CABLE...399
RENEWAL...399
TRAILER BRAKING AIR PRESSURE GAUGE...401
REMOVAL...401
REFITTING...401
TRANSMISSION STATUS DISPLAY...402
REMOVAL...402
REFITTING...402
CAB...403
REMOVAL...403
REFITTING...410
ENGINE AND TRANSMISSION...411
SEPARATING...411
ASSEMBLY...419
SECTION 40...420
THE STRUCTURE OF THE UNIT...422
HOW TO CONSULT THE UNIT...423
1. INTRODUCTION...424
1.1 LIST OF WIRING HARNESSES...424
1.2 DEFINITION OF COMPONENTS AND SYMBOLS...425
1.3 GENERAL RULES...425
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING...426
d. Renewal of damaged electrical components...427
1.4 DIAGNOSTIC INSTRUMENTS...427
1.5 WIRE COLOUR CODES...427
2. INDICES...428
2.1 COMPONENT DESCRIPTION INDEX...428
2.2 COMPONENT CODE INDEX...433
2.3 CONNECTOR INDEX...437
3. COMPONENTS...445
3.1 CONNECTOR LAYOUTS...445
3.2 COMPONENT TECHNICAL DATA...450
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS...458
4. SYSTEMS...468
4.1 EARTH POINTS...468
4.2 STARTING...469
4.3 PREHEATING...470
4.4 ELECTRICAL ENGINE CONTROL...471
4.5 LIGHTS - STEERING COLUMN SWITCH UNIT...472
4.6 CAB ACCESORIES...473
4.7 WORKLIGHTS...474
4.8 WINDSCREEN WIPERS...475
4.9 INFOCENTER...476
4.10 POWER OUTLET SOCKETS...477
4.11 RADIO - CB...478
4.12 AIR CONDITIONING - HEATER FANS...479
4.13 BRAKING SYSTEM...480
4.14 TRAILER BRAKES...481
4.15 FRONT AXLE SUSPENSION...482
4.16 TRASMISSION...483
4.17 ASM - 4WD - DIFFERENTIAL...484
4.18 ELECTRONIC LIFT...485
4.19 FRONT AND REAR PTO...486
4.20 CLEANFIX...487
5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS, CONNECTOR POSITIONS...488
ENGINE WIRING (KHD) (1/2)...490
ENGINE WIRING (KHD) (2/2)...491
ENGINE WIRING (4 CYLINDERS) (1/2)...496
ENGINE WIRING (4 CYLINDERS) (2/2)...497
ENGINE WIRING (6 CYLINDERS) (1/2)...498
ENGINE WIRING (6 CYLINDERS) (2/2)...499
CLEAN FIX WIRING...508
TRANSMISSION WIRING (1/2)...510
TRANSMISSION WIRING (2/2)...511
TRAILER BRAKING WIRING (ITALY)...520
TRAILER BRAKING WIRING (EXPORT)...521
FRONT AXLE SUSPENSION (CAB LINE) WIRING...524
CAB POWER SUPPLY WIRING...528
FRONT AXLE SUSPENSION WIRING...534
FENDER WIRING...540
NUMBER PLATE LIGHT WIRING...541
FRONT CONSOLE WIRING (1/2)...546
FRONT CONSOLE WIRING (2/2)...547
SIDE CONSOLE WIRING (1/3)...552
SIDE CONSOLE WIRING (2/3)...553
SIDE CONSOLE WIRING (3/3)...554
AIR CONDITIONING SYSTEM WIRING...564
DISPLAY WIRING...570
ROOF WIRING (1/2)...574
ROOF WIRING (2/2)...575
ROTATING BEACON WIRING...576
WORKLIGHTS WIRING...577
LIGHTS SELECTOR WIRING...584
ARMREST WIRING...588
CONTROL UNIT - FUSES - RELAYS (1/2)...590
CONTROL UNIT - FUSES - RELAYS (2/2)...591
Deutz-Fahr AGROTRON 80 MK3->6001, AGROTRON 90 MK3->6001, AGROTRON 100 MK3->6001, AGROTRON 105 MK3->6001 Workshop Manual...592
307.1117.3.6 AGROTRON 80 - 90 - 100 - 105 » 6001...592
INTRODUCTION...594
SAFETY NOTES...596
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS...599
LIFTING INSTRUCTIONS...601
HOW THE MANUAL IS STRUCTURED...602
HOW TO CONSULT THE MANUAL...603
HOW TO USE AND UPDATE THE MANUAL...604
STANDARD TIGHTENING TORQUES...605
1. NUTS AND BOLTS...605
2. FITTINGS...606
3. PLUGS...607
4. FITTINGS WITH SEAL AT 37...608
5. FITTINGS FOR PIPES WITH EYE ATTACHMENT...608
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS...609
CONVERSION FACTORS...611
SECTION 10...612
1. TRANSMISSION...614
