Deutz-Fahr Tractors AGROTRON K90, AGROTRON K100, AGROTRON K110, AGROTRON K120 Profiline Repair Service Manuals
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Model:
Complete repair service manual with Electrical Wiring Diagrams for Deutz-Fahr AGROTRON K90 Profiline, AGROTRON K100 Profiline, AGROTRON K110 Profiline, AGROTRON K120 Profiline, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Deutz-Fahr Tractors AGROTRON K90/K100/K110/K120 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.
307.1132.3.6 - Deutz-Fahr AGROTRON K90 Profiline, AGROTRON K100 Profiline, AGROTRON K110 Profiline, AGROTRON K120 Profiline Workshop Manual.pdf
Deutz-Fahr AGROTRON K90 Profiline, AGROTRON K100 Profiline, AGROTRON K110 Profiline, AGROTRON K120 Profiline Workshop Manual.pdf
...
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 the user guides for the software needed to configure the machine and the engine and to read any fault diagnosis.
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
Engine DEUTZ 2012
Gearbox ZF T7100KT
Rear axle 7100
0312 0361 Spanish
AGROTRON K 90
AGROTRON K 100
AGROTRON K 110
AGROTRON K 120
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 the user guides for the software needed to configure the machine and the engine and to read any fault diagnosis.
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.
ATTENTION!
The manual does not contain information and instructions regarding the engine and transmission, which can be found in the following manuals:
Engine DEUTZ 2012
Gearbox ZF T7100KT
Rear axle 7100
307.1132.3.6 - Deutz-Fahr AGROTRON K90 Profiline, AGROTRON K100 Profiline, AGROTRON K110 Profiline, AGROTRON K120 Profiline Workshop Manual...2
307.1132.3.6 AGROTRON K 90-100-110-120 PROFILE Ing...2
SECTION 00...4
INTRODUCTION...5
SAFETY NOTES...7
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS...10
LIFTING INSTRUCTIONS...12
WIRE ROPES - SLINGS...12
HOW THE MANUAL IS STRUCTURED...13
HOW TO CONSULT THE MANUAL...14
1. Removal and refitting of assembled units...14
3. List of special tools...14
4. Tightening torques...14
HOW TO USE AND UPDATE THE MANUAL...15
1. UPDATING THE MANUAL...15
2. INSERTING UPDATES...15
3. SYMBOLS USED IN THE MANUAL...15
TIGHTENING TORQUES...16
1. BOLTS AND NUTS...16
2. FITTINGS...17
3. PLUGS...18
4. FITTINGS WITH SEAL AT 37...19
5. FITTINGS FOR PIPES WITH BANJO UNION...19
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS...20
CONVERSION FACTORS...22
CONVERSION FROM BRITISH TO METRIC UNITS...22
CONVERSION FROM METRIC TO BRITISH UNITS...22
SECTION 10...23
1. TRANSMISSION...0
INTRODUCTION...25
1.1 POWER SHUTTLE TRANSMISSION...26
1.1.1 MAIN COMPONENTS...26
1.1.2 TRANSMISSION HYDRAULIC SYSTEM...29
1.1.3 GEARBOX...30
1.1.4 MAIN CLUTCH...32
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE CONTROL VALVE...33
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC...36
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC...37
1.2 REAR AXLE...39
1.3 REAR PTO...41
2. BRAKING SYSTEM...43
DESCRIPTION...43
2.1 BRAKE MASTER CYLINDER...44
2.2 BRAKE...45
2.3 TRAILER BRAKING SYSTEM...46
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)...46
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)...48
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)...50
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)...51
COMPRESSOR...52
ANTIFREEZE PUMP...53
PRESSURE LIMITING VALVE...54
TRAILER BRAKING VALVE (2-WAY)...55
TRAILER BRAKING VALVE (1-WAY)...56
3. HYDRAULIC FRONT AXLE SUSPENSION...57
DESCRIPTION...57
3.1 FRONT SUSPENSION CONTROL VALVE...58
4. FRONT AXLE...63
5. HYDRAULIC SYSTEM...64
DESCRIPTION...64
5.2 GEAR PUMP FOR TRANSMISSION ZF 7100...67
5.3 VARIABLE DISPLACEMENT PUMP...68
5.3.1 HYDRAULIC PUMP...71
5.3.2. LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE...73
