SAME DEUTZ-FAHR DEUTSCHLAND GmbH

WORKSHOP MANUAL

AGROTRON 80 MK3 –> 6001

AGROTRON 90 MK3 –> 6001
AGROTRON 100 MK3 –> 6001
AGROTRON 105 MK3 –> 6001
 INTRODUCTION

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

00-1
 GENERAL SAFETY RULES

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

To prevent injury to operators, the symbols and are used in this manual to indicate the
safety precautions required. The warnings accompanying these symbols must always be ad-
hered to carefully.
In potentially hazardous situations, always give priority to personal safety and take the necessary
actions to eliminate the danger.

GENERAL SAFETY RULES

1 - Even if you have a thorough knowledge of the machine as regards its com-
ponents, operation and controls, always take particular care when carrying
out the following operations. Remember that the machine you are working
on is in need of repair or overhaul and consequently may not always be-
have as expected.
2 - Before starting work, clean the machine thoroughly to remove all mud,
dust and road dirt.
Also clean the cab to remove all traces of oil, snow and ice from the access
steps and grab rails.
3 - When climbing up to or down from the cab, always ensure you maintain
three points of contact at a time (foot or handholds) in order to keep your
balance and prevent accidental falls.
4 - Always take special care when carrying out fault diagnosis operations;
these operations often require two persons, who must never stand in front
of the wheels when the engine is running.
5 - When carrying out checks and repairs, wear close-fitting clothing, safety
goggles and protective gloves that are suitable for the task (cleaning,
draining fluids, repairs).
When working near moving parts, long hair should be gathered up and se-
cured safely under a cap to prevent the risk of entanglement and sever in-
jury.
6 - Do not allow anyone who is not directly involved in the work to come near
the machine; ensure that they remain at a safe distance.
7 - Keep well clear of moving parts; when the engine is running, some moving
parts are not easily visible and therefore present a risk of entanglement,
even if protected by safety guards.
8 - Ensure that the area is well ventilated before starting the engine in order to
avoid the formation of dangerous concentrations of toxic gases; always
connect suitable fume extraction equipment to the exhaust pipe.

00-3
 GENERAL SAFETY RULES

9 - Under no circumstances start the engine with the safety guards removed;
all repair and adjustment operations must be carried out with the engine
stopped.
10 - Do not top up fuel, oil or coolant levels when the engine is running.
11 - Never smoke and ensure there are no naked flames nearby when topping
up fuel or oil.
Always remove the battery from the machine before recharging.
12 - Before checking or removing the battery, stop the engine and remove the
key from the starter switch.
13 - Remove the battery and recharge in a well-ventilated area where the tem-
perature exceeds 0°C.
14 - When checking or recharging the battery, do not smoke or allow naked
flames in the vicinity as the hydrogen gas given off by the battery is highly
explosive.
15 - The liquid (electrolyte) contained in the battery is very harmful if it comes
into contact with the skin and the eyes; for this reason, always wear gloves
and safety goggles with side shields when checking or topping up the bat-
tery.
Should any electrolyte accidentally come into contact with your skin, wash
the affected parts immediately with copious amounts of water. If electro-
lyte comes into contact with your clothing, this should be removed as soon
as possible.
In case of accidental ingestion of electrolyte, drink copious amounts of wa-
ter, milk or vegetable oil and take antacids such as magnesium, bicarbo-
nate, etc.. and seek medical attention immediately.
16 - Before working on the electrical systems, always disconnect the battery
terminals.
IMPORTANT!
Always disconnect the negative terminal (--) first and then the positive ter-
minal (+); when re-connecting the battery on completion of the work, first
connect the positive terminal (+) and then the negative (--).
17 - Before carrying out any arc welding, on the tractor, always disconnect the
battery terminals and unplug all the connectors of the electronic control
units and the alternator.
18 - When topping up lubricants, always wear suitable protective gloves.
19 - Do not wear clothing contaminated by engine or hydraulic oil; prolonged
contact with the skin can be harmful and may cause allergic reactions.
20 - Used engine oil and hydraulic oil must be disposed of in a proper manner;
recover used lubricants and dispose of them in accordance with the ap-
plicable regulations.
21 - Before carrying out any work on the hydraulic or pneumatic systems, dis-
charge all residual pressure from the circuits.
22 - Before carrying out any work on the hydraulic system or engine, allow the
oil and engine coolant to cool down.

00-4
 GENERAL SAFETY RULES

23 - When removing and refitting certain assemblies, it will be necessary to

support the machine; use stands, jacks or blocks capable of supporting
the weight and arrange them in a triangular pattern to prevent the machine
from overturning.
24 - To lift heavy components, use a hoist or crane.
Check that wire ropes, chains or fibre slings are not worn and that hooks
are not damaged.
25 - Always use lifting equipment of suitable capacity for the weight of the com-
ponents to be removed. Ensure lifting equipment is attached correctly.
26 - When lifting or supporting an assembly or component, manoeuvre the
parts slowly and carefully to avoid oscillation or collision with other com-
ponents.
27 - Never work on components suspended from a hoist or crane.
28 - When removing the retaining bolts of a component that could fall, always
leave two opposing bolts in place for safety; these bolts should only be re-
moved when the component has been securely attached to a hoist or when
supporting blocks have been put in position.
29 - Any oil or fuel spilled during removal or dismantling operations should be
cleaned up as soon as possible to prevent the risk of slipping and fire.
30 - When refitting electrical wiring looms and wires, ensure that they are prop-
erly secured with their original retaining straps or brackets to prevent the
possibility of damage caused by vibration.
31 - Never insert your fingers or hands to check the alignment between fixing
holes in components; always use a suitable dowel of soft material.
32 - When refitting assemblies or components, always use the specified tight-
ening torques; the tightening torques indicated in the paragraphs regard-
ing assembly/refitting operations have been determined through
experimentation and must be scrupulously adhered to.
33 - When refitting parts that are subject to vibration or that rotate at high
speed, take particular care when carrying final installation checks.

00-5
 SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS

SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING

OPERATIONS
★ When removing or refitting parts, always take the following safety precau-
tions.

1. PRECAUTIONS FOR REMOVAL OPERATIONS

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

2. PRECAUTIONS FOR REFITTING OPERATIONS

• Tighten nuts and bolts to the specified tightening torques.
• When refitting flexible pipes and wires, take care not to twist or tangle
them.
• Always fit new seals, O-rings, cotter pins and safety stop rings on reas-
sembly; make sure that the ends of the cotter pins are separated and bent
back so that the pin cannot be withdrawn from the hole.
• Ensure that circlips are correctly installed in their seatings.
• Always fit new seals, O-rings, cotter pins and safety stop rings; ensure that
cotter pins are bent over so that they cannot work loose.
• When applying sealant, first clean the surface removing all traces of oil and
grease and check for dirt or indentations, then apply the sealant evenly
making sure that it forms a continuous film around any fixing holes.
• Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and in-
dentations.

00-6
 SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS

• Coat all moving parts with a thin film of engine oil.

• When reconnecting electrical connectors, first remove all traces of oil, dust
and water from the inside of the connector and then push the two halves to-
gether firmly; only apply the force necessary to clip the two halves togeth-
er.
• Bolt down flanged fittings evenly, tightening the bolts gradually in a cross-
wise pattern.

3. PRECAUTIONS TO BE TAKEN ON COMPLETION OF REMOVAL/REFITTING OPERATIONS

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

00-7
 LIFTING INSTRUCTIONS

LIFTING INSTRUCTIONS

Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equip-
ment with wire rope or polyester slings.
In the paragraphs regarding removal and refitting operations, the weight of the component or assembly to be lifted is
indicated with the symbol

WIRE ROPES - SLINGS

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

WIRE ROPES POLYESTER SLINGS

(standard twisted «S» or «Z» type) (eye-and-eye - simple loop)
Capacity (kg) Capacity (kg)
Ø rope Width
mm 60° 90° (mm) 60° 90°

8 650 620 500 25 500 400 860 700

10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530

NOTE. Lifting capacities are calculated with a safety coefficient.

• The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the
rope/sling, this could cause the load to slip during lifting.
• Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope
strands to untwist or the load to slip; this could lead to serious injury.
• Never lift a heavy load when the two branches of the ropes form a wide angle.
The permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the
permitted load varies according to the angle of suspension for two Ø 10 mm ropes each with a load capacity of 1000 kg.

2000
1900
1700
2000
Load capacity: kg

1400

1000
1000
500

30° 60° 90° 120° 150°

Angle of suspension: ␣

00-8
 HOW THE MANUAL IS STRUCTURED

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 tight-
ening torques and a conversion table for units of measurement.

SECTION 10 Contains technical descriptions and information regarding the mechan-

ical and hydraulic operation of machine components, the designations of
the various components, hydraulic diagrams and general technical data.

SECTION 20 Contains information on the tractor's electrical and electronic systems,

the procedures for putting into service, the list of alarms and a guide to the
use of the software required for tractor and engine configuration and ac-
cess to diagnostic codes.

SECTION 30 Contains the methods, checks and adjustments regarding the external
components; the operations dealt with in this section do not require re-
moval 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!
This manual does not contain the engine and transmision sections.
For these sections refer to the follow manuals:

Italian
English
Engine DEUTZ 2012 0312 0361
French
German
0298 6837 German
0298 6838 English
Trasmission ZF 7100L
0298 6839 French
0298 6840 Spanish
0298 6871 German
0298 6872 English
Trasmission ZF 7100S
0298 6873 French
0298 6874 Spanish
0298 6877 German
0298 6878 English
Rear axle 7100
0298 9879 French
0298 9880 Spanish
0298 6803 German
0298 6856 English
Front axle ZF 2025-2035-2045 AS
0298 6857 French
0298 6858 Spanish

00-9
 HOW TO CONSULT THE MANUAL

HOW TO CONSULT THE MANUAL

1. Removal and refitting of assembled units

(1) For the removal or refitting of assembled units, the sequence of operations and the methods to be applied are de-
scribed in the removal procedure; if the refitting sequence of operations is the exact reverse of the removal pro-
cedure, it is not described.
(2) All special techniques that apply only to the refitting procedure are indicated by the symbol 1 ; this same
symbol appears at the end of each major step in the removal procedure to indicate the parts for which special
techniques are to be applied during refitting.
E.g.: REMOVAL OF UNIT : ................................................ Operation heading
: ............................................................................. Safety rules to be observed when carrying out the pro-
cedure described
1 - Remove part (1):...................................................... Step of the procedure
★: ................................................................................. Technique or important information regarding the re-
moval operation.
2 - Disconnect (2) ......... 1 : ...................................Indicates the existence of special information regard-
ing refitting of the component in question.
.......... ᐉ: .............................................................. Recover oil, liquid or fuel and the quantity to be recov-
ered
E.g.: REFITTING UNIT: ...................................................... Operation heading
• Refitting is the reverse of removal

1 :.......................................................................Technique to be applied during refitting

★: ................................................................................. Technique or important information regarding the refit-
ting operation
• .......... ᐉ: ........................................................... Filling with oil or liquid with quantity
2. During removal and refitting operations, in addition to the general safety rules, you must also apply the specific
«SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS».
Always adhere to these precautions.

3. List of special tools

(1) For details regarding the type, code numbers and quantity of all the tools (T1, T2, etc.) specified in the operating
procedures, see the heading «SPECIAL TOOLS».

4. Tightening torques
1 - In the operating procedures, the symbol denotes a specific tightening torque that has been determined ex-
perimentally and that must be adhered to.
2 - If the symbol does not appear, the torque values to be used are those indicated in the table in Section 00 of this
manual.