INTRODUCTION...614
1.1 TRANSMISSION POWER SHUTTLE...615
1.1.1 MAIN COMPONENTS...615
1.1.2 TRANSMISSION HYDRAULIC SYSTEM...618
1.1.3 GEARBOX...619
GEARBOX COMPONENTS...620
1.1.4 MAIN CLUTCH...621
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE...622
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC...625
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC...626
1.2 REAR AXLE...628
1.3 REAR PTO...630
2. BRAKING SYSTEM...632
DESCRIPTION...632
2.1 BRAKE MASTER CYLINDER...633
2.2 BRAKE...634
2.3 TRAILER BRAKING SYSTEM...635
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)...635
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)...637
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)...639
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)...640
COMPRESSOR...641
PRESSURE LIMITING VALVE...642
TRAILER BRAKING VALVE (2-WAY)...643
TRAILER BRAKING VALVE (1-WAY)...644
3. HYDRAULIC FRONT AXLE SUSPENSION...645
DESCRIPTION...645
3.1 FRONT SUSPENSION CONTROL VALVE...646
4. FRONT AXLE...650
5. HYDRAULIC DIAGRAM...652
5.1 HYDRAULIC DIAGRAM (version with remote control valves without flow control)...652
5.2 HYDRAULIC DIAGRAM (version with remote control valves with flow control)...653
5.3 GEAR PUMP FOR TRANSMISSION ZF 7100...654
5.4 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING...655
5.5 POWER STEERING...656
5.6 AUXILIARY SERVICES CONTROL VALVE...657
5.6.1 TYPES OF CONTROL VALVE...658
5.6.2 SERVICES CONTROL SECTION...660
5.6.3 DESCRIPTIONS OF COMPONENTS...661
5.6.4 INLET MANIFOLD (CC version)...663
5.6.5 LIFT CONTROL VALVE SECTION...666
SECTION 20...670
1. DIAGNOSIS TOOLS “ALL ROUND TESTER”...672
1.1 ALL ROUND TESTER...672
1.1.1 DESCRIPTION OF THE KIT...672
1.1.2 NOTES ON CORRECT USE...673
1.1.3 DESCRIPTION OF THE TESTER...673
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER...674
1.1.5 SELECTION OF THE DISPLAY LANGUAGE...674
1.1.6 SETTING THE SERIAL PORTS...676
1.2 “SERDIA 3.5 LEVEL III” SOFTWARE...678
1.2.1 DESCRIPTION OF THE KIT...678
1.3 “EDS EST45” SOFTWARE...679
1.3.1 DESCRIPTION OF THE KIT...679
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS...680
2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND FRONT AXLE SUSPENSION CONTROL UNITS...680
2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 3.5” SOFTWARE TO THE ENGINE CONTROL UNIT...681
2.3 CONNECTING THE PORTABLE COMPUTER WITH “EDS” SOFTWARE TO THE TRANSMISSION CONTROL UNIT AND INFOCENTER...682
2.3.1 CONNECTION TO THE TRANSMISSION CONTROL UNIT...682
2.3.2 CONNECTION TO THE INFOCENTER...682
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR...684
3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)...684
3.2 TRANSMISSION CONTROL UNIT...686
3.3 POWER LIFT CONTROL UNIT...687
3.3.1 HYDRAULIC LIFT SYSTEM...687
3.3.2 ASM SYSTEM...688
3.4 INFOCENTER 2 or 3...689
3.5 FRONT AXLE SUSPENSION CONTROL UNIT...690
3.6 FRONT AND REAR PTO CONTROL UNIT...691
4. PUTTING THE TRACTOR INTO SERVICE...692
4.1 INTRODUCTION...692
4.2 RENEWAL OF THE ENGINE CONTROL UNIT...692
4.2.1 READING AND SAVING DATA...692
4.2.2 PROGRAMMING THE CONTROL UNIT...693
4.2.3 CALIBRATION OF THE ACCELERATOR PEDAL...694
4.2.4 CALIBRATION OF THE HAND THROTTLE...695
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT...696
4.3.1 SETTING THE TRACTOR VERSION AND SERIAL NUMBER...696