5.4 STEERING GEAR PUMP...81
5.5 POWER STEERING...82
5.6 AUXILIARY SERVICES CONTROL VALVE...83
5.6.1 CONTROL VALVE TYPES...84
5.6.2 LIFT CONTROL ELEMENT...86
CONTENTS...23
SECTION 20...91
1. DIAGNOSIS TOOLS...93
1.1 ALL ROUND TESTER...93
1.1.1 DESCRIPTION OF THE KIT...93
1.1.2 NOTES ON CORRECT USE...94
1.1.3 DESCRIPTION OF THE TESTER...94
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER...95
1.1.5 SELECTION OF THE DISPLAY LANGUAGE...95
1.1.6 SETTING THE SERIAL PORTS...97
1.2 “SERDIA 2000 LEVEL III" SOFTWARE...99
1.2.1 DESCRIPTION OF THE KIT...99
1.3 “EDS EST45” SOFTWARE”...100
1.3.1 DESCRIPTION OF THE KIT...100
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS...101
2.1 CONNECTING ART® TO THE HLHP CONTROL UNITS...101
2.2 CONNECTING THE LAPTOP COMPUTER WITH “SERDIA 2000” SOFTWARE TO THE ENGINE CONTROL UNIT...102
3. INTRODUCTION TO THE TRACTOR ELECTRONIC SYSTEM...103
3.1 ELECTRONIC SYSTEM...103
3.2 CANBUS SYSTEM...104
3.3 TRANSMISSION CONTROL UNIT...112
3.4 INFOCENTER...113
4. PUTTING THE TRACTOR INTO SERVICE...115
4.1 INTRODUCTION...115
4.2 RENEWING THE ENGINE CONTROL UNIT...115
4.2.1 READING AND SAVING DATA...115
4.2.2 PROGRAMMING THE CONTROL UNIT...116
4.2.3 PROCEDURE FOR SETTING ENGINE OPERATING HOURS...117
4.2.4 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE SERDIA PROGRAM)...118
4.2.5 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE ART)...119
4.2.6 CALIBRATION OF THE HAND THROTTLE (USING THE SERDIA PROGRAM)...120
4.2.7 CALIBRATION OF THE HAND THROTTLE (USING THE ART)...121
4.3 RENEWING THE TRANSMISSION CONTROL UNIT...124
4.3.1 MODEL CONFIGURATION...124
4.3.2 CONFIGURATION OF THE BASIC WHEEL...127
4.3.3 CONFIGURATION OF THE WHEEL CIRCUMFERENCE (USING THE ART)...129
4.3.4 CALIBRATION OF THE WHEEL CIRCUMFERENCE (WITHOUT USING THE ART)...131
4.3.5 CONFIGURATION OF THE MAXIMUM TRAVEL SPEED (GERMAN MARKET ONLY)...132
4.3.6 CALIBRATION OF THE CLUTCH PEDAL...134
4.3.7 CALIBRATION OF THE MAIN CLUTCH...136
4.3.8 CALIBRATION OF THE FIELD/ROAD SENSOR...138
4.3.9 CLEARING ALL ALARMS...140
4.4 RENEWING THE HLHP CONTROL UNIT (VALID UP TO SOFTWARE SC.0038.AC)...141
4.4.1 INITIALIZATION OF THE HLHP CONTROL UNIT...141
4.4.2 CONFIGURING THE SYSTEM FOR THE PRESENCE OF THE FRONT PTO (ONLY IF INSTALLED)...143
4.4.3 ENABLING THE ASM SYSTEM (ONLY IF INSTALLED)...144
4.4.4 CALIBRATION OF THE STEERING ANGLE SENSOR (WITH ASM ONLY)...146
4.4.5 CONFIGURING THE SYSTEM FOR THE PRESENCE OF RADAR (ONLY IF INSTALLED)...147
4.4.6 CALIBRATION OF THE HIGH AND LOW POSITIONS OF THE LIFT...149
4.4.7 CONFIGURING THE SYSTEM FOR THE PRESENCE OF FRONT AXLE SUSPENSION (ONLY IF INSTALLED)...151
4.4.8 SETTING THE INFOCENTER DISPLAY LANGUAGE...153
4.4.9 CLEARING ALL ALARMS...154
4.5 RENEWING THE HLHP CONTROL UNIT (VALID UP TO SOFTWARE SC.0038.AD)...156
4.5.1 INITIALIZATION OF THE HLHP CONTROL UNIT...156
4.5.2 CONFIGURATION OF THE TRACTOR MODEL...158
4.5.3 CONFIGURING THE SYSTEM FOR THE PRESENCE OF THE FRONT PTO (ONLY IF INSTALLED)...159
4.5.4 ENABLING THE ASM SYSTEM (ONLY IF INSTALLED)...160
4.5.5 CALIBRATION OF THE STEERING ANGLE SENSOR (WITH ASM ONLY)...162
4.5.6 CONFIGURING THE SYSTEM FOR THE PRESENCE OF RADAR (ONLY IF INSTALLED)...163
4.5.7 CALIBRATION OF THE HIGH AND LOW POSITIONS OF THE LIFT...165
4.5.8 CONFIGURING THE SYSTEM FOR THE PRESENCE OF FRONT AXLE SUSPENSION (ONLY IF INSTALLED)...167
4.5.9 SETTING THE INFOCENTER DISPLAY LANGUAGE...169
4.5.10 CONFIGURE THE ASSOCIATION BETWEEN CONTROL VALVE LEVERS AND AUXILIARY SERVICES (FOR VERSIONS WITH 4 CONTROL VALVES ONLY)...170
4.5.11 CLEARING ALL ALARMS...172
4.6 RENEWAL OF THE ARMREST CONTROL UNIT...173
5. ALARMS...179
INTRODUCTION...179
5.1 ALARMS DISPLAYED ON THE INFOCENTER...180
5.2 HLHP CONTROL UNIT ALARMS...191
5.3 ENGINE CONTROL UNIT ALARMS...263
5.6 CANBUS ALARMS...287
5.4 TRANSMISSION CONTROL UNIT ALARMS...297