00-10
 HOW TO USE AND UPDATE THE MANUAL

HOW TO USE AND UPDATE THE MANUAL

1. UPDATING THE MANUAL

All additions, corrections or amendments to the manual will be sent to the Authorised Service Centres.
Before starting any repair or overhaul operations, check that you have the most recent updates as these may contain
supplementary data not present in previous issues.

2. INSERTING UPDATES
1- Check the number of the page and insert it in the appropriate section of the manual following the consecutive or-
der of the page numbers. Example:
20 5

Consecutive page number

Section number

2 - Supplementary pages: indicated with a hyphen (-) and consecutive number after the page number. Example:
20-5
20-5-1
Supplementary page
20-5-2
20-6
NOTE. The contents of supplementary pages are structured so that there is no overlap with existing pages.
3 - Updated pages: indicated by a consecutive number in a circle; this symbol appears below the page number.
Example:

20-5
20-5-1 Existing page
20-5-1 Update page

20-5-2 Existing page

NOTE. All supplementary and updated pages are indicated in the manual page list; a revised page list is
sent with each update and supersedes the previous list.

3. SYMBOLS USED IN THE MANUAL

For greater clarity, important information pertaining to operator safety and to critical stages in the working proce-
dures is highlighted by the symbols shown in the following table.

Symbol Meaning Notes Symbol Meaning Notes

Safety rules to be applied during op- Parts must be coated with adhesive,
Coating
eration. lubricant, etc.
Safety Points at which oil, water or fuel
Operation requiring special safety
Oil, water must be added and quantity re-
measures due to internal pressure.
quired.
Operations requiring special techni-
★ Warning cal or other precautionsto ensure
compliance with standard values.
Drain
Points from which oil, water or fuel
must be drained with quantity.

Weight of main assemblies.

Tightening Parts requiring special tightening
Weight Choose lifting ropes/slings careful-
torques torque during refitting or assembly.
ly; supports required, etc.

00-11
 STANDARD TIGHTENING TORQUES

STANDARD TIGHTENING TORQUES

1. NUTS AND BOLTS

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

BOLT CLASS

BOLT SIZE 8.8 10.9 12.9

Nm lb.ft. Nm lb.ft. Nm lb.ft.
M6x1 8.0 – 8.8 5.9 – 6.5 11.8 – 13.0 8.7 – 9.6 13.8 – 15.2 10.2 – 11.2

M8x1.25 19.4 – 21.4 14.3 – 15.8 28.5 – 31.5 21.0 – 23.2 33.3 – 36.9 24.5 – 27.2

M10x1.5 38.4 – 42.4 28.3 – 31.2 56.4 – 62.4 41.6 – 46.0 67.4 – 74.4 49.7 – 54.8

M12x1.75 66.5 – 73.5 49.0 – 54.2 96.9 – 107 71.4 – 78.9 115 – 128 84.8 – 94.3
COARSE THREAD

M14x2 106 – 117 78.1 – 86.2 156 – 172 115.0 – 126.8 184 – 204 135.6 – 150.3

M16x2 164 – 182 120.9 – 134.1 241 – 267 117.6 – 196.8 282 – 312 207.8 – 229.9

M18x2.5 228 – 252 168.0 – 185.7 334 – 370 246.2 – 272.7 391 – 432 288.2 – 318.4

M20x2.5 321 – 355 236.6 – 261.6 472 – 522 347.9 – 384.7 553 – 611 407.6 – 450.3

M22x2.5 441 – 487 325.0 – 358.9 647 – 715 476.8 – 527.0 751 – 830 553.5 – 611.7

M24x3 553 – 611 407.6 – 450.3 812 – 898 598.4 – 661.8 950 – 1050 700.2 – 773.9

M27x3 816 – 902 601.4 – 664.8 1198 – 1324 882.9 – 975.8 1419 – 1569 1045.8 – 1156.4

M8x1 20.8 – 23.0 15.3 – 17.0 30.6 – 33.8 22.6 – 24.9 35.8 – 39.6 26.4 – 29.2

M10x1.25 40.6 – 44.8 29.9 – 33.0 59.7 – 65.9 44.0 – 48.6 71.2 – 78.6 52.5 – 57.9

M12x1.25 72.2 – 79.8 53.2 – 58.8 106 – 118 78.1 – 87.0 126 – 140 92.9 – 103.2

M12x1.5 69.4 – 76.7 51.1 – 56.5 102 – 112 75.2 – 82.5 121 – 134 89.2 – 98.8
FINE THREAD

M14x1.5 114 – 126 84.0 – 92.9 168 – 186 123.8 – 137.1 199 – 220 146.7 – 162.1

M16x1.5 175 – 194 129 – 143 257 – 285 189.4 – 210.0 301 – 333 221.8 – 245.4

M18x1.5 256 – 282 188.7 – 207.8 375 – 415 276.4 – 305.9 439 – 485 323.5 – 357.4

M20x1.5 355 – 393 261.6 – 289.6 523 – 578 385.5 – 426.0 611 – 676 450.3 – 498.2

M22x1.5 482 – 532 355.2 – 392.1 708 – 782 521.8 – 576.3 821 – 908 605.1 – 669.2

M24x2 602 – 666 443.7 – 490.8 884 – 978 651.5 – 720.8 1035 – 1143 762.8 – 842.4

00-12
 STANDARD TIGHTENING TORQUES

2. FITTINGS
★ The tightening torques indicated below refer to fittings assembled on any material.

Straight end fittings “T” end fittings “L” end fittings 90° end fittings

Thread size Wrench Torque Wrench Torque Wrench Torque Wrench Torque
Nm ±10% Nm ±10% Nm ±10% Nm ±10%
17 14 14 14 14 14
M10x1.25 14 14
19 14 17 14 17 14
M12x1.25 19 30 17 30 17 30 17 30
M14x1.5 19 40 19 40 19 40 19 40
METRIC THREADS

M16x1.5 22 48 22 48 22 48 22 48
M18x1.5 24 58 24 58 24 58 24 58
M20x1.5 27 65 27 65 27 65 27 65
M22x1.5 30 73 30 73 30 73 30 73
M26x1.5 36 95 36 95 36 95 36 95
M27x2 36 100 36 100 36 100 36 100
M33x2 41 160 41 160 41 160 41 160
M42x2 50 250 50 250 50 250 50 250
M48x2 60 305 60 305 60 305 60 305

17 13
G 1/8” 14 13 14 13 14 13
19 13
19 37
G 1/4” 19 37 19 37 19 37
THREADS IN INCHES

22 37
G 3/8” 24 53 24 53 24 53 24 53
27 73
G 1/2” 27 73 27 73 27 73
30 73
G 3/4” 36 100 36 100 36 100 36 100
41 160
G 1” 41 160 41 160 41 160
46 160
G 1 1/4” 50 250 50 250 50 250 50 250
G 1 1/2” 60 305 60 305 60 305 60 305

00-13
 STANDARD TIGHTENING TORQUES

3. PLUGS

Hex plugs Threaded plugs with hex socket head

Torque Torque
Thread size Wrench Nm ±10% Wrench Nm ±10%
M6x1 10 10 – –
M8x1 13 12 – –
M10x1 13 14 5 14
M10x1.25 13 14 – –
M10x1.5 13 14 – –
M12x1.25 17 30 – –
M12x1.5 17 30 6 30
M12x1.75 17 30 – –
M14x1.5 19 40 6 40
METRIC THREADS

M14x2 19 40 – –
M16x1.5 22 48 8 48
M16x2 22 48 – –
M18x1.5 17 58 10 58
M18x2.5 17 58 – –
M20x1.5 19 65 – –
M22x1.5 – – 12 73
M24x1.5 22 80 12 80
M24x2 22 80 – –
M27x2 22 100 – –
M28x1.5 – – 17 110
M30x1.5 22 130 – –
M32x1.5 – – 19 150
M35x1.5 – – 22 180
M40x1.5 – – 24 225
THREADS IN INCHES

G 1/8” 14 13 – –
G 1/4” 19 37 – –
G 3/8” 22 53 – –
G 1/2” 19 73 – –
G 5/8” 22 85 – –
G 3/4” 22 100 – –
G 1” 22 160 – –

00-14
 STANDARD TIGHTENING TORQUES

4. FITTINGS WITH SEAL AT 37°

Torque Torque
Thread size Wrench Nm ±10% Thread size Wrench Nm ±10%
7/16” - 20 14 13 1 3/16” - 12 36 138
1/2” - 20 16 19 1 5/16” - 12 38 155
9/16” - 18 17 28 1 5/8” - 12 50 215
3/4” - 16 22 47 1 7/8” - 12 60 290
7/8” - 14 27 76 2 1/2” - 12 75 345
32 110
1 1/16” - 12
36 110

5. FITTINGS FOR PIPES WITH EYE ATTACHMENT

★ These tightening torques refer to tightening the fitting with new copper sealing washers.
Unions for one-way fittings Unions for three-way fittings Unions for four-way fittings

Thread size Wrench Torque Wrench Torque Wrench Torque

Nm ±10% Nm ±10% Nm ±10%
M8x1 – – 12 14 – –
M8x1.25 13 14 – – – –
M10x1 – – 14 20 14 20
M10x1.25 13 20 – – – –
M12x1.25 17 30 – – – –
M12x1.5 – – 17 30 17 30
M14x1.5 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48
M18x1.5 22 58 24 58 24 58
M20x1.5 27 65 – – – –
M22x1.5 – – 27 73 27 73
M24x1.5 32 80 – – – –
M26x1.5 – – 32 95 32 95
M28x1.5 36 110 – – – –
M30x1.5 – – 36 130 36 130
M35x2 41 180 – – – –
M38x1.5 46 200 46 200
M42x2 50 250 – – – –
M45x1.5 – – 55 280 55 280
M50x2 60 320 – – – –
M52x1.5 – – 60 320 60 320
M65x2 – – 75 450 75 450

00-15
 THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS

THREADLOCKERS, ADHESIVES, SEALANTS AND

LUBRICANTS

FUNCTION DESIGNATION DESCRIPTION

Loctite 222
Anaerobic product suitable or low-strength locking of retaining, adjustment and precision
Colour:
fasteners.
opaque fluorescent All traces of lubricant must first be removed using the specific activator.
purple

Anaerobic product that prevents loosening of all types of nut and bolt; used in place of con-
THREADLOCKER

Loctite 242
ventional mechanical locking systems.
Colour:
Used for medium-strength locking.
fluorescent blue All traces of lubricant must first be removed using the specific activator.

Loctite 243
Alternative product to 242; oil tolerant and so can used on lightly lubricated surfaces without
Colour: opaque
prior use of activator.
fluorescent blue

Loctite 270 Anaerobic product for high-strength locking of bolts and studs that do not normally require
disassembly.
Colour:
Parts must be heated to approximately 80°C for removal.
fluorescent green All traces of lubricant must first be removed using the specific activator.
DEGREASERS AND

Product used for degreasing and cleaning parts prior to application of Loctite anaerobic prod-
Loctite 703
ACTIVATORS

ucts; after drying, promotes uniform curing of threadlockers.

Product used for specifically for treatment of passive metals prior to use of slow-cure anaer-
obic threadlockers(series 5 and 6).
Loctite 747
Can also be used to increase cure speed at low temperatures or in applications where there is
large gaps between the parts.

Super-rapid anaerobic sealant for sealing between rigid metal faces; can eliminate the need
Loctite 510 for conventional gaskets as it can fill gaps up to 0.4 mm.
Colour: red Does not shrink and therefore fasteners do not need re-tightening to specified torque values
after curing.