4.3.2 CALIBRATION OF THE CLUTCH PEDAL POSITION SENSOR...698
4.3.3 CALIBRATION OF THE MAIN CLUTCH PROPORTIONAL SOLENOID VALVE...700
4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT...702
4.4.1 PROGRAMMING THE TYPE OF TRACTOR...703
4.4.2 CONFIGURING NO RADAR STATUS...704
4.4.3 CALIBRATION OF THE LIFT POSITION SENSOR...705
4.4.4 CHECKING AND CALIBRATING THE LIFT CONTROL LEVER...707
4.5 RENEWAL OF THE INFOCENTER...710
4.5.1 ENTERING CONSTANTS...710
4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT...712
4.6.1 CHECKING CALIBRATION OF THE SUSPENSION POSITION SENSOR...712
5. ALARMS...714
5.1 LIFT AND ASM CONTROL UNIT ALARMS...714
5.1.1 LIST OF ALARMS BY EXTENDED CODE...715
5.1.2 LIST OF ALARMS BY STANDARD CODE...717
5.1.3 LIST OF ALARMS DISPLAYED ON ART...719
5.1.4 ANALYSIS OF LIFT AND ASM ALARMS...721
5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS...750
5.2.1 ABNORMALITIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT...750
5.2.2 ALARMS INDICATED ON THE TRANSMISSION DISPLAY AND BY THE EDS PROGRAM...750
5.2.3 DEFINITION OF TRANSMISSION OPERATING MODES...754
5.2.4 ANALYSIS OF ALARMS...755
5.3 LIST OF ALARMS DISPLAYED BY SERDIA...810
5.3.1 ALARMS DISPLAYED USING THE SERDIA PROGRAM...810
5.3.2 ANALYSIS OF ALARMS...812
5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS...832
5.4.1 LIST OF ALARMS BY TEXT CODE...832
5.4.2 LIST OF ALARMS BY STANDARD CODE...833
5.4.3 LIST OF ALARMS DISPLAYED BY ART...834
5.4.4 ANALYSIS OF ALARMS...835
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System)...848
1. GENERAL INTRODUCTION...848
1.1 FUNCTIONAL SCOPE...848
1.2 HARDWARE REQUIREMENTS...849
1.3 STARTING AND TERMINATING OF THE EDS PROGRAM...851
2. TRANSMISSION DIAGNOSIS...853
2.1 THE MAIN MENU...853
2.2 ONLINE HELP...855
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45...856
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45...856
3.2 DEST 45 PROGRAM DESCRIPTION...857
3.3 ERROR CODES POWER-SHUTTLE /DEST 45...872
3.4 DISPLAY POWERSHUTTLE...873
3.5 ERROR CODE LIST WITH DESCRIPTION...874
3.6 OTHER INFORMATIONS...885
3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100...886
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100...887
3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200...888
3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300...889
3.11 ERROR ANALYSIS...890
4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER...892
4.1 PROGRAM DESCRIPTION...893
4.2 CONSTANT VALUES FOR INFOCENTER...903
7. ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT...908
PRESENTATION SCREEN...908
MAIN MENU...908
1. MONITOR...909
1.1 LIFT...909
1.2 CONSOLE...911
1.3 ASM...911
1.4 POWER...912
1.5 SENSORS...913
2. CONFIGURATION...913
2.1 SPEED CONSTANTS...914
2.2 OPTIONS...914
3. CALIBRATIONS...915
3.1 MINIMUM HEIGHT...916
3.2 MAXIMUM HEIGHT...916
3.3 LOCK SPEED...917
3.5 TRANSPORT...918
3.6 STOP...918
3.7 CONTROL...919
3.8 FLOAT...919
4. ALARMS LIST...920
8. ALL ROUND TESTER FOR AXLE SUSPENSION CONTROL UNIT...922
PRESENTATION SCREEN...922
MAIN MENU...922
1. MONITOR...923
1.1 SUSPENSION...923
2. PARAMETERS...924
3. ALARMS LIST...926
4. CONFIGURATIONS...926
9. SERDIA (LEVEL III)...928
1. SETUP AND COMMUNICATIONS...928
1.1 MINIMUM EQUIPMENT REQUIRED...928