5.4.1 DEFINITION OF TRANSMISSION OPERATING MODES...297
5.4.2 SYSTEM ANOMALIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT...298
5.5 ARMREST ALARMS...379
6. ENGINE CONTROL UNIT TESTER PROGRAM...389
6. 1 ACCESS AND COMUNICATION...389
6. 1.1 MINIMUM RESOURCES...389
6. 1.2 ORDERING...389
6. 1.3 CONNECTION OF NOTEBOOK AND SOFTWARE INSTALLATION...390
6. 1.4 PROGRAM COMMANDS...394
6. 1.5 END COMMUNICATION...396
6. 2 CONTROL UNIT SELECTION...397
6. 2.1 SELECTION OF TWO CONTROL UNITS...397
6. 2.2 PRINT (EXPORT)...398
6. 2.3 PROTOCOL...399
6. 2.4 IDENTIFICATION AND MEASUREMENT DATA...399
6. 3 MEASUREMENT VALUES...400
6. 3.1 CURRENT VALUES (IN GENERAL)...400
6. 3.2 RAM VALUES...404
6. 3.3 INPUT/OUTPUT CONFIGURATION...409
6. 3.4 CAN STATUS...409
6. 4 PARAMETERS...412
6. 4.1 CONFIGURATION (GENERAL)...412
6. 4.2 COMPLETE PROGRAMMING...413
6. 4.3 CALIBRATION...414
6. 5 FAULTS MEMORY...415
6. 5.1 GENERAL INFORMATION...415
6. 6 EXTRA...417
6. 6.1 TOP SPEED...417
6. 6.2 LOGISTIC DATA...417
6. 6.3 LOADS COLLECTIVE...418
6. 7 ACTIVITY...419
6. 7.1 EMR2...419
6. 8 WHAT TO DO IF...?...423
6. 8.1 SERDIA IN GENERAL...423
6. 8.2 EMR2...424
Definition of parameters...427
Configuration...427
SECTION 30...0
CONTENTS...435
ENGINE HOOD...439
Removal...439
Refitting...439
WHEELS...440
FRONT WHEELS...440
Removal...440
Refitting...440
REAR WHEELS...441
Removal...441
Refitting...441
FRONT FENDERS...442
Removal...442
Refitting...442
CAB ACCESS STEPS...443
Removal...443
Refitting...443
FUEL TANK...444
Removal...444
Refitting...446
COOLERS-RADIATOR ASSEMBLY...447
COMPLETE ASSEMBLY...447
Removal...447
Refitting...451
FUEL COOLER...452
Removal...452
Refitting...452
TRANSMISSION OIL COOLER...453
Removal...453
Refitting...454
ENGINE COOLING SYSTEM RADIATOR...455
Removal...455
Refitting...458
AIR FILTER ASSEMBLY...459
Removal...459
Refitting...459
INTERCOOLER...460
Removal...460
Refitting...460
AIR CONDITIONING SYSTEM...461
TECHNICAL SPECIFICATIONS...461
Operation...462
Evacuation, flushing and recharging...463
1. Emptying the system...463
2. Flushing and recharging the system...463
FILTER - DRIER...465
Removal...465
Refitting...465
CONDENSER ASSEMBLY...466
Removal...466
Refitting...466
COMPRESSOR...467
Removal...467
Refitting...468
HEATER ASSEMBLY (MANUAL VERSION)...469
COMPLETE ASSEMBLY...469
Removal...469
Refitting...471
UPPER HALF DUCT...472
Assembly...472
FANS...473
Disassembly...473
Assembly...473
HEATER MATRIX...474
Disassembly...474
Assembly...474
AIR CONDITIONING EVAPORATOR...475
Disassembly...475
Assembly...475
ENGINE COOLING FAN ASSEMBLY...476
ENGINE COOLING FAN...476
Removal...476
Refitting...477
ENGINE FAN DRIVE BELT...478
Removal...478
Refitting...479
Tensioning...480
ALTERNATOR ASSEMBLY...481
ALTERNATOR...481
Removal...481
Refitting...481
ALTERNATOR DRIVEBELT...482
Removal...482
Refitting...483
Tensioning...484
STARTER MOTOR...485
Removal...485
Refitting...485
COMPRESSED AIR CIRCUIT...486
AIR COMPRESSOR...486
Removal...486
Refitting...487
COMPRESSOR DRIVE BELT...488
Removal...488
Refitting...488
Tensioning...489
FRONT PTO...490
ASSEMBLY...490
Removal...490
Refitting...490
FLEXIBLE COUPLING...491
Renewal...491
Refitting...491
FRONT AXLE DRIVE SHAFT...492
Removal...492
Refitting...494
FRONT AXLE...495
VERSION WITHOUT AXLE SUSPENSION...495
Removal...495
Refitting...496
VERSION WITH AXLE SUSPENSION...497
Removal...497
Refitting...500
FRONT SUPPORT...501
COMPLETE ASSEMBLY (Version without axle suspension)...501
Removal...501
Refitting...502
COMPLETE ASSEMBLY (Version with axle suspension)...503
Removal...503
Refitting...505
FRONT AXLE SUSPENSION...506
FRONT SUSPENSION CONTROL VALVE...506
Removal...506
Refitting...509
FRONT SUSPENSION POSITION SENSOR...510
Removal...510
Positioning...510
Checking...511
FRONT SUSPENSION CYLINDERS...512
Removal...512
Refitting...514