Loctite 542 Anaerobic product used a liquid sealant for threaded fittings up to 3/4” gas; rapid curing and
Colour: brown parts may be disassembled with ordinary tools.
(for faces and flanges)

Loctite 554 Anaerobic sealant and locking compound used for sealing cooling and industrial fluid circuits.
SEALANTS

Colour: red Slow curing, also suitable for use on non-ferrous alloys.

Anaerobic sealant and locking compound used for sealing pipes and threaded fittings up to 2"
Loctite 572
in diameter.
Colour: white Very slow curing on most metal surfaces.

Thixotropic anaerobic product used for sealing joints between metal faces.
Loctite 573 Ensures total contact between surfaces with maximum tolerance of 0.10 mm, filling micro-
Colour: green voids caused by flatness errors.
Very slow curing on most metal surfaces and requires prior application of an activator.

Loctite 576 Anaerobic product used a liquid thread sealant for large diameter threaded fittings (up to 2").
Colour: brown Very slow curing; also suitable for non-ferrous alloys and parts requiring subsequent removal.

00-16
 THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS

FUNCTION DESIGNATION DESCRIPTION

Cyanoacrylate instant adhesive suitable for bonding a wide range of acidic and porous ma-
Loctite 401 terials including, ceramics, wood, rubber and plastic (excluding polyolefin).
ADHESIVES
INSTANT

Colour: colourless Curing takes place in a few seconds as an effect of the condensed humidity present on the
surfaces to be bonded, and is independent of environmental conditions.

Loctite 495 Cyanoacrylate instant adhesive suitable for bonding a rubber, plastics and metal in any com-
Colour: colourless bination.

Silastic 738 One-part silicone adhesive/sealant, ready for use.

(Dow Corning) Cures on exposure to air to form a rubbery solid and obviates the need for conventional seals
SEALANTS
SILICONE

Colour: milky white on flexible joints, filling gaps greater than 1 mm.

One-part silicone adhesive/sealant, shrinking, ready for use.

Dirko Transparent
Cures rapidly when exposed to humidity in the air to form a rubbery solid; resistant to high
Colour: transparent temperatures.
POLYURETHANE
SEALANTS

Betaseal HV3 Polyurethane prepolymer based adhesive/sealant, high viscosity, suitable for permanent,
high-strength flexible bonding.
(Gurit Essex)
Slow curing, used for bonding glass to frames, wire mesh, metal plates, etc. surfaces must be
Colour: black degreased with primer.

Loctite 601 Anaerobic, fast-curing, high-strength adhesive.

Colour: Suitable for sealing and retaining cylindrical assemblies with gap clearances of up to 0.10 mm;
fluorescent green used for retaining rotors, gears, bearings, pulleys, bushes etc. on shafts.
RETAINING COMPOUNDS

Loctite 638
Anaerobic structural adhesive, quick-curing, very high strength; suitable for bonding cylin-
Colour:
drical parts in non-ferrous alloys.
fluorescent green

Loctite 648 Anaerobic structural adhesive, quick-curing, high-strength; suitable for bonding cylindrical
parts, permanent retention of threaded parts, sealing of refrigeration systems, retention of
Colour:
bearings, etc.
fluorescent green Alternative to Loctite 601 in high-temperature applications.

Loctite 986/AVX Anaerobic sealant/retaining compound for metal cylindrical parts.

Colour: Slow-curing, high-strength, heat-resistant and resistant to chemical pressure.
fluorescent red Parts must be first treated with an activator.

Grease
Multi-purpose Lithium grease used for lubrication of seals, to prevent oxidization and to fa-
(NLGI 2 EP
cilitate assembly operations.
ASTM D217: 265/295)
LUBRICANTS

Molikote Anti-wear compound, contains Molybdenum bisulphate, use neat or diluted with engine oil
(Dow Corning) for assembly of main engine bearings.

Vaseline Neutral pH compound used to protect battery terminals against oxidization and corrosion.

Engine oil
Used to dilute Molikote anti-wear lubricant during assembly of main engine bearings.
10W - 30

00-17
 CONVERSION FACTORS

CONVERSION FACTORS

CONVERSION FROM BRITISH TO METRIC UNITS CONVERSION FROM METRIC TO BRITISH UNITS
inch x 25,40 = mm mm x 0,0394 = inch
foot x 0,305 m x 3,281 = foot
=m
yard x 0,914 m x 1,094 = yard
Eng.miles x 1,609 = km km x 0,622 = Eng.miles
Sq.in. x 6,452 = cm² cm² x 0,155 = Sq.in.
Sq.ft. x 0,093 m² x 10,77 = Sq.ft.
= m²
Sq.yard x 0,835 m² x 1,197 = Sq.yard
Cu.in. x 16,39 = cm³ cm³ x 0,061 = Cu.in.
Cu.ft. x 28,36 m³ x 0,035 = Cu.ft
= m³
Cu.yard x 0,763 m³ x 1,311 = Cu.yard
Imp.gall. x 4,547 litres x 0,220 = Imp.gall.
US gall. x 3,785 litres x 0,264 = US gall.
= litres
pint x 0,568 litres x 1,762 = pint
quart x 1,137 litres x 0,880 = quart
US.gpm x 3,785 = ᐉ/min ᐉ/min x 0,2642 = US.gpm
oz. x 0,028 kg x 35,25 = oz.
= kg
lb. x 0,454 kg x 2,203 = lb.
lb.ft. x 0,139 = kgm kgm x 7,233 = lb.ft.
lb.in. x 17,87 = kg/m kg/m x 0,056 = lb.in.
psi x 0,070 = kg/cm² kg/cm² x 14,22 = psi
lb./Imp.gall x 0,100 kg/ᐉ x 10,00 = lb./Imp.gal.
= kg/ᐉ
lb./US.gall x 0,120 kg/ᐉ x 8,333 = lb./US.gal.
lb./cu.ft. x 16,21 = kg/m³ kg/m³ x 0,062 = lb./cu.ft.
lb.ft. x 1,356 = Nm Nm x 0,737 = lb.ft.
psi x 1,379 = bar bar x 14,503 = psi

00-18
 CONTENTS

SECTION 10
CONTENTS

1. TRANSMISSION ................................................................. 1 3. HYDRAULIC FRONT AXLE SUSPENSION...................... 32

• INTRODUCTION.................................................................. 1 • DESCRIPTION................................................................... 32
• 1.1 TRANSMISSION POWER SHUTTLE............................. 2 • 3.1 FRONT SUSPENSION CONTROL VALVE ................. 33
• • 1.1.1 MAIN COMPONENTS .......................................2
• • 1.1.2 TRANSMISSION HYDRAULIC SYSTEM ...........5 4. FRONT AXLE..................................................................... 37
• • 1.1.3 GEARBOX..........................................................6
• • GEARBOX COMPONENTS ........................................7 5. HYDRAULIC SYSTEM ...................................................... 38
• • 1.1.4 MAIN CLUTCH ..................................................8 • 5.1 HYDRAULIC DIAGRAM
• • 1.1.5 HYDRAULIC GEARBOX AND SHUTTLE (version with remote control valves
DISTRIBUTION VALVE ......................................9 without flow control)................................................... 39
• • 1.1.6 CLUTCH ENGAGEMENT AND SOLENOID
• 5.2 HYDRAULIC DIAGRAM
VALVE OPERATION SCHEMATIC...................12
• • 1.1.7 TRANSMISSION ELECTRONIC (version with remote control valves
SYSTEM SCHEMATIC.....................................13 with flow control)........................................................ 40
• 1.2 REAR AXLE ................................................................ 15 • 5.3 GEAR PUMP FOR TRANSMISSION ZF 7100 ............ 41
• 1.3 REAR PTO.................................................................. 17 • 5.4 GEAR PUMP FOR HYDRAULIC SERVICES
AND STEERING ......................................................... 42
2. BRAKING SYSTEM........................................................... 19 • 5.5 POWER STEERING.................................................... 43
• DESCRIPTION................................................................... 19 • 5.6 AUXILIARY SERVICES CONTROL VALVE................. 44
• 2.1 BRAKE MASTER CYLINDER ..................................... 20 • • 5.6.1 TYPES OF CONTROL VALVE ......................... 45
• 2.2 BRAKE ....................................................................... 21 • • 5.6.2 SERVICES CONTROL SECTION .................... 47
• • 5.6.3 DESCRIPTIONS OF COMPONENTS .............. 48
• 2.3 TRAILER BRAKING SYSTEM .................................... 22
• • 5.6.4 INLET MANIFOLD (CC version)....................... 50
• • 2.3.1 HYDRAULIC TRAILER BRAKING
• • 5.6.5 LIFT CONTROL VALVE SECTION................... 53
(ITALY VERSION).............................................22
• • 2.3.2 HYDRAULIC TRAILER BRAKING
(EXPORT VERSION) ........................................24
• • 2.3.3 AIR TRAILER BRAKING (ITALY VERSION)......26
• • 2.3.4 AIR TRAILER BRAKING
(EXPORT VERSION) ........................................27
• • COMPRESSOR ........................................................28
• • PRESSURE LIMITING VALVE...................................29
• • TRAILER BRAKING VALVE (2-WAY) ........................30
• • TRAILER BRAKING VALVE (1-WAY) ........................31

10-i
1. TRANSMISSION INTRODUCTION

1. TRANSMISSION

INTRODUCTION
• The AGROTON 80-105 series is supplied with the POWER SHUTTLE transmission.
Shifting between forward and reverse is managed entirely by the electronic control unit without the operator having
to use the clutch pedal.
This is achieved by way of a proportional solenoid valve that directly controls the main clutch.
• The transmission can be divided into the following three sections:
A. Transmission Power Shuttle
B. Rear axle
C. Rear PTO

B A

D0012950

10-1
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

1.1 TRANSMISSION POWER SHUTTLE

1.1.1 MAIN COMPONENTS

1 2 3 4 5

12

11

10

D0012940

9 8 7 6

1. Four-wheel drive control solenoid valve 5. Gearbox output shaft speed sensor (nLsa) 9. Rear PTO control valve
2. Proportional solenoid valve for clutch control 6. Clutch revs sensor (NHK) 10. Rear power take-off
3. Transmission oil low pressure sensor 7. Transmission oil temperature sensor 11. Rear PTO control solenoid valve
4. Engine speed sensor (nLse - nMot) 8. Speed sensor for odometer (nAb) 12. Rear PTO speed selector lever

10-2
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

13

14

19 18 17 16 15

13. Left brake cylinder

14. Field/road sensor
15. Mechanical gearbox shift lever
16. Transmission in neutral sensor
17. Right brake cylinder
18. Differential lock control valve
D0012960
19. Differential lock control solenoid valve

10-3
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

21

22
20

25

D0012970
24 23

20. Left axle casing

21. Lift shaft
22. Right axle casing
23. Rear PTO speed sensor
24. Gearbox oil level indicator
25. Rear reduction unit oil level indicator

10-4
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

1. TRANSMISSION
1.1 TRANSMISSION POWER SHUTTLE
1.1.2 TRANSMISSION HYDRAULIC SYSTEM
The transmission hydraulic system is supplied by a gear pump driven from a lateral power take-off.
The gear pump supplies pressurised fluid for the following uses:
• hydraulic gearbox control valve
• 4WD control solenoid valve
• rear PTO control solenoid valve
• differential lock control solenoid valve
• lubrication of the gearbox

Lubrication circuit
pressure relief valve

Lubrication of
Heat exchanger gear box
Main clutch

Proportional
Gearbox control solenoid valve
distribution valve
Y8

Differential lock
control solenoid valve PTO control
solenoid valve 4WD control
solenoid valve
Filter

Gear pump
Cold start
safety valve
Inlet filter

D0012612

10-5
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

1.1.3 GEARBOX

DESCRIPTION
• The drive from the engine (1) is transmitted through the hydraulically-controlled gearbox (2), the main clutch (3), the
4-speed mechanical gearbox (4) and the creeper (8) to the pinion (5) and the power take-off (7), that transfers drive to
the front axle.