1.2 ORDERING...929
1.3 SWITCHING ON AND INSTALLING THE SOFTWARE...930
1.4 USING THE PROGRAM...934
1.5 CLOSING THE PROGRAM...937
2. ECU SELECTION...938
2.1 SELECTING TWO CONTROL UNITS...938
2.2 PRINTING...939
2.3 PROTOCOL...940
2.4 IDENTIFICATION AND MEASUREMENT DATA...940
3. MEASURED VALUES...942
3.1 ACTUAL MEASURED VALUES (GENERAL)...942
3.2 RAM-VALUES...947
3.3 DATA LOGGER (ONLY EMS2)...951
3.4 INPUT/OUTPUT ASSIGNMENT...951
3.5 CAN STATUS...951
4. PARAMETERS...954
4.1 CONFIGURATION (GENERAL)...954
4.2 OVERALL PROGRAMMING...955
4.2 CALIBRATION...956
5. ERROR MEMORY...957
5.1 GENERAL...957
5.2 ERROR TABLE...958
6. EXTRAS...968
6.1 MAXIMUM SPEED...968
6.2 LOGISTIC DATA...968
6.3 LOAD SPECTRUM...969
6.4 MAINTENANCE INTERVAL EXCEEDED...969
6.5 OVERRIDE MEMORY...969
6.6 MAINTENANCE DATA...969
7. TASKS...970
7.1 EMR1...970
8. WHAT TO DO IF...?...974
8.1 SERDIA GENERAL...974
8.2 EMR1...976
SECTION 30...988
METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING...992
TOP VIEW OF WIRING AND PIPES...993
VIEW OF UPPER WIRING AND PIPES...994
PIPES ON RIGHT-HAND SIDE...995
TOP VIEW OF REAR PIPES...996
DETAIL OF AIR TRAILER BRAKING SYSTEM...997
ENGINE HOOD AND LAMP ASSEMBLIES...998
Removal...998
Refitting...1001
BATTERY...1002
Removal...1002
Refitting...1003
CAB ACCESS STEPS...1004
Removal...1004
Refitting...1004
BATTERY SUPPORT...1005
Removal...1005
Refitting...1005
STARTER MOTOR...1006
Removal...1006
Refitting...1006
COMPRESSOR DRIVEBELT...1007
Renewal...1007
Tensioning...1007
AIR COMPRESSOR...1009
Removal...1009
Refitting...1011
FAN DRIVE BELT...1012
Renewal...1012
FAN...1014
Removal...1014
Renewal...1015
Refitting...1016
ALTERNATOR DRIVEBELT...1017
Renewal and tensioning...1017
ALTERNATOR...1020
Removal...1020
Refitting...1020
AIR RESERVOIRS...1021
(for version with air trailer braking only)...1021
Removal...1021
Refitting...1021
AIR BRAKING SYSTEM VALVES...1022
Removal...1022
Refitting...1024
TRAILER AIR BRAKES COUPLING HEADS...1025
Removal...1025
Refitting...1025
HYDRAULIC TRAILER BRAKING VALVES...1026
Removal...1026
Refitting...1027
AIR CONDITIONING SYSTEM...1028
Description...1028
Technical specifications...1028
Operation...1029
Maintenance...1030
Tension of the compressor drivebelt...1030
Discharging, flushing and recharging...1031
AIR CONDITIONING COMPRESSOR...1032
Removal...1032
Refitting...1033
RECEIVER-DRIER...1034
Removal...1034
Refitting...1034
CONDENSER ASSEMBLY...1035
Removal...1035
Refitting...1035
GEARBOX OIL/FUEL COOLERS...1036
Removal...1036
Refitting...1037
RADIATOR...1038
Removal...1038
Refitting...1039
EXPANSION TANK...1040
Removal...1040
Refitting...1040
INTERCOOLER...1041
Removal...1041
Refitting...1042
COMPLETE RADIATOR/COOLERS ASSEMBLY...1043
Removal...1043
Refitting...1045
FLEXIBLE COUPLING OF THE FRONT PTO...1046
Renewal...1046
Refitting...1049
TURBOCHARGER...1050
Removal...1050
Refitting...1051
AIR INLET PIPE...1052
Removal...1052
Refitting...1052
AIR CLEANER...1053
Removal...1053
Refitting...1054
EXHAUST PIPE...1055
Removal...1055
Refitting...1055
SILENCER...1056
Removal...1056
Refitting...1056
4WD PROPELLER SHAFT...1057
Removal...1057
Refitting...1058
4WD PROPELLER SHAFT...1059
Removal...1059
Refitting...1062
BRAKE MASTER CYLINDERS...1063
Removal...1063
Refitting...1064
BRAKING SYSTEM...1065
Bleeding...1065