Disassembly...515
Assembly...516
BRAKE CYLINDERS...517
Removal...517
Refitting...519
POWER STEERING PUMP...520
STEERING VALVE ASSEMBLY...520
Removal...520
Refitting...522
Disassembly...523
Assembly...528
RELIEF VALVE...538
Testing the operating pressure...538
Adjusting the calibration...538
BATTERY SUPPORT...539
Removal...539
Refitting...540
HYDRAULIC PUMPS...541
TRANSMISSION PUMP...541
Removal...541
Refitting...543
SERVICES PUMP...546
Removal...546
Refitting...549
STEERING PUMP...550
Removal...550
Refitting...551
EXHAUST SYSTEM...552
SILENCER...552
Removal...552
Refitting...552
EXHAUST PIPE...553
Removal...553
Refitting...554
CAB...555
Removal...555
Refitting...563
ENGINE...564
Preparation for removal...564
Preparation before separating the engine from the transmission...564
Separation or removal...565
Refitting...569
TORSIONAL SPRING PLATE...570
Removal...570
Refitting...570
FLOOR MAT...571
Removal...571
Refitting...571
MULTIFUNCTION ARMREST...572
Removal...572
Refitting...572
SEAT...573
Removal...573
Refitting...573
ACCELERATOR PEDAL POTENTIOMETER...574
Removal...574
Refitting...575
RIGHT-HAND CONSOLE...576
Removal...576
Refitting...578
CREEPER...579
CONTROL CABLES...579
Removal...579
Refitting...580
REAR PTO SPEED SELECTOR LEVER...581
Removal...581
Refitting...582
GEARSHIFT CONTROL...583
Removal...583
Refitting...584
PARKING BRAKE...585
CONTROL CABLE...585
Removal...585
Refitting...586
PARKING BRAKE LEVER...587
Adjustment...587
SERVICE BRAKE...588
BRAKE DEVICE...588
Adjustment...588
STEERING WHEEL...589
Removal...589
Refitting...589
SHUTTLE LEVER...590
Removal...590
Refitting...591
LIGHTS SELECTOR SWITCH...592
Removal...592
Refitting...593
FRONT CONSOLE...594
Removal...594
Refitting...596
CLUTCH PEDAL AND ACCESSORIES...597
POSITION SENSOR...597
Removal...597
Refitting...597
PROXIMITY SENSOR (Clutch pedal depressed sensor)...600
Removal...600
Refitting...600
CAB DOOR LATCH CABLE...601
Renewal...601
LIFT DRAFT SENSOR...603
Removal...603
Refitting...603
LIFT POSITION SENSOR...604
Checking...604
Removal...604
Renewal of the position sensor bush (only if necessary)...605
Refitting...605
Adjustment...605
AUXILIARY SERVICES CONTROL VALVE...607
Removal...607
Refitting...610
Disassembly...611
Assembly...612
SECTION 40...613
STRUCTURE OF THE UNIT...615
HOW TO CONSULT THE UNIT...616
1. INTRODUCTION...617
1.1 LIST OF WIRING HARNESSES...617
1.2 DEFINITION OF COMPONENTS AND SYMBOLS...618
1.3 GENERAL RULES...619
1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/ELECTRONIC CIRCUITS...619
1.3.2 MAIN WIRING FAULTS...619
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING...620
1.4 DIAGNOSTIC INSTRUMENTS...621
1.5 WIRE COLOUR CODES...621
2. INDEXES...622
2.1 INDEX BY PART DESCRIPTION...622
2.2 INDEX BY PART CODE...628
2.3 INDEX BY CONNECTOR...634
3. COMPONENTS...643
3.1 COMPONENT TECHNICAL DATA...643
3.2 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS...650
3.2.1 ENGINE CONTROL UNIT (0421.3098)...650
3.2.2 TRANSMISSION CONTROL UNIT (2.8519.028.0)...652
3.2.3 HLHP CONTROL UNIT (P/N 2.8519.027.0/10)...654
3.2.4 INFOCENTER...657
4. SYSTEMS...659
4.1 EARTHING POINTS...659
4.2 STARTING...660
4.3 PREHEATING...661
4.4 ELECTRONIC ENGINE CONTROL...662
4.5 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITHOUT FRONT LIFT)...663
4.6 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH FRONT LIFT)...664
4.7 DIAGNOSTICS ACCESSORIES...665
4.8 WORKLIGHTS (VERSION WITHOUT DEMISTING MIRRORS)...666
4.9 WORKLIGHTS (VERSION WITH DEMISTING MIRRORS)...667
4.10 WINDSCREEN WIPERS...668
4.11 INSTRUMENT PANEL...669
4.12 RADIO...670
4.13 MANUAL AIR CONDITIONER...671
4.14 BRAKES...672
4.15 FRONT AXLE SUSPENSION...673
4.16 TRANSMISSION...674
4.17 ASM - 4WD - DIFFERENTIAL...675
4.18 ELECTRONIC LIFT...676
4.19 FRONT AND REAR PTO...677