2 3 4

4ª 3ª 2ª 1ª
1
ST FE

E
5

ST
7

NO LL

8 D0012600

COMPONENTS
1. Engine
2. Hydraulically-controlled 4-speed gearbox (3 forward and 1 reverse)
3. Main clutch
4. 8-speed mechanical gearbox (4 field and 4 road)
5. Pinion
6. 4WD engagement clutch
7. Power take-off for front axle drive
8. Creeper unit

10-6
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLELE

1. TRANSMISSION
1.1 TRANSMISSION POWER SHUTTLELE
GEARBOX COMPONENTS

4 9

1 2 3
5 6 7 8 10 11 12 13

14

21 20
19

17 18 15

16
D0012660

1. Flywheel and damper 8. Main clutch 15. 4WD control clutch

2. Housing 9. Mechanical gearbox 16. Creeper unit
3. Input shaft 10. 3rd and 4th speed synchronizer 17. Creeper unit synchronizer
4. Hydraulically-controlled gearbox 11. 1st and 2nd speed synchronizer 18. Creeper unit driven shaft
5. Clutch “A ” 12. Field/road synchronizer 19. Reverse gear driven shaft
6. Clutch “B ” 13. Rear PTO drive shaft 20. Clutch “C ”
7. Clutch housing 14. Pinion 21. Clutch “D ”

10-7
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLELE

1.1.4 MAIN CLUTCH

The main clutch of the POWER SHUTTLE transmission is an oil-bath multiplate unit with hydraulic control.
Clutch operation is entirely automatic and is controlled by an electronic control unit which receives signals from the clutch
pedal position sensor.
The system has a clutch control solenoid valve that directs pressurised fluid to the clutch in accordance with the pedal po-
sition.

4
2
3
1

ECU

D0013010

1. Clutch pedal
2. Clutch pedal position sensor
3. Electronic transmission control unit
4. Transmission gear pump
5. Clutch control proportional solenoid valve
6. Main clutch

10-8
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

1. TRANSMISSION
1.1 TRANSMISSION POWER SHUTTLE
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE
The function of the hydraulic gearbox distribution valve is to pilot and control the engagement of the gears in the hy-
draulically-controlled gearbox .
The hydraulic gearbox control valve controls the engagement of the H, M and L gears and the direction of travel.
This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox, the rear differential and
the rear PTO control shaft.

Y1

P2

H2

Y3

R
G1
Reset valve
Y4

R1

H1-H2
Ø 2,8
Ø 0,7 Y2
P1

Pressure
control valve

P3
Reducing valve
p= 10 bar
Ø 2,4 A

Ø 2,8
C

P4
B

Pilot pressure valve

p= 18 bar

Y8 D0012630

Trasmission lubrification Control and lubricating pump

10-9
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

A. GEARBOX CONTROL VALVE

PRESSURE TEST POINTS

8
2

7 3

D0012640
5 4

Pos. Function Thread size

1 General pressure (18 bar) M10x1

2 A Clutch pressure M10x1

3 Pressure Pg to relief valve M10x1

4 Engagement pressure M10x1

5 D clutch pressure M10x1

6 C clutch pressure M10x1

7 B Clutch pressure M10x1

8 Pilot pressure (10 bar) M10x1

10-10
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

MAIN COMPONENTS

P3 P2

P4

P1
Y4

Y3 R1

Y2 G1

Y1

H1 H2 D0012620

G1 Clutch selection valve

H1 Clutch engagement valve for B/C or A/B clutches
H2 Forward, reverse and neutral selection valve
P1 Pressure modulating valve
P2 Engagement valve
P3 Pilot pressure regulating valve (10 bar)
P4 General pressure regulating valve (18 bar)
R1 Null shift valve
Y1 Pilot solenoid valve for engagement valve H2 (MRV electr. REV)
Y2 Pilot solenoid valve for engagement valve H1 (GV1 valve TRASM.1)
Y3 Pilot solenoid valve for engagement valve H2 (MVV electr. FWD)
Y4 Pilot solenoid valve for valve G1 (GV2 valve TRASM. 2)

10-11
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC

Forward

A B A B A B

D C D C D C

Output
Input shaft
shaft
A B
L gear M gear H gear

D C

A B

POSIZIONE FOLLE

D C

D0012592
Reverse

Solenoid valve operation when shifting from L to H gear (L→M→H)

Forward
Solenoid valve Reverse
L M H
Y1 ●
Y2 ● ●
● = Solenoid valve energised
Y3 ● ● ●
Y4 ●
Clutch A B C D
Point of measure 2 7 6 5

Solenoid valve operation when shifting from H to L gear (H→M→L)

Forward
Solenoid valve Reverse
H M L
Y1 ●
Y2 ●
● = Solenoid valve energised
Y3 ● ● ●
Y4 ● ●
Clutch C B A D
Point of measure 6 7 2 5

10-12
1. TRANSMISSION 1.1 TRANSMISSION POWER SHUTTLE

1. TRANSMISSION
1.1 TRANSMISSION POWER SHUTTLE
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC COMPONENTS
A1 Electronic transmission control unit (EST57)
A2.1 Range selector lever (L M H S)
EST-45
36 SD 4
A2.2 Shuttle control lever (FORWARD/REVERSE)
ED 11 29
A9
ED 8 44 57 ADM 5
EU 1
ED 6
38
67
11 ADM 6 A3 Gearbox control valve
ED 7 22
ED 1 63 32 AIP 3
ED 2 65 55 AIP 4 A5 Diagnostics
ED 3 20 A1

EDM 1 31 56 AIP 1 H3
A6 Display
ER 1 39
EF 7 17 5 ADM 4 A12
EF 6
EF 5
40
16 A9 Tachymeter
EF 4 62 14 SD 1 A6
15 SDDK
H5
A11 Proportional solenoid valve for main clutch control

A5
A12 INFOCENTER
B1 Engine speed sensor (nLse - nMot)
B10 +
-
A2.1 B3 Hydraulic gearbox output speed sensor (nAb)
A2.2
B4 Transmission input speed sensor (nLsa)

B11
B9 Clutch speed sensor (nHk)
B13
A11 S4
S6 PEDALE K1 B10 Clutch pedal position sensor
FRIZIONE

B11 Temperature sensor

B9
TRASMISSIONE B13 Clutch proximity sensor
B3 4+4+4 VELOCITA' B4
MOTORE
ENDOTERMICO
FRIZIONE
F1 Fuse (7.5A)
B1 F2 Fuse (7.5A)
H3 Low oil pressure indicator lamp
H5 Audible alarm
K1 Interlock starter relay 70A
S4 Mechanical gearbox neutral sensor
1 F1 2 KL.30
(+)
1 F2 2 KL.15
S6 Transmission oil low pressure sensor (18 bar)
(+)

1 1

B13 H3 P S6
B9 3 B4 3 B3 3 B1 3 2 2
A5 1
2 2 2 2 44 45 23 68 5 66 29
ED8 VP1 VPE1 VPE2 ADM4 ED9 ED11
4 15 2
1 1 1 1 VMG2 SDDK
17
EF7
3 36 A6 X2:D H5
40
VMG1 SD4 A9
EF6
62 3 X2:A
EF4 14 X1:B
16 SD1
EF5
38
EU1
37 57 C
2 AU ADM5 Y2(GV1)
11 F X2:C
A1 ADM6 Y4(GV2)
B10 H
3 VPS2
8 E
(+)
A12
T
24
1 VMGA1
OPTION
H
T
B11 32 D A3
39 AIP3 Y3(MVV)
ER1 55 B
VP 67 AIP4 Y1(MVR)
A2.1 TIPP + ED6 A
22 (+)
TIPP - ED7
56 1
63 AIP1 FK
V - AUTOM. ED1 13 2 A11
65 VPS1 (+)
VP N - AUTOM. ED2
20
R - AUTOM. ED3
EDM1 VM1 VM2
A2.2
KL.30 31 01 02
87 85
1
K1 S4
30 86
2

KL.50a KL.50
Mot. avv. Blocco. avv.

D0012680

10-13
PAGE INTENTIONALLY
LEFT BLANK
1. TRANSMISSION 1.2 REAR AXLE

1. TRANSMISSION
1.2 REAR AXLE
DESCRIPTION
The rear axle receives drive from the pinion (4) and transmits drive through the differential (5) and epicyclic reduction units
(2) to the rear wheels (1).
The rear axle is equipped with an electro-hydraulically controlled differential lock (6) and two hydraulically operated brakes
(3)

2 3 4 3 2

1
1

6 5
D0012670

COMPONENTS
1. Wheels
2. Epicyclic reduction unit
3. Brake
4. Pinion
5. Differential
6. Differential lock

10-15
1. TRANSMISSION 1.2 REAR AXLE

COMPONENTS

1 1

2 3 4

9
10 9 8 7

D0012690
12 11

1. Brake control device 9. Brake

2. Central axle housing 10. Half-shaft
3. Differential lock 11. Crown wheel
4. Crown wheel 12. Differential
5. Axle casing
6. Half-shaft
7. Planet carrier
8. Planet gear

10-16
1. TRANSMISSION 1.3 REAR PTO

1.3 REAR PTO

DESCRIPTION
The rear PTO provides drive for external implements at a preselected rotation speed.
The rotary drive is taken directly from the engine and then reduced through a 2 -or 4-speed gearbox with manual speed se-
lection.
The PTO is engaged by way of an electro-hydraulically controlled clutch.

2 SPEED VERSION 4 SPEED VERSION

1
1

3 2 3
5 5
4 4

1000 rpm a 750 rpm a c 1400 rpm

540 rpm b 540 rpm b d 1000 rpm

D0012700

1. Clutch 1. Clutch
2. Synchronizer 2. Synchronizer
3. 540 rpm driven gear 3. 540 rpm driven gear
4. 1000 rpm driven gear 4. 750 rpm driven gear
5. PTO shaft 5. PTO shaft
6. 1000 rpm driven shaft
7. 1400 rpm driven gear

10-17
1. TRANSMISSION 1.3 REAR PTO

COMPONENTS

2 SPEED VERSION 4 SPEED VERSION

1 2 1 2

3 3
4 4

5 5
6 6
7 7 D0012710

1. PTO input shaft 1. PTO input shaft

2. PTO clutch 2. PTO clutch
3. PTO output shaft 3. PTO output shaft
4. Power take-off 4. Power take-off
5. Synchronizer 5. Synchronizer
6. 1000 rpm driven gear 6. 750 rpm driven gear
7. 540 rpm driven gear 7. 540 rpm driven gear
8. 1001400750 rpm driven gear

10-18
2. BRAKING SYSTEM DESCRIPTION

2. BRAKING SYSTEM

DESCRIPTION
The braking system is comprised of 2 braking devices (one for each rear wheel) operated by two hydraulic pumps by way
of mechanical controls.
Each pump supplies fluid to the brake on one side (left or right) thereby allowing the operator to brake on one side only and
thus reduce the steering radius.