BRAKE LIGHT SWITCHES...1067
Adjustment...1067
POWER STEERING UNIT...1068
Testing...1068
Adjustment...1068
Removal...1069
Refitting...1069
Dismantling...1070
Assembly...1077
FRONT WHEELS...1087
Removal...1087
Refitting...1087
FRONT FENDERS...1088
Removal...1088
Refitting...1088
REAR WHEELS...1089
Removal...1089
Refitting...1089
LIFT VALVE BLOCK...1090
Removal...1090
Refitting...1090
FRONT LIFT CYLINDERS...1091
Removal...1091
Refitting...1092
FRONT LIFT ASSEMBLY...1093
Removal...1093
Refitting...1095
FRONT PTO ASSEMBLY...1096
Removal...1096
Refitting...1096
FRONT SUSPENSION CYLINDERS...1097
Removal...1097
Refitting...1099
Disassembly...1100
Assembly...1101
FRONT AXLE AND SWINGING SUPPORT...1102
Removal...1102
Refitting...1104
FRONT SUSPENSION VALVES...1105
Removal...1105
Refitting...1105
FRONT SUSPENSION POSITION SENSOR...1106
Removal...1106
Positioning...1106
Testing...1107
REINFORCING SIDE MEMBERS...1108
Removal...1108
Refitting...1108
FRONT CARRIER...1109
Removal...1109
Refitting...1109
ACCELERATOR POTENTIOMETER...1110
Renewal...1110
Refitting...1110
FUEL TANK...1111
Removal...1111
Refitting...1111
GEARBOX GEAR PUMP...1112
Removal...1112
Refitting...1113
POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS...1116
Removal...1116
Refitting...1119
REMOTE CONTROL VALVES...1120
Removal...1120
Refitting...1124
Disassembly...1125
Assembly...1127
REMOTE CONTROL VALVES ASSEMBLY...1128
Removal...1128
Refitting...1131
LIFT CYLINDERS...1132
Removal...1132
Refitting...1133
Disassembly...1134
Assembly...1134
LIFT POSITION SENSOR...1135
Testing...1135
Renewal...1136
Refitting...1136
Adjusting...1137
LIFT DRAFT SENSOR...1139
Removal...1139
Refitting...1139
DRIVER'S SEAT...1140
Removal...1140
Refitting...1140
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL...1141
Removal...1141
Refitting...1142
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER...1143
Removal...1143
Refitting...1144
CENTRE CONSOLE AND SHROUD...1145
Removal...1145
Refitting...1148
RIGHT-HAND CONSOLE...1149
Removal e opening...1149
Refitting...1155
LEFT-HAND CONSOLE...1156
Removal...1156
Refitting...1157
LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS...1158
Removal...1158
Refitting...1159
FUSE AND RELAY BOARD...1160
Removal...1160
Refitting...1161
ENGINE ECU...1162
Removal...1162
Refitting...1162
CLUTCH PEDAL AND RELATED DEVICES...1163
Removal of the potentiometer...1163
Refitting the potentiometer...1163
Adjustment of the clutch pedal position and travel...1164
Renewal of the proximity sensor...1164
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO...1165
Removal...1165
Refitting...1168
PTO ENGAGEMENT AND SELECTION CONTROL CABLES...1169
Removal...1169
Refitting...1170
AUXILIARY SERVICE VALVE CONTROL CABLES...1172
Removal...1172
Refitting...1173
PARKING BRAKE SWITCH...1174
Adjustment...1174
CLIMATE CONTROL PANEL...1175
Removal...1175
Refitting...1175
HEATER VALVE...1176
Removal...1176
Refitting...1176
HEATER MATRIX...1178
Removal...1178
Refitting...1180
AIR CONDITIONING EVAPORATOR...1181
Removal...1181
Refitting...1182
RIGHT-HAND AIR CONDITIONING FAN...1183
Removal...1183
Refitting...1183
LEFT-HAND AIR CONDITIONING FAN...1184
Removal...1184
Refitting...1184
PARKING BRAKES...1185
Adjustment...1185
CAB DOOR CABLE...1186
Renewal...1186