4.20 DIRECTIONAL CONTROL VALVES...678
4.21 CAN BUS...679
5. WIRING LOOMS...681
ENGINE WIRING (4 CYLINDERS) (1/2)...681
ENGINE WIRING (4 CYLINDERS) (2/2)...682
ENGINE WIRING (6 CYLINDERS) engine serial number-> 0109278 (1/2)...683
ENGINE WIRING (6 CYLINDERS )(2/2) engine serial number -> 0109278...684
ENGINE WIRING (6 CYLINDERS) engine serial number 10063954 -> (1/2)...685
ENGINE WIRING (6 CYLINDERS) (2/2) engine serial number 10063954->...686
ENGINE HOOD WIRING...691
FRONT WORKLIGHTS WIRING...692
RIGHT-HAND TRANSMISSION WIRING (1/2)...695
RIGHT-HAND TRANSMISSION WIRING (2/2)...696
LEFT-HAND TRANSMISSION WIRING (1/2)...705
LEFT-HAND TRANSMISSION WIRING (2/2)...706
CONTROL VALVES WIRING 2/4...707
TRAILER BRAKE WIRING (ITALY)...717
TRAILER BRAKE WIRING (GERMANY)...719
FRONT AXLE SUSPENSION WIRING...721
BATTERY POSITIVE WIRING - BATTERY NEGATIVE WIRING...724
POWER SUPPLY WIRING (1/2)...725
POWER SUPPLY WIRING (2/2)...726
CAB EARTH WIRING...727
INSTRUMENT PANEL WIRING (1/2)...732
INSTRUMENT PANEL WIRING (2/2)...733
FENDERS WIRING...734
WIRING FOR LIGHTS ON ARMS...735
WIRING FOR SUPPLEMENTARY LIGHTS ON ARMS...736
UPPER LIGHTS WIRING (VERSION WITH LIFT)...737
WIRING FOR WORKLIGHTS ON ARMS (VERSION WITHOUT LIFT)...738
LIGHTS SELECTOR SWITCH WIRING...750
CENTRAL WIRING (1/2)...752
CENTRAL WIRING (2/2)...753
ENGINE WIRING...754
ROOF LINE WIRING (1/2)...762
ROOF LINE WIRING (2/2)...763
WIRING FOR WORKLIGHTS, DEFROST MIRROR ON CAB (HL VERSION)...764
WIRING FOR WORKLIGHTS ON CAB (STANDARD VERSION)...765
WINDSCREEN WIPER WIRING...766
ROTATING BEACON WIRING...767
Deutz-Fahr AGROTRON K90 Profiline, AGROTRON K100 Profiline, AGROTRON K110 Profiline, AGROTRON K120 Profiline Workshop Manual...779
INTRODUCTION...781
SAFETY NOTES...783
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTINGOPERATIONS...786
LIFTING INSTRUCTIONS...788
HOW THE MANUAL IS STRUCTURED...789
HOW TO CONSULT THE MANUAL...790
HOW TO USE AND UPDATE THE MANUAL...791
STANDARD TIGHTENING TORQUES...792
1. NUTS AND BOLTS...792
2. FITTINGS...793
3. PLUGS...794
4. FITTINGS WITH SEAL AT 37...795
5. FITTINGS FOR PIPES WITH EYE ATTACHMENT...795
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS...796
CONVERSION FACTORS...798
SECTION 10...799
1. TRANSMISSION...801
INTRODUCTION...801
1.1 POWER SHUTTLE TRANSMISSION...802
1.1.1 MAIN COMPONENTS...802
1.1.2 TRANSMISSION HYDRAULIC SYSTEM...805
1.1.3 GEARBOX...806
1.1.4 MAIN CLUTCH...808
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE CONTROL VALVE...809
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC...812
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC...813
1.2 REAR AXLE...815
1.3 REAR PTO...817
2. BRAKING SYSTEM...819
DESCRIPTION...819
2.1 BRAKE PUMP...820
2.2 BRAKE...821
2.3 TRAILER BRAKING SYSTEM...822
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)...822
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)...824
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)...826
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)...827
3. HYDRAULIC FRONT AXLE SUSPENSION...833
DESCRIPTION...833
3.1 FRONT SUSPENSION CONTROL VALVE...834
4. FRONT AXLE...839
5. HYDRAULIC SYSTEM...840
DESCRIPTION...840
5.1 HYDRAULIC DIAGRAM (standard version)...841
5.2 HYDRAULIC DIAGRAM (full version)...842
5.3 GEAR PUMP FOR TRANSMISSION ZF 7100...843
5.4 GEAR PUMP FOR SERVICES AND STEERING...844
5.5 POWER STEERING...845
5.6 AUXILIARY SERVICES CONTROL VALVE...846
5.7 FRONT LIFT MECHANISM SOLENOID VALVE...847
5.8 LIFT CONTROL ELEMENT...848
5.9 PRIORITY VALVE FOR FRONT AXLE SUSPENSION...849
SECTION 20...851
1. DIAGNOSIS TOOLS...853
1.1 ALL ROUND TESTER...853
1.1.1 DESCRIPTION OF THE KIT...853
1.1.2 NOTES ON CORRECT USE...854
1.1.3 DESCRIPTION OF THE TESTER...854
1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER...855
1.1.5 SELECTION OF THE DISPLAY LANGUAGE...855