3
2
5

4
6

8
7

D0011720

1. Brake fluid reservoir 6 Right brake

2. Right master cylinder 7. Left brake
3. Brake microswitches (n° 2) 8 Left master cylinder
4. Brake pedal
5. Rear axle

10-19
2. BRAKING SYSTEM 2.1 BRAKE MASTER CYLINDER

2.1 BRAKE MASTER CYLINDER

1
2
3

D0004520

1. Bleed screw TECHNICAL DATA

2. Barrel Piston diameter: 23.81 mm (0.938 in.)
3. Push-rod Piston stroke: 30 mm (1.182 in.)
Maximum operating pressure: 120 bar (1740 psi)

10-20
2. BRAKING SYSTEM 2.2 BRAKE

2.2 BRAKE

5
1

A-A

A A

7
D0004530

1. Piston 5. Support
2. Plunger 6. Rod
3. Adjustment nuts 7. Parking brake control lever
4. Lever

10-21
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

2.3 TRAILER BRAKING SYSTEM

The tractor may be equipped with one of the four following trailer braking systems:
1. hydraulic trailer braking (Italy version)
2. hydraulic trailer braking (Export version)
3. air trailer braking (Italy version)
4. air trailer braking (Export version)

2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)

Parking brake
Freno a mano

1
3

P
Y

E
B N 2
2

D0012720

1. Valve activation lever in position “1”

• When the lever (1) is in position “1” (valve activated) and the brake pedals are not pressed, a pressure of 12.5 bar
(181.3 psi) is available at port B.
• This pressure is supplied constantly to the trailer to release the parking brake.
• When the operator engages the parking brake, the solenoid valve (2) is energised; this nullifies the pressure at
port B.
• The pressure at port B is directly proportional to the pressure present in the tractor braking circuits Y.

2. Valve activation lever in position “O”

• When the lever (1) is in position “O” (valve deactivated), there is no pressure at port B.
In this condition, the pressure at port B is always null independently of the pressure in the tractor braking circuits.

10-22
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

1
N

E B

HYDRAULIC DIAGRAM
P

E
B T
D0012730

FUNCTION TECHNICAL DATA

Port P - Valve feed • Maximum pressure at port N:
Port N - To lubrication line 210 bar (3046 psi)
Port B - To trailer brake • Minimum constant pressure at port B::
Port T - Drain 12.5±2 bar (181.3±29 psi)
Port Y - Connection to tractor braking system • Maximum pressure at port B:
135 --0 5 bar (1957.5 --0 72.5 psi)
• Feed flow rate:
20–80 ᐉ/min (5.3 -- 21.14 US.gpm)

10-23
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)

N
B

D0022940

• When the brakes are not operated the pressure at port B is null.
• When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at
port B increases proportionally to the pressure in the tractor braking circuit.

10-24
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

HYDRAULIC DIAGRAM
P T

D0004570
N B

Port P - Valve feed TECHNICAL DATA

Port N - To lubrication line • Maximum pressure at port N:
Port B - To trailer brake 200 bar (2900 psi)
Port Y - Connection to tractor braking system • Minimum constant pressure at port B:
Port T - Drain • Maximum pressure at port B:
130–150 bar (1885–2175 psi)
• Feed flow rate:
20–80 ᐉ/min (5.3 -- 21.14 US.gpm)

10-25
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

2.3.3 AIR TRAILER BRAKING (ITALY VERSION)

3
E
2 4
5
1

G
9
10
8 7

D0011690

COMPONENTS 6. Trailer braking valve

1. Compressed air reservoir 7. Circuit pressure sensor
2. Air compressor 8. Circuit pressure indicator
3. Engine 9. Brake master cylinder
4. Pressure limiting valve (7.8 bar (113 psi)) 10. Brake
5. Quick-action coupler for trailer

10-26
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)

3
E
2 4

1 5

Red

Yellow 5

6 Black

7
G

9 8

10 11

D0011681

1. Compressed air reservoir 6. Trailer braking valve (2-way)

2. Air compressor 7. Trailer braking valve (1-way)
3. Engine 8. Circuit pressure sensor
4. Pressure limiting valve (7.8 bar (113 psi)) 9. Circuit pressure indicator
5. Quick-action coupler for trailer 10. Brake master cylinder
11. Brake

10-27
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

COMPRESSOR

3
a

D0012880

a. Compressor lubrication TECHNICAL DATA

b. Compressor lube oil return Bore: 75 mm
c. Port 0 - Air intake Stroke: 36 mm
d. Port 2 - Air delivery Displacement: 159 cm³
1. Cylinder head Max. pressure.: 18 bar
Crankshaft end float: 0.2 – 0.6 mm
2. Cylinder
3. Drive shaft

10-28
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

PRESSURE LIMITING VALVE

1 21

1-2

DIAGRAM

7,8±0,2 bar

1 21
0
12 + 2 bar

22 3 1-2

D0004690

Port 1 - From compressor TECHNICAL DATA

Port 3 - Excess pressure vent Cut-out pressure: 7.8±0,2 bar (113±2.9 psi)
Port 21 - To compressed air reservoir Cut-in pressure: 0.6–1 bar (8.7 – 14.5 psi)
Relief valve setting: 12 +0 2 bar (174 +0 29 psi)

10-29
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

TRAILER BRAKING VALVE (2-WAY)

41 42 1

DIAGRAM
3

1
41
42

P2 (bar)
9
Pressione di mandata

7
2
)
,42

6
41
f (P

)
5 42
f(
1
2=

2 =
P4

4 P4
1)
3 P4
f(
2=
2 P4

0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
P41/P42 (bar) D0004760
Pressione idraulico di comando

a. Parking brake actuating lever Port 1 - From compressed air reservoir

b. Bleed screw Port 2 - To trailer brake
Port 41 - From left brake
Port 42 - From right brake

10-30
2. BRAKING SYSTEM 2.3 TRAILER BRAKING SYSTEM

TRAILER BRAKING VALVE (1-WAY)

4
2
1

D0004710

Port 1 - From compressed air reservoir

Port 2 - To trailer brake
Port 4 - Pilot from delivery line to trailer
(2-way braking)

10-31
3. HYDRAULIC FRONT AXLE SUSPENSION DESCRIPTION

3. HYDRAULIC FRONT AXLE SUSPENSION

DESCRIPTION
The function of the hydraulic front suspension system is to absorb impacts when travelling over rough terrain and to keep
the tractor body on an even keel on the road.
The system comprises
• swinging axle support arm (1)
• position sensor (2)
• 2 suspension cylinders (3)
• front suspension control valve (4)
• electronic control unit (5)

4
5

2
1 D0004720

10-32
3. HYDRAULIC FRONT AXLE SUSPENSION 3.1 FRONT SUSPENSION CONTROL VALVE

3.1 FRONT SUSPENSION CONTROL VALVE

FUNCTION
In addition to the primary function of enabling front axle suspension by charging the hydraulic-pneumatic accumulators
that constitute the elastic elements of the system, the front suspension control valve also serves to control the raising and
lowering of the front axle.

1 ASP

A
SV1

BL2 RV3

DBV2 LS-V
LS 6
5 BL3 AV2

SV2
2
B

ZSP1
ASP
RV1
BL1 3

SCHEMA
5
A LS
LS DBV1
LS-V P T
BL3

BL2
ASP1 ASP2 T AV1
S
RV2
AV1 DBV1 DBV2
SV1

250 +10 bar 250 +10 bar RV3

A
AV2
RV2

H
ZSP1 SV2
BL1
RV1
B P
D0004750

1. Cylinder retraction control solenoid valve 5. Pressure discharge valve

2. LS signal control solenoid valve 6. Accumulator (setting: 140 bar)
3. Cylinder extension control solenoid valve 7. Use A relief valve (setting: 250 bar)
4. Accumulator (setting: 65 bar) 8. Use B relief valve (setting: 250 bar)

10-33
3. HYDRAULIC FRONT AXLE SUSPENSION 3.1 FRONT SUSPENSION CONTROL VALVE

OPERATION

1. When the suspension is deactivated

LS
LS
A
1
LS-V

BL3
P T 7

6 ASP1 ASP2 T
BL2
4 S

DBV1 DBV2
SV1
AV1
RV3
A AV2

3 ZSP1
RV2
5 2
H

b
SV2
BL1
B RV1 P

a D0004640

• When the suspension is deactivated, the electronic control unit energises the solenoid (1) by sending an LS signal to
the priority valve (in the case of the gear pump version) or to the variable displacement pump.
• This allows the pressurised oil from the pump (2) to flow to line a and compress the membrane of the accumulator (3)
up to the maximum circuit pressure.
• The oil is discharged from the piston side through passage B and through the solenoid valve (7) which is energised.
• The piston (4) is consequently pushed upwards to its stroke-end position, thereby returning the system to fixed axle
condition.
• The suspension is deactivated by the operator pressing a switch.

10-34
3. HYDRAULIC FRONT AXLE SUSPENSION 3.1 FRONT SUSPENSION CONTROL VALVE

2. When the operator activates the system

A
LS
LS
LS-V
P T
BL3

6 ASP1 ASP2 T
BL2 S
4
DBV1 DBV2
SV1
AV1
RV3
5
A AV2

RV2
ZSP1
2
b H
SV2
BL1
B RV1 P

a D0004650

• When the operator presses the switch to activate the suspension, the electronic control unit energises the solenoids
(1) and (5).
• This allows the pressurised oil from the pump (2) to flow to line b and thus start to push the piston (4) downwards.
• At the same time, the oil compresses the membranes of the accumulators and the oil in lines a and b increases.
• When the pressure in line a reaches the opening pressure of the relief valve (8), the valve opens and discharges some
of the oil to the drain circuit.
• When the position sensor detects that the suspension has attained the levelling position, the electronic control unit
de-activates the solenoids (1) and (5) and the part of the system containing the precharged accumulators is isolated
from the rest of the system.

10-35
3. HYDRAULIC FRONT AXLE SUSPENSION 3.1 FRONT SUSPENSION CONTROL VALVE

3. When the system is active

• When the tractor is in motion and the wheels encounter an obstacle, the front axle is pushed upwards.
• This causes the pressure P2 to increase (the accumulators 6 are compressed) while the pressure P1 decreases (ac-
cumulator 3 is decompressed).
• The pressure balance is thus altered and the system (which is closed) acts to restore the original condition..
1

A
LS
LS
LS-V
P T
BL3

6 ASP1 ASP2 T
BL2 S

DBV1 DBV2
SV1
P2 AV1
RV3
5
A AV2

3 ZSP1 RV2
2
P1 H
SV2
BL1
B RV1 P

4 D0004660
S

S max
P2 max
S,P2

S min
t
P1

P1 min

t shock t damping t
D0002411

10-36
4. FRONT AXLE

4. FRONT AXLE

B B

1660
=

A A
=

52º –0 2

1660
D0011790

10-37
5. HYDRAULIC SYSTEM

5. HYDRAULIC SYSTEM

DESCRIPTION
The Agrotron series is equipped with a Closed Centre (CC) hydraulic system, with one gear pump to supply the trans-
mission circuit and a tandem gear pump to supply the steering circuit and services (auxiliary service control valves, trailer
braking, etc.).

The CC hydraulic system supplies oil to the loads at a rate of flow that is proportional to the engine speed.
This means that when the engine is running at top speed and no hydraulic services are in operation (e.g. during road use),
the pump will continue to circulate oil in the hydraulic circuit at the rate of approximately 80 litres per minute (with a con-
sequent increase in temperature and oil consumption) without any of this oil being used.