TRAILER BRAKING AIR PRESSURE GAUGE...1188
Removal...1188
Refitting...1188
TRANSMISSION STATUS DISPLAY...1189
Removal...1189
Refitting...1189
CAB...1190
Removal...1190
Refitting...1197
ENGINE -TRANSMISSION...1198
Separation...1198
Reconnection...1200
SECTION 40...1202
THE STRUCTURE OF THE UNIT...1204
HOW TO CONSULT THE UNIT...1205
1. INTRODUCTION...1206
1.1 LIST OF WIRING HARNESSES...1206
1.2 DEFINITION OF COMPONENTS AND SYMBOLS...1207
1.3 GENERAL RULES...1207
1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/ELECTRONIC CIRCUITS...1207
1.3.2 MAIN WIRING FAULTS...1207
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING...1208
1.4 DIAGNOSTIC INSTRUMENTS...1209
1.5 WIRE COLOUR CODES...1209
2. INDICES...1210
2.1 INDEX BY PART DESCRIPTION...1210
2.2 INDEX BY PART CODE...1215
2.3 INDEX BY CONNECTOR...1219
3. COMPONENTS...1227
3.1 CONNECTOR LAYOUTS...1227
3.2 COMPONENT TECHNICAL DATA...1232
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS...1241
3.3.1 ENGINE CONTROL UNIT (0419.4998)...1241
3.3.2 TRANSMISSION CONTROL UNIT (0443.8083/10)...1243
3.3.3 INFOCENTER (0443.7488/10)...1246
3.3.4 HPSA CONTROL UNIT (2.8519.013.0)...1248
3.3.5 FRONT SUSPENSION CONTROL UNIT (2.8519.008.0/10)...1250
4. SYSTEMS...1252
4.1 GROUND POINTS...1252
4.2 ENGINE START...1253
4.3 PREHEATING...1254
4.4 ELECTRICAL ENGINE CONTROL...1255
4.5 LIGHTS - LIGHT SELECTOR SWITCH (MACHINE WITHOUT FRONT LIFT)...1256
4.6 LIGHTS - LIGHT SELECTOR SWITCH (MACHINE WITH FRONT LIFT)...1257
4.7 CAB ACCESSORY...1258
4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)...1259
4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT)...1260
4.10 WINDSCREEN WIPER...1261
4.11 INFOCENTER...1262
4.12 ELECTRICAL POWER SUPPLY...1263
4.13 RADIO - CB...1264
4.14 AIR CONDITIONING - HEATING FAN...1265
4.15 BRAKES...1266
4.16 TRAILER BRAKES...1267
4.17 FRONT AXLE SUSPENSION...1268
4.18 TRANSMISSION...1269
4.19 ASM - 4WD - DIFFERENTIAL...1270
4.20 REAR LIFTER...1271
4.21 FRONT AND REAR PTO...1272
5. WIRING...1274
ENGINE WIRING (4 CYLINDERS) (1/2)...1274
ENGINE WIRING (4 CYLINDERS) (2/2)...1275
ENGINE WIRING (6 CYLINDERS) (1/2)...1276
ENGINE WIRING (6 CYLINDERS) (2/2)...1277
ENGINE WIRING (1/2)...1282
ENGINE WIRING (2/2)...1283
TRANSMISSION WIRING (1/2)...1292
TRANSMISSION WIRING (2/2)...1293
TRAILER BRAKE WIRING (ITALY)...1302
TRAILER BRAKE WIRING...1303
FRONT AXLE SUSPENSION WIRING (CAB)...1306
CAB POWER SUPPLY WIRING...1310
FRONT AXLE SUSPENSION WIRING...1316
FENDER WIRING - NARROW...1320
NUMBER PLATE LIGHT WIRING...1321
FRONT CONSOLE WIRING (1/2)...1326
FRONT CONSOLE WIRING (2/2)...1327
SIDE CONSOLE WIRING (1/2)...1332
SIDE CONSOLE WIRING (2/2)...1333
AIR CONDITIONING WIRING (CAB)...1342
DISPLAY WIRING...1348
ROOF WIRING (1/2)...1352
ROOF WIRING (2/2)...1353
CAB ROOF FRONT AND REAR WORKLIGHTS WIRING...1362
CAB LOWER HEADLIGHTS WIRING...1360
WINDSCREEN WIPER MOTOR WIRING...1360
CAB LOWER FRONT WORKLIGHTS WIRING (MACHINE WITHOUT FRONT LIFT)...1361
CAB LOWER FRONT WORKLIGHTS WIRING (WITH FRONT LIFT)...1361
LIGHTS SELECTOR SWITCH...1368
ARMREST WIRING...1372
FUSES AND RELAYS CONTROL UNIT (1/2)...1374
FUSES AND RELAYS CONTROL UNIT (2/2)...1375
Deutz-Fahr Tractors AGROTRON 80 MK3, AGROTRON 85 MK3, AGROTRON 90 MK3, AGROTRON 100 MK3, AGROTRON 105 MK3 Repair Service Manual