1.1.6 SETTING THE SERIAL PORTS...857
1.2 "SERDIA 2000 LEVEL III" SOFTWARE...859
1.2.1 DESCRIPTION OF THE KIT...859
1.3 EDS EST45 SOFTWARE...860
1.3.1 DESCRIPTION OF THE KIT...860
2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS...861
2.1 CONNECTING THE ART TO THE HLHP CONTROL UNITS...861
2.2 CONNECTING THE PORTABLE COMPUTER WITH "SERDIA 2000" SOFTWARE TO THE ENGINE ECU...862
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR...863
3.1 ELECTRONIC SYSTEM...863
3.2 CANBUS SYSTEM...864
3.3 TRANSMISSION CONTROL UNIT...871
3.4 INFOCENTER...872
4. COMMISSIONING THE TRACTOR...873
4.1 INTRODUCTION...873
4.2 RENEWAL OF THE ENGINE CONTROL UNIT...873
4.2.1 READING AND SAVING DATA...873
4.2.2 PROGRAMMING THE CONTROL UNIT...874
4.2.3 PROCEDURE FOR SETTING THE ENGINE OPERATING HOURS...875
4.2.4 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE SERDIA PROGRAM)...876
4.2.5 CALIBRATION OF THE ACCELERATOR PEDAL (USING THE ART)...877
4.2.6 CALIBRATION OF THE HAND THROTTLE (USING THE SERDIA PROGRAMME)...878
4.2.7 CALIBRATION OF THE HAND THROTTLE (USING THE ART)...879
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT...882
4.3.1 CONFIGURATION OF THE MODEL...882
4.3.2 CONFIGURATION OF THE BASIC WHEEL...885
4.3.3 CONFIGURATION OF THE WHEEL CIRCUMFERENCE (USING THE ART)...887
4.3.4 CALIBRATION OF THE WHEEL CIRCUMFERENCE (WITHOUT USING THE ART)...889
4.3.5 CONFIGURATION OF THE MAXIMUM TRAVEL SPEED (FOR GERMAN MARKET ONLY)...890
4.3.6 CALIBRATION OF THE CLUTCH PEDAL...892
4.3.7 CALIBRATION OF THE MAIN CLUTCH...894
4.3.8 CALIBRATION OF THE FIELD/ROAD SENSOR...896
4.3.9 CANCELLATION OF ALL ALARMS...898
4.4 RENEWAL OF THE HLHP CONTROL UNIT...899
4.4.1 INITIALIZATION OF THE HLHP CONTROL UNIT...899
4.4.2 CONFIGURING THE SYSTEM FOR THE PRESENCE OF THE FRONT PTO (ONLY IF INSTALLED)...901
4.4.3 ENABLING THE ASM SYSTEM (ONLY IF INSTALLED)...902
4.4.4 CALIBRATION OF THE STEERING ANGLE SENSOR (WITH ASM ONLY)...904
4.4.5 CONFIGURING THE SYSTEM FOR THE PRESENCE OF RADAR (ONLY IF INSTALLED)...905
4.4.6 CALIBRATION OF THE HIGH AND LOW POSITIONS OF THE LIFT...907
4.4.7 CONFIGURING THE SYSTEM FOR THE PRESENCE OF FRONT AXLE SUSPENSION (ONLY IF INSTALLED)...909
4.4.8 SETTING THE INFOCENTER DISPLAY LANGUAGE...910
4.4.9 CANCELLING ALL THE ALARMS...912
5. ALARMS...913
INTRODUCTION...913
5.1 ALARMS DISPLAYED ON THE INFOCENTER...914
5.2 HLHP CONTROL UNIT ALARMS...925
5.3 ENGINE CONTROL UNIT ALARMS...1009
5.4 TRANSMISSION CONTROL UNIT ALARMS...1033
5.4.1 DEFINITION OF TRANSMISSION OPERATING MODES...1033
5.4.2 ABNORMALITIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT...1034
5.5 CANBUS ALARMS...1115
6. ENGINE CONTROL UNIT TEST PROGRAM...1125
6. 1 ACCESS AND COMMUNICATION...1125
6. 1.1 MINIMUM EQUIPMENT REQUIREMENTS...1125
6. 1.2 ORDERING INFORMATION...1125
6. 1.3 CONNECTING THE NOTEBOOK AND INSTALLING THE SOFTWARE...1126
6. 1.4 PROGRAM COMMANDS...1130
6. 1.5 TERMINATE COMMUNICATION...1132
6. 2 ECU SELECTION...1133
6. 2.1 SELECTION OF TWO ECUs...1133
6. 2.2 PRINT (EXPORT)...1134
6. 2.3 PROTOCOL...1135
6. 2.4 IDENTIFICATION AND MEASUREMENT DATA...1135
6. 3 MEASUREMENT VALUES...1136
6. 3.1 CURRENT VALUES (IN GENERAL)...1136
6. 3.2 RAM VALUES...1140
6. 3.3 INPUT/OUTPUT CONFIGURATION...1145
6. 3.4 CAN Status...1145
6. 4 PARAMETERS...1148
6. 4.1 CONFIGURATION (GENERAL)...1148
6. 4.2 COMPLETE PROGRAMMING...1149
6. 4.3 CALIBRATION...1150
6. 5 ERROR MEMORY...1151
6. 5.1 GENERAL INFORMATION...1151
6. 6 EXTRA...1153
6. 6.1 MAXIMUM SPEED...1153
6. 6.2 LOGISTICAL DATA...1153
6. 6.3 GENERAL LOADS...1154
6. 7 ACTIVITY...1155
6. 7.1 EMR2...1155
6. 8 POSSIBLE PROBLEMS...1159
6. 8.1 SERDIA IN GENERAL...1159
6. 8.2 EMR2...1160
Definition of the parameters...1163
Configuration:...1163
SECTION 30...1171
ENGINE HOOD...1175
Removal...1175
Refitting...1175
WHEELS...1176