10-38
5. HYDRAULIC DIAGRAM 5.1 HYDRAULIC DIAGRAM (version with remote control valves without flow control)

5. HYDRAULIC DIAGRAM
5.1 HYDRAULIC DIAGRAM (version with remote control valves without flow control)

1. Suspension control valve

6

EP
Load Sensing suspension
1
2. Front axle suspension

WV3
LS
A cylinder (2)
LS
LS-V P T
A 3. Trailer braking valve

1
0

F
BL3
T
4. Solenoid valve controlling flow
ASP1 ASP2
BL2
B
p =65bar
0
p =65bar
0
DBV1 DBV2
to front axle control valve
S
AV1

WV4
250 +10 bar
5. Power steering

250 +10 bar

SV1

2 RV3 5 6. Steering cylinder

A 3 3

ZSP1 A 7. Auxiliary services control valve

1
0

F
RV2 AV2
p =140bar
0

H
SV2 B (spools 3 and 4)
B RV1
BL1

L R
8. Auxiliary services control valve
P (spools 1, 2 and lift)
250±10
250±10 barbar 250±10 bar 4
9. Lift

AP
10. Trailer brake connection

Y
R

P
11. Rear PTO lubrication

N B 3 12. Rear axle lubrication

7

EP
13. Filter for services circuit

Y
24 Y 180 +10 bar 14. Filter for steering circuit

WV1
180 +10 bar

P T 15. Gear pump for services and

P T steering circuit
A

1
0

F
23 16. Filter for transmission circuit
B 8 17. Gear pump for

EHR
40 bar
R1 transmission circuit
20

H
18. Filter for transmission circuit

S
25 A 19. Four-wheel drive control
22 21 18 bar
solenoid valve

WV2
19 20. Hydraulic gearbox
control solenoid valve
A

1
0

F
21. Differential lock
B control solenoid valve

AP
22. Rear PTO control
solenoid valve
18 15 p= 3 bar in pos. 0
p=8,4 bar in pos. 1 or 2
23. Lubrication circuit
P
32 14 pressure relief valve
R P
24. Cooler
25. Transmission lubrication
9

17 13 14
25
10
25 +10 bar

16
12 11
D0022950

10-39
5. HYDRAULIC DIAGRAM 5.2 HYDRAULIC DIAGRAM (version with remote control valves with flow control)

5.2 HYDRAULIC DIAGRAM (version with remote control valves with flow control)

6 1. Suspension control valve

EP
1 Load Sensing suspension

WV4
LS 2. Front axle suspension
A
cylinder (2)
LS
LS-V P T
A 3. Trailer braking valve

1
0

F
BL3
T
ASP1 ASP2
BL2
B 4. Solenoid valve controlling flow
p =65bar p =65bar

2
0 0

AV1
DBV1 DBV2 S
to front axle control valve

WV3
250 +10 bar

250 +10 bar

SV1
5. Power steering
RV3 5
A 3 3
6. Steering cylinder
ZSP1 A

1
0

F
RV2 AV2
p =140bar
0 7. Auxiliary services control valve
H
SV2 B (spools 3 and 4)
BL1
B RV1
L R 8. Auxiliary services control valve
P 250±10
250±10 barbar 250±10 bar 4 (spools 1, 2 and lift)
9. Lift
10. Trailer brake connection

Y
R

P
11. Rear PTO lubrication
N B 3 12. Rear axle lubrication
7

EP
13. Filter for services circuit

Y
24 Y 180 +10 bar
14. Filter for steering circuit

WV2
180 +10 bar

P T 15. Gear pump for services and

P T steering circuit
A

1
0

F
23 16. Filter for transmission circuit
B 8
17. Gear pump for

EHR
40 bar
R1 transmission circuit
20

H
18. Filter for transmission circuit

S
25 A 19. Four-wheel drive control
22 21 18 bar
solenoid valve

WV1
19 20. Hydraulic gearbox
A
control solenoid valve

1
0

F
21. Differential lock
B control solenoid valve

AP
22. Rear PTO control
solenoid valve
18 15 p= 3 bar in pos. 0
p=8,4 bar in pos. 1 or 2
23. Lubrication circuit
32 14
P pressure relief valve
R P
24. Cooler
9 25. Transmission lubrication

17 13 14
25
10
25 +10 bar

16
12 11
D0022960

10-40
5. HYDRAULIC DIAGRAM 5.3 GEAR PUMP FOR TRANSMISSION ZF 7100

5. HYDRAULIC DIAGRAM

5.3 GEAR PUMP FOR TRANSMISSION ZF 7100

P P

L View X

0
25 + 10 bar
P

D0011730
L

FUNCTION TECHNICAL DATA

Port L: suction Displacement: 25 cc/rev
Port P: delivery Maximum pressure: 25 +0 10 bar

10-41
5. HYDRAULIC DIAGRAM 5.4 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING

5.4 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING

L1 L2

P1 P2

P2 P1

View X
D0011710

FUNCTION CHARACTERISTICS
Port L1: inlet Pump P1
Port L2: suction Displacement: 32 cc/rev
Port P1: supply to services Maximum pressure: 200 bar (2900 psi)
Port P2: supply to power steering Pump P2
Displacement: 14 cc/rev
Maximum pressure: 180 bar (2610 psi)

10-42
5. HYDRAULIC DIAGRAM 5.5 POWER STEERING

5.5 POWER STEERING

L R
T P

L R

LS

P T LS

D0012010

FUNCTION CHARACTERISTICS
Port P: delivery Displacement: 150 cc/rev
Port T: return Maximum pressure: 180–190 bar
Port R: right steering Relief valve: 240–260 bar
Port L: left steering

10-43
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

5.6 AUXILIARY SERVICES CONTROL VALVE

FUNCTION
• The function of the auxiliary services control valve is to control the flow of oil to the auxiliary services and the rear lift.
• This control valve is of the serial type, i.e. it can be operated one spool at a time.

1 2 3 3 5 4

B A B A A

7 6

REAR GEARBOX D0011800

DESCRIPTION
• The pressurised oil from the pump (1) enters the inlet section (2), from where it is distributed to the spools (3), (4)
through the internal passages.
• The inlet section (2) has a pressure relief valve (7) that serves to prevent an excessive increase in the operating pres-
sure of the loads.
• On the lift element (4) there is a flow control valve (6) that serves to send excess oil supplied by the pump to the lu-
brication circuit.
• On the lift control element (5) there is also an antishock valve (on the "up" control side), which serves to prevent any
excessive pressure surges caused by jolting of the implement.

10-44
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

5.6.1 TYPES OF CONTROL VALVE

8-WAY VERSION (without flow control)

2 3
4 5 7 8

A A A A
R1
1 P
P 9

A R

Y B B B B
6
10 10 10 10

HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM

1 2 3 4 5 6 7 8 9

EP WV1 EHR WV2 AP EP WV3 WV4 R

R
Y
S
P P
p=8.4 bar in pos. 1 or 2
p= 3 bar in pos. 0

1 1 1 1

0 0 0 0
2 2 2 2
H
F F F F

Y A B R1 A A B A B A B

11 D0022980
10 10 10 10

1. End cover 7. Control valve section n° 3

2. Control valve section n° 1 8. Control valve section n° 4
3. Lift control valve section 9. Inlet manifold
4. Control valve section n° 2 10. Check valve
5. Inlet manifold 11. Pressure relief valve
6. End cover

10-45
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

8-WAY VERSION (with flow control)

2 3
4 5 7 8

A A A A
R1
1 P
P 9

A R

Y B B B B
6
10 10 10 10

HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM

1 2 3 4 5 6 7 8 9

EP WV1 EHR WV2 AP EP WV3 WV4 R

R
Y
S
P P
p=8.4 bar in pos. 1 or 2
p= 3 bar in pos. 0

1 1 1 1

0 0 0 0
2 2 2 2
H
F F F F

Y A B R1 A A B A B A B

11 D0022990
10 10 10 10

1. End cover 7. Control valve section n° 3

2. Control valve section n° 1 8. Control valve section n° 4
3. Lift control valve section 9. Inlet manifold
4. Control valve section n° 2 10. Check valve
5. Inlet manifold 11. Pressure relief valve
6. End cover

10-46
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

5.6.2 SERVICES CONTROL SECTION

2
B
A
3

R R

Y
4

P
1

6 5 D0005100

1. Spool return device 4. Flow control

2. Check valve 5. Flow control spool
3. Spool 6. Check valve

10-47
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

5.6.3 DESCRIPTIONS OF COMPONENTS

SPOOL RETURN DEVICE

1
2

D0005040

1. Spool return spring

2. Spool

CHECK VALVE (NR)

3 B
4
1
R
2

D0005050

1. Slide 4. Valve seat

2. Ball 5. Spool
3. Check valve spring

10-48
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

FLOW CONTROL VALVE

1 2
3

D0005060

1. Spring
2. Flow control spool
3. Control shaft

10-49
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

5.6.4 INLET MANIFOLD (CC version)

DESCRIPTION
The function of the inlet manifold is to send only the required amount of oil to the actuators and to send any excess oil sup-
plied by the pump to the drain circuit.
The inlet manifold also includes a relief valve that limits the operating pressure of the actuators.

3 HYDRAULIC DIAGRAM

4
1
4
P 3

2
R

2 1
D0005070

1. Pressure compensating valve spool

2. Compensating valve spring
3. Relief valve
4. Relief valve spring

10-50
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

OPERATION

1. When the actuators are not operated

b
a

1 CONTROL VALVE

D0005080

• When the engine is running and the driver does not operate any of the hydraulic service controls, the pump sends oil
to the inlet manifold (port P).
• As all the actuators are stationary, the oil pressure increases in chamber a and consequently also in chamber b.
• When the oil pressure in chambers a and b exceeds the force exerted by the spring (2), the spool (1) is shifted down-
wards, allowing the excess oil from the pump to flow to drain.

10-51
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

2. When an actuator is operated

b
CONTROL VALVE
a

P
y

5
c 2

D0005090

• When an actuator is operated, the pressure required for its operation is also directed to the channel y (Load Sensing
signal channel) and then sent to chamber c of the manifold.
• This causes the spool (1) to shift upwards and the oil required to operate the load is sent to the control valve.
• When the load pressure balances the force of the spring (4), poppet (5) is shifted to the left, allowing limitation of the
operating pressure.

10-52
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

5.6.5 LIFT CONTROL VALVE SECTION

DESCRIPTION
• The lift control section is a 1-way hydraulic control valve operated by two proportional solenoid valves.
• The control incorporates an antishock valve that protects the hydraulic circuit and against pressure surges caused by
jolting of the implement during work and transpor.

HYDRAULIC DIAGRAM
P Y R

A
P Y R

1 2 3 4 5 7

A R

D0004920

11 10 9 8 6

COMPONENTS 7. DOWN control solenoid valve

1. UP control solenoid valve 8. Flow control spring
2. Check valve 9. Flow control spool
3. Check valve spring 10. Spring
4. Antishock valve 11. UP control spool
5. Antishock valve spring
6. DOWN control spool

10-53
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

OPERATION
1. When the lift control is in neutral position)
• The oil from the pump enters chamber a and from here flows into passage b.
• At the same time the oil flows into chamber c of the flow control (1) through passage d.
• This causes the spool to shift to the right until the connecting passage between chamber a and passage b is closed.
• The pressure in chamber e caused by the weight of the implement mounted on the linkage (e.g.: plough), keeps the
check valve (2) closed, thereby ensuring that the lift maintains its position.
• The chamber e is thus a closed chamber that prevents any uncontrolled movement of the lift.
• The pressure in chamber e also acts on the antishock valve (3) that eliminates any pressure surges caused by jolting
of the implement during work or transport.

e 3

A R

c b d a 1 D0004930

10-54
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

2. When the lift is raised

• When the lift is raised, the electronic lift control energises the solenoid (4) which move the spool (5) to the right.
• The oil in passage b can therefore flow through the check valve (2) into chamber e and from there to the lift cylinders.
• At the same time, the pressure present in passage b can flow into the chamber i and into the passage f and from there
through the channel g into chamber h of the flow control (1).
• As the oil pressure is the same on both sides of the spool, the spool is shifted by the force of the spring (6) and the oil
can flow from chamber a into the passage b.

e 2

4 5

A R

i D0004940

b 1 g a 6 h

10-55
5. HYDRAULIC DIAGRAM 5.6 AUXILIARY SERVICES CONTROL VALVE

3. When the lift is lowered

• During lifting or when the lift is stationary, the spool (8) is pushed to the right by the spring (9).
• As a result, the passage between the chambers m and n is closed and the pressure in chamber p pushes the spool
(10) to the right.
• When the lift is lowered, the electronic lift control energises the solenoid (7) that moves the spool (8) to the left.
• The oil in chamber n can flow into chamber m and the pressure in chamber p is reduced.
• Now the force balance coming from the pressure in the chambers e and p influencing the spool (10), is disturbed and
moved to the left. Oil can flow now from e to m.
• As a result, the oil in the lift cylinders is directed to the drain circuit and the lift is lowered.
• As the solenoid is of the proportional type, the more current supplied, the more the spool (8) shifts to the left, thereby
allowing more oil to flow and the lift to descend more rapidly.
• The electronic control obtains float position by energising the solenoid valve (7) and holding it fully open.
• In this condition, the oil in the lift cylinders is sent to the drain circuit so that the lift is free to move up and down and
follow the contours of the terrain.

10 e n m 9 8

A R

p
7
A R

D0004950

10-56
 CONTENTS

SECTION 20

CONTENTS

1. DIAGNOSIS TOOLS “ALL ROUND TESTER .................... 1 • • 4.3.3 CALIBRATION OF THE MAIN CLUTCH
• 1.1
ALL ROUND TESTER ......................................................... 1 PROPORTIONAL SOLENOID VALVE........................29
• •
1.1.1 DESCRIPTION OF THE KIT ....................................... 1 • 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM
• •
1.1.2 NOTES ON CORRECT USE ...................................... 2 CONTROL UNIT ................................................................31
• •
1.1.3 DESCRIPTION OF THE TESTER ............................... 2 • • 4.4.1 PROGRAMMING THE TYPE OF TRACTOR............. 32
• •
1.1.4 GENERAL NOTES ON CONNECTING AND • • 4.4.2 CONFIGURING NO RADAR STATUS ...................... 33
POWERING UP THE TESTER ................................... 3 • • 4.4.3 CALIBRATION OF THE LIFT POSITION
• • 1.1.5 SELECTION OF THE DISPLAY LANGUAGE ............. 3 SENSOR................................................................... 34
• • 1.1.6 SETTING THE SERIAL PORTS.................................. 5 • • 4.4.4 CHECKING AND CALIBRATING THE LIFT
• 1.2 “SERDIA 3.5 LEVEL III” SOFTWARE .................................. 7 CONTROL LEVER 36
• • 1.2.1 DESCRIPTION OF THE KIT ....................................... 7 • 4.5 RENEWAL OF THE INFOCENTER ....................................39
• 1.3 “EDS EST45” SOFTWARE ................................................. 8 • • 4.5.1 ENTERING CONSTANTS ......................................... 39
• • 1.3.1 DESCRIPTION OF THE KIT ....................................... 8 • 4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT ......41
• • 4.6.1 CHECKING CALIBRATION OF THE
2. CONNECTING THE TESTER TO THE ELECTRONIC
SUSPENSION POSITION SENSOR 41
CONTROL UNITS .............................................................. 9
• 2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND 5. ALARMS .......................................................................... 43
FRONT AXLE SUSPENSION CONTROL UNITS ................ 9 • 5.1 LIFT AND ASM CONTROL UNIT ALARMS .......................43
• 2.2 CONNECTING THE PORTABLE COMPUTER WITH • • 5.1.1 LIST OF ALARMS BY EXTENDED CODE ................ 44
“SERDIA 3.5” SOFTWARE TO THE ENGINE CONTROL • • 5.1.2 LIST OF ALARMS BY STANDARD CODE................ 46
UNIT ................................................................................. 10 • • 5.1.3 LIST OF ALARMS DISPLAYED ON ART .................. 48
• • 5.1.4 ANALYSIS OF LIFT AND ASM ALARMS.................. 50
• 2.3 CONNECTING THE PORTABLE COMPUTER WITH “EDS”
SOFTWARE TO THE TRANSMISSION CONTROL UNIT • 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS .......79
AND INFOCENTER............................................................ 11 • • 5.2.1 ABNORMALITIES NOT DETECTED BY THE
• • 2.3.1 CONNECTION TO THE TRANSMISSION TRANSMISSION CONTROL UNIT 79
CONTROL UNIT 11 • • 5.2.2 ALARMS INDICATED ON THE TRANSMISSION
• • 2.3.2 CONNECTION TO THE INFOCENTER .................... 11 DISPLAY AND BY THE EDS PROGRAM 79
• • 5.2.3 DEFINITION OF TRANSMISSION OPERATING
3. INTRODUCTION TO THE ELECTRONIC SYSTEM MODES 83
OF THE TRACTOR .......................................................... 13 • • 5.2.4 ANALYSIS OF ALARMS ........................................... 84
• 3.1 ENGINE CONTROL UNIT (DEUTZ EMR2) ........................ 13 • 5.3 LIST OF ALARMS DISPLAYED BY SERDIA ....................139
• 3.2 TRANSMISSION CONTROL UNIT ................................... 15 • • 5.3.1 ALARMS DISPLAYED USING THE SERDIA
PROGRAM 139
• 3.3 POWER LIFT CONTROL UNIT ......................................... 16
• • 5.3.2 ANALYSIS OF ALARMS ......................................... 141
• • 3.3.1 HYDRAULIC LIFT SYSTEM..................................... 16
• • 3.3.2 ASM SYSTEM.......................................................... 17 • 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL
VALVE ALARMS ..............................................................161
• 3.4 INFOCENTER 2 or 3 ......................................................... 18
• • 5.4.1 LIST OF ALARMS BY TEXT CODE ........................ 161
• 3.5 FRONT AXLE SUSPENSION CONTROL UNIT ................. 19 • • 5.4.2 LIST OF ALARMS BY STANDARD CODE.............. 162
• 3.6 FRONT AND REAR PTO CONTROL UNIT ....................... 20 • • 5.4.3 LIST OF ALARMS DISPLAYED BY ART................. 163
• • 5.4.4 ANALYSIS OF ALARMS ......................................... 164
4. PUTTING THE TRACTOR INTO SERVICE .................... 21
• 4.1 INTRODUCTION ............................................................... 21 6. OPERATOR’S MANUAL EDS
(Electronic Diagnosis System) .................................... 177
• 4.2 RENEWAL OF THE ENGINE CONTROL UNIT ................. 21
• • 4.2.1 READING AND SAVING DATA ................................ 21 • 1. GENERAL INTRODUCTION ............................................177
• • 4.2.2 PROGRAMMING THE CONTROL UNIT .................. 22 • • 1.1 FUNCTIONAL SCOPE............................................ 177
• • 4.2.3 CALIBRATION OF THE ACCELERATOR PEDAL .... 23 • • 1.2 HARDWARE REQUIREMENTS .............................. 178
• • 4.2.4 CALIBRATION OF THE HAND THROTTLE ............. 24 • • 1.3 STARTING AND TERMINATING OF THE EDS
PROGRAM 180
• 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT .... 25
• • 4.3.1 SETTING THE TRACTOR VERSION AND SERIAL • 2. TRANSMISSION DIAGNOSIS .........................................182
NUMBER .................................................................. 25 • • 2.1 THE MAIN MENU ................................................... 182
• • 4.3.2 CALIBRATION OF THE CLUTCH PEDAL • • 2.2 ONLINE HELP ........................................................ 184
POSITION SENSOR ................................................. 27

20-i
 CONTENTS

• 3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45 .185 9. SERDIA (LEVEL III) ...................................................... 257

• • 3.1 PREPARATIONS FOR TRANSMISSION • 1.
SETUP AND COMMUNICATIONS .................................. 257
DIAGNOSIS WITH DEST 45 185 • •
1.1 MINIMUM EQUIPMENT REQUIRED...................... 257
• • 3.2 DEST 45 PROGRAM DESCRIPTION .................... 186 • •
1.2 ORDERING............................................................. 258
• • 3.3 ERROR CODES POWER-SHUTTLE /DEST 45 ...... 201 • •
1.3 SWITCHING ON AND INSTALLING THE
• • 3.4 DISPLAY POWERSHUTTLE................................... 202 SOFTWARE 259
• • 3.5 ERROR CODE LIST WITH DESCRIPTION ............. 203 • • 1.4 USING THE PROGRAM ......................................... 263
• • 3.6 OTHER INFORMATIONS ....................................... 214 • • 1.5 CLOSING THE PROGRAM .................................... 266
• • 3.7 SENSORS AND SOLENOID VALVES AT
THE TRANSMISSION T-7100 215 • 2. ECU SELECTION ............................................................ 267
• • 3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100 ....... 216 • • 2.1 SELECTING TWO CONTROL UNITS..................... 267
• • 3.9 SENSORS AND SOLENOID VALVES AT • • 2.2 PRINTING............................................................... 268
THE TRANSMISSION T-7200 217 • • 2.3 PROTOCOL............................................................ 269
• • 3.10 ELECTRO-HYDRAULIC GEAR SHIFT • • 2.4 IDENTIFICATION AND MEASUREMENT DATA..... 269
T-7200 / T-7300 218 • 3. MEASURED VALUES ...................................................... 271
• • 3.11 ERROR ANALYSIS ................................................. 219 • • 3.1 ACTUAL MEASURED VALUES (GENERAL) .......... 271
• 4. PREPARATIONS FOR DIAGNOSIS OF • • 3.2 RAM-VALUES ........................................................ 276
THE INFOCENTER ..........................................................221 • • 3.3 DATA LOGGER (ONLY EMS2) ............................... 280
• • 4.1 PROGRAM DESCRIPTION .................................... 222 • • 3.4 INPUT/OUTPUT ASSIGNMENT............................. 280
• • 4.2 CONSTANT VALUES FOR INFOCENTER.............. 232 • • 3.5 CAN STATUS ......................................................... 280
• 4. PARAMETERS ................................................................ 283
7. ALL ROUND TESTER FOR LIFT AND ASM • • 4.1 CONFIGURATION (GENERAL) .............................. 283
CONTROL UNIT ............................................................ 237 • • 4.2 OVERALL PROGRAMMING................................... 284
• PRESENTATION SCREEN ....................................................237 • • 4.2 CALIBRATION........................................................ 285
• MAIN MENU ..........................................................................237 • 5. ERROR MEMORY ........................................................... 286
• 1. MONITOR ........................................................................238 • • 5.1 GENERAL............................................................... 286
• • 1.1 LIFT ........................................................................ 238 • • 5.2 ERROR TABLE....................................................... 287
• • 1.2 CONSOLE .............................................................. 240 • 6. EXTRAS .......................................................................... 297
• • 1.3 ASM........................................................................ 240 • • 6.1 MAXIMUM SPEED ................................................. 297
• • 1.4 POWER .................................................................. 241 • • 6.2 LOGISTIC DATA..................................................... 297
• • 1.5 SENSORS .............................................................. 242 • • 6.3 LOAD SPECTRUM................................................. 298
• 2. CONFIGURATION ...........................................................242 • • 6.4 MAINTENANCE INTERVAL EXCEEDED ................ 298
• • 2.1 SPEED CONSTANTS ............................................. 243 • • 6.5 OVERRIDE MEMORY ............................................ 298
• • 2.2 OPTIONS................................................................ 243 • • 6.6 MAINTENANCE DATA ........................................... 298
• 3. CALIBRATIONS ..............................................................244 • 7. TASKS ............................................................................. 299
• • 3.1 MINIMUM HEIGHT................................................. 245 • • 7.1 EMR1 ..................................................................... 299
• • 3.2 MAXIMUM HEIGHT................................................ 245 • 8. WHAT TO DO IF...? ......................................................... 303
• • 3.3 LOCK SPEED ......................................................... 246 • • 8.1 SERDIA GENERAL................................................. 303
• • 3.5 TRANSPORT .......................................................... 247 • • 8.2 EMR1 ..................................................................... 305
• • 3.6 STOP ...................................................................... 247
• • 3.7 CONTROL .............................................................. 248
• • 3.8 FLOAT .................................................................... 248
• 4. ALARMS LIST .................................................................249
8. ALL ROUND TESTER FOR AXLE SUSPENSION
CONTROL UNIT ............................................................ 251
• PRESENTATION SCREEN ....................................................251
• MAIN MENU ..........................................................................251
• 1. MONITOR ........................................................................252
• • 1.1 SUSPENSION ........................................................ 252
• 2. PARAMETERS ................................................................253
• 3. ALARMS LIST .................................................................255
• 4. CONFIGURATIONS .........................................................255