FRONT WHEELS...1176
Removal...1176
Refitting...1176
REAR WHEELS...1177
Removal...1177
Refitting...1177
FRONT FENDERS...1178
Removal...1178
Refitting...1178
CAB ACCESS STEPS...1179
Removal...1179
Refitting...1179
FUEL TANK...1180
Removal...1180
Refitting...1181
COOLERS-RADIATOR ASSEMBLY...1182
COMPLETE ASSEMBLY...1182
Removal...1182
Refitting...1185
FUEL COOLER...1187
Removal...1187
Refitting...1187
TRANSMISSION OIL COOLER...1188
Removal...1188
Refitting...1189
ENGINE COOLING SYSTEM RADIATOR...1190
Removal...1190
Refitting...1193
AIR FILTER ASSEMBLY...1194
Removal...1194
Refitting...1194
INTERCOOLER...1195
Removal...1195
Refitting...1195
AIR CONDITIONING SYSTEM...1196
TECHNICAL DATA...1196
Operation...1197
Discharging, flushing and recharging...1198
1. Discharging the system...1198
2. Flushing and recharging the system...1198
RECEIVER - DRIER...1200
Removal...1200
Refitting...1200
CONDENSER ASSEMBLY...1201
Removal...1201
Refitting...1201
COMPRESSOR...1202
Removal...1202
Refitting...1203
HEATER ASSEMBLY...1204
COMPLETE ASSEMBLY...1204
Removal...1204
Refitting...1206
UPPER HALF DUCT...1207
Assembly...1207
FANS...1208
Disassembly...1208
Assembly...1208
HEATER MATRIX...1209
Disassembly...1209
Assembly...1209
AIR CONDITIONING EVAPORATOR...1210
Disassembly...1210
Assembly...1210
ENGINE COOLING FAN ASSEMBLY...1211
ENGINE COOLING FAN...1211
Removal...1211
Refitting...1212
FAN BELT...1213
Removal...1213
Refitting...1214
Tensioning...1215
ALTERNATOR ASSEMBLY...1216
ALTERNATOR...1216
Removal...1216
Refitting...1216
ALTERNATOR DRIVEBELT...1217
Removal...1217
Refitting...1218
Tensioning...1219
STARTER MOTOR...1220
Removal...1220
Refitting...1220
COMPRESSED AIR CIRCUIT...1221
AIR COMPRESSOR...1221
Removal...1221
Refitting...1222
COMPRESSOR DRIVEBELT...1223
Removal...1223
Refitting...1223
Tensioning...1224
FRONT PTO...1225
COMPLETE ASSEMBLY...1225
Removal...1225
Refitting...1225
FLEXIBLE COUPLING...1226
Renewal...1226
Refitting...1226
FRONT AXLE DRIVE SHAFT...1227
Removal...1227
Refitting...1228
FRONT SUPPORT...1229
COMPLETE ASSEMBLY (Version without front axle suspension)...1229
Removal...1229
Refitting...1230
BRAKE MASTER CYLINDERS...1231
Removal...1231
Refitting...1233
POWER STEERING...1234
STEERING VALVE ASSEMBLY...1234
Removal...1234
Refitting...1236
Disassembly...1237
Assembly...1243
RELIEF VALVE...1254
Testing the operating pressure...1254
Adjusting the operating pressure...1254
HYDRAULIC PUMPS...1255
TRANSMISSION PUMP...1255
Removal...1255
Refitting...1256
STEERING AND SERVICES PUMP...1259
Removal...1259
Refitting...1261
COMPLETE EXHAUST SYSTEM...1262
SILENCER...1262
Removal...1262
Refitting...1262
EXHAUST PIPE...1263
Removal...1263
Refitting...1263
CAB...1264
Removal...1264
Refitting...1270
ENGINE...1271
Preparation for removal...1271
Preparation before separating the engine from the transmission...1271
Separation or removal...1272
Refitting...1276
TORSIONAL SPRING PLATE...1277
Removal...1277
Refitting...1277
FLOOR MAT...1278
Removal...1278
Removal...1278
DRIVER'S SEAT...1279
Removal...1279
Refitting...1279
ACCELERATOR PEDAL POTENTIOMETER...1280
Removal...1280
Refitting...1281
CONSOLE SHROUDS ON RIGHT SIDE...1282
REMOTE VALVE LEVERS SHROUD...1282
Removal...1282
Refitting...1282
RIGHT-HAND CONSOLE...1283
Removal...1283
Refitting...1285
CONTROL CABLES...1286
REMOTE VALVE CROSS-GATE CONTROL LEVER...1286
Removal...1286
Refitting...1286
REMOTE CONTROL VALVE - 3rd SPOOL CONTROL...1287
Removal...1287
Refitting...1287
REAR PTO SPEED SELECTOR LEVER...1288
Removal...1288
Refitting...1289
GEARSHIFT CONTROL...1290
Removal...1290
Refitting...1291
PARKING BRAKE...1292
CONTROL CABLE...1292
Removal...1292
Refitting...1293
PARKING BRAKE LEVER...1294
Adjustment...1294
SERVICE BRAKE...1295
BRAKE...1295
Adjustment...1295
STEERING WHEEL...1296
Removal...1296
Refitting...1296
SHUTTLE LEVER...1297
Removal...1297
Refitting...1298
STEERING COLUMN SWITCH UNIT...1299
Removal...1299
Refitting...1300
FRONT CONSOLE...1301
Removal...1301
Refitting...1303
CLUTCH PEDAL AND ACCESSORIES...1304
POSITION SENSOR...1304
Removal...1304
Refitting...1304
PROXIMITY SENSOR (Clutch pedal depressed sensor)...1307
Removal...1307
Refitting...1307
CAB DOOR CABLE...1308
Renewal...1308
LIFT DRAFT SENSOR...1310
Removal...1310
Refitting...1310
LIFT POSITION SENSOR...1311
Check...1311
Removal...1311
Renewal of the position sensor bush (only if necessary)...1312
Refitting...1312
Adjustment...1312
LIFT DRAFT SENSOR...1314
Removal...1314
Refitting...1314
SECTION 40...1315
THE STRUCTURE OF THE UNIT...1317
HOW TO CONSULT THE UNIT...1318
1. INTRODUCTION...1319
1.1 LIST OF WIRING HARNESSES...1319
1.2 DEFINITION OF COMPONENTS AND SYMBOLS...1320
1.3 GENERAL RULES...1321
1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/ELECTRONIC CIRCUITS...1321
1.3.2 MAIN WIRING FAULTS...1321
1.3.3 REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRINGI...1322
1.4 DIAGNOSTIC INSTRUMENTS...1323
1.5 WIRE COLOUR CODES...1323
2. INDEX...1324
2.1 INDEX BY PART DESCRIPTION...1324
2.2 COMPONENT CODE INDEX...1332
2.3 CONNECTOR INDEX...1338
3. COMPONENTS...1348
3.1 COMPONENT TECHNICAL DATA...1348
3.2 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS...1356
3.2.1 ENGINE CONTROL UNIT (0421.3098)...1356
3.2.2 TRANSMISSION CONTROL UNIT (2.8519.028.0)...1358
3.2.3 HLHP CONTROL UNIT (CODE 2.8519.027.0/10)...1360
3.2.4 INFOCENTER...1363
4. SYSTEMS...1365
4.1 EARTHING POINTS...1365
4.2 STARTING THE ENGINE...1366
4.3 PRE-HEATING...1367
4.4 ELECTRONIC ENGINE CONTROL...1368
4.5 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITHOUT FRONT LIFT)...1369
4.6 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH FRONT LIFT)...1370
4.7 DIAGNOSTICS ACCESSORIES...1371
4.8 WORKLIGHTS (VERSION WITHOUT DEMISTING MIRRORS)...1372
4.9 WORKLIGHTS (VERSION WITH DEMISTING MIRRORS)...1373
4.10 WINDSCREEN WIPERS...1374
4.11 INSTRUMENT PANEL...1375
4.12 RADIO...1376
4.13 MANUAL AIR CONDITIONER...1377
4.14 BRAKES...1378
4.15 FRONT AXLE SUSPENSION...1379
4.16 TRANSMISSION...1380
4.17 ASM - FOUR-WHEEL DRIVE - DIFFERENTIAL...1381
4.18 ELECTRONIC LIFT...1382
4.19 FRONT AND REAR PTO...1383
4.20 CONTROL VALVES...1384
4.21 CAN BUS...1385
5. WIRING...1387
ENGINE WIRING (4 CYLINDERS) (1/2)...1387
ENGINE WIRING (4 CYLINDERS) (2/2)...1388
ENGINE WIRING (6 CYLINDERS) (1/2)...1389
ENGINE WIRING (6 CYLINDERS) (2/2)...1390
ENGINE BONNET WIRING...1395
FRONT WORKLIGHTS WIRING...1396
RIGHT-HAND TRANSMISSION WIRING (1/2)...1399
RIGHT-HAND TRANSMISSION WIRING (2/2)...1400
LEFT-HAND TRANSMISSION WIRING (1/2)...1407
LEFT-HAND TRANSMISSION WIRING (2/2)...1408
TRAILER BRAKE WIRING (ITALY)...1417
TRAILER BRAKE WIRING (GERMANY)...1419
FRONT AXLE SUSPENSION WIRING...1421
BATTERY POSITIVE WIRING - BATTERY NEGATIVE WIRING...1423
SUPPLY WIRING (1/2)...1424
SUPPLY WIRING (2/2)...1425
INSTRUMENT PANEL WIRING (1/2)...1431
INSTRUMENT PANEL WIRING (2/2)...1432
MUDGUARD WIRING...1433
WIRING FOR LIGHTS ON ARMS...1434
WIRING FOR SUPPLEMENTARY LIGHTS ON ARMS...1435
UPPER LIGHTS WIRING (VERSION WITH LIFT)...1436
WIRING FOR WORKLIGHTS ON ARMS (VERSION WITHOUT LIFT)...1437
LIGHTS SELECTOR SWITCH WIRING...1451
CENTRAL WIRING (1/2)...1453
CENTRAL WIRING (2/2)...1454
ENGINE WIRING...1455
ROOF LINE WIRING (1/2)...1463
ROOF LINE WIRING (2/2)...1464
WIRING FOR WORKLIGHTS, DEFROST MIRROR ON CAB (HL VERSION)...1465
WIRING FOR WORKLIGHTS ON CAB (STANDARD VERSION)...1466
WINDSCREEN WIPER WIRING...1467
ROTATING BEACON WIRING...1468
CONTROL VALVE WIRING...1475
CONTROL VALVE SOLENOID VALVE WIRING...1476
CONTROL VALVE WIRING...1477
Deutz-Fahr Tractors AGROTRON K90, AGROTRON K100, AGROTRON K110, AGROTRON K120 Profiline Repair Service Manuals