20-ii
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.1 ALL ROUND TESTER

1. DIAGNOSIS TOOLS “ALL ROUND TESTER”

1.1 ALL ROUND TESTER
To enable a correct analysis of faults, facilitate the procedure of putting the tractor into service and verify correct operation
of the electrical components used in the lift systems, front axle suspension and ASM, the service technician is provided
with an instrument dubbed the All Round Tester (abbreviated to ART throughout the manual).
Using the ART, the technician can:
- display errors (faults) that have occurred;
- carry out sensor calibration or setting procedures;
- display data monitored by the various electronic control units (e.g. status of sensors) by which systems are managed.
The exchange of data between the ART and the control units occurs by way of one or more diagnosis sockets incorporated
into the wiring harnesses of the tractor.
Accordingly, the ART comes with different types of interface cables for the different models and versions of tractor being
serviced, which must be used as indicated in the relative workshop manuals or on the CD supplied with the kit.
1.1.1 DESCRIPTION OF THE KIT
The ART is supplied to Authorised Workshops in a carrying case containing:

1
9 2
7 8

4
6 5 3
F0057690

Pos Code Description Qty

5.9030.730.6/30 Case, complete 1
1 5.9030.730.0 All Round Tester 1
Rear hydraulic lift diagnosis cable - BOSCH EHR4 1
2 5.9030.681.3 Engine electronic rpm control diagnosis and programming cable - type 1 1
SBA system diagnosis cable - type 1 1
3 5.9030.681.7 Adapter cable for radar connector 1
4 5.9030.681.5 Adapter cable for wheel speed sensor connector 1
5 5.9030.681.4 Cable for diagnostic socket 1
6 0.011.6178.4 Adapter cable for connection to armrest diagnosis socket 1
7 0.011.5445.4 Cable for connection to engine-transmission-lift control units diagnosis socket 1
8 0.010.2145.2 EPROM box 1
9 307.1056.8/60 CD ROM 1
CAUTION
To enable connection of the ART to the tractor electronics, a further adapter cable is required: code 0.012.6655.4
(not supplied with the kit). The cable can be purchased from the parts service.

20-1
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.1 ALL ROUND TESTER

1.1.2 NOTES ON CORRECT USE

The ART is protected against battery polarity inversion, and positive or negative overvoltages of momentary duration (1
msec).
Do not attempt to connect the ART to non-dedicated sockets, and do not use trailing connections or extension ca-
bles.
The display is permanently backlit to ensure readability in any ambient light conditions.
A knob on the side allows adjustment of the contrast. If the display appears blank, the contrast control knob may be in a po-
sition that renders the characters invisible.
The tester operates correctly at temperatures between 0 and 40 °C, and should be switched off every 30 minutes to max-
imise its service life.
Before disconnecting the ART from the diagnostic socket, turn the starter key to the “O” (OFF) position..

1.1.3 DESCRIPTION OF THE TESTER

F0057700

The ART includes:

1 - A backlit liquid crystal display
2 - An alphanumeric keypad with 16 keys
3 - Display contrast control knob.
Used to adjust the contrast. If the display appears blank, the contrast control knob may be in a position that renders
the characters invisible.
4 - Parallel port (used to connect the ART to systems with electronic control units that do not have microprocessors).
5 - Serial port (used to connect the ART to systems with electronic control units incorporating microprocessors).

20-2
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.1 ALL ROUND TESTER

1.1.4 GENERAL NOTES ON CONNECTING AND POWERING UP THE TESTER

To connect the tester to the electronic system of the tractor, proceed as follows:
1 - switch off the engine and remove the starter key;
2 - connect the ART to a diagnosis socket;
3 - insert the starter key and position at “I” (ON).

When the ART powers up, a page appears showing an in- S + L + H T E S T E R

ternal test run by the instrument to check the battery = = = = = = = = = = = = = = = =
charge. If the voltage registers less than 10V, the ART does
not have sufficient power to connect to the control units,
V E R S I O N x x x
whereas if the value is higher than 15V the instrument
could be damaged.
After a few seconds, the tester attempts to connect to the B A T T E R Y T E S T
electronic system and displays a page (which may vary de- I N P R O G R E S S
pending on the tractor or the connector to which it is
plugged), from which the technician can choose to con- V O L T A G E x x . x V
nect to a given control unit and test the operation of the
components.
C O P Y R I G H T 1 9 9 1
E L . E N . S A S
M I L A N O

= = = = = = = = = = = = = = = =

1.1.5 SELECTION OF THE DISPLAY LANGUAGE

The ART is able to display information in a number of different languages (factory setting: ITALIAN).
To change the display language, proceed as follows.
1 - Switch off the engine and remove the starter key.
2 - Connect the ART to a diagnosis socket.
3 - Press and hold A on the keypad, while inserting and positioning the starter key at “I” (ON).

4 - Enter the password 1 2 3 F.

P A S S W O R D :

20-3
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.1 ALL ROUND TESTER

5 - Press 1. C O N F I G U R A Z I O N E

M E N U

1 - S E L . L i n g u a

2 - P o r t e S e r i a l i

S C E L T A

E U S C I T A

6 - Press C and select the key corresponding to the S E L E Z I O N E L I N G U A

required language.
In the example illustrated, pressing 2 selects English D i s p o n i b i l i
language.
7 - Press E twice to exit
1 - I T A L I A N O
8 - Turn the starter key to the “O” (OFF) position and dis-
connect the ART from the diagnosis socket. 2 - E N G L I S H
3 - D E U T S C H
4 - F R A N C A I S
5 - P O R T U G U E S
6 - E S P A N O L
A T T U A L E : I t a l i a n o
N U O V A : E N G L I S H

C p e r c a m b i a r e
E U S C I T A

20-4
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.1 ALL ROUND TESTER

1.1.6 SETTING THE SERIAL PORTS

The tractor electronic systems to which the ART can be connected are different one from another and utilize different
pinouts at the diagnosis socket for interfacing purposes.
For this reason, the serial ports must first be configured so as to guarantee full compatibility of the ART with all SAME elec-
tronic systems.
To change the serial port settings, proceed as follows.
1 - Switch off the engine and remove the starter key
2 - Connect the ART to a diagnosis socket
3 - Press and hold A on the keypad, while inserting and positioning the starter key at “I” (ON)

4 - Enter the password 1 2 3 F.

P A S S W O R D :

5 - Press 2. C O N F I G U R A T I O N

M E N U

1 - L A N G U A G E S E L .

2 - S E R I A L P O R T S

S E L E C T

E T O E S C A P E

20-5
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.1 ALL ROUND TESTER

6 - Enable all serial ports by pressing 1 seven times. S E R I A L . C O N F I G .

7 - Press E twice to exit.
8 - Turn the starter key to the “O” (OFF) position and dis- P r e s e n t 1 0 0 0 1 1 1
connect the ART from the diagnosis socket. S e r i a l N r 7 6 5 4 3 2 1
N e w c o n f i g 1 1 1 1 1 1 1

1 - S e r i a l p o r t O N
0 - S e r i a l p o r t O F F

E T O E S C A P E

20-6
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.2 “SERDIA 3.5 LEVEL III” SOFTWARE

1.2 “SERDIA 3.5 LEVEL III” SOFTWARE

SERDIA is the name given to a software package (code 5.9030.740.4/10) for installation on a portable computer, designed
to assist the technician in making an accurate analysis of faults, setting up the tractor for service and verifying the correct
operation of electrical components associated with the engine.
With SERDIA, the technician can:
- display errors (faults) that have occurred;
- program the control unit;
- carry out sensor calibration or setting procedures.

1.2.1 DESCRIPTION OF THE KIT

The SERDIA software is supplied to Authorised Workshops in a carrying case with all the basic items needed for operation.
The case contains:

3
2

F0059950

Pos. Code Description Qty

5.9030.740.4/10 Case, complete 1
1 5.9030.740.0 . Installation disk 1
2 5.9030.740.2 . Level III interface, General revision 1
3 5.9030.741.0 Adapter cable (not included in kit) 1

The exchange of data between the SERDIA software and the control units occurs by way of a diagnosis socket incor-
porated into a wiring harness of the tractor.
Accordingly, the SERDIA package is supplied with an interface cable that must be used on the particular model and version
of tractor being serviced.

20-7
1. DIAGNOSIS TOOLS “ALL ROUND TESTER” 1.3 “EDS EST45” SOFTWARE

1.3 “EDS EST45” SOFTWARE

EDS is the name given to a software package (code) for installation on a portable computer, designed to assist the tech-
nician in making an accurate analysis of faults, setting up the tractor for service and verifying the correct operation of trans-
mission and Infocenter components.
With EDS, the technician can:
- display errors (faults) that have occurred;
- configure the control unit;
- carry out sensor calibration or setting procedures.

1.3.1 DESCRIPTION OF THE KIT

EDS is supplied to Authorised Workshops with the following basic items needed for operation.
The kit includes:

1
3
F0059400

Pos. Code Description Qty

5.9030.742.0 Kit completo in lingua inglese 1
5.9030.742.1 Kit completo in lingua tedesca 1
1 5.9030.742.2 Disco d’installazione (Rif. Wilbar 236162) 1
2 5.9030.742.3 Cavo d’interfaccia (Rif. Wilbar 0797-385) 1
3 5.9030.742.4 Cavo d’interfaccia (Rif. Wilbar KA 96-0526) 1

The exchange of data between the EDS software and the control units occurs by way of a diagnosis socket incorporated
into a wiring harness of the tractor.
Accordingly, the EDS software comes with different types of interface cables for the different models and versions of trac-
tor being serviced, which must be used as indicated in the relative workshop manuals.

20-8
2. CONNECTING THE TESTER TO THE ELECTRONIC 2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT

2. CONNECTING THE TESTER TO THE ELECTRONIC CONTROL UNITS

This chapter describes how to connect the various diagnostics tools provided for the use of the technician.

2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND

FRONT AXLE SUSPENSION CONTROL UNITS
CAUTION
Before connecting the ART, switch off the engine and remove the starter key

1
2

5 X18

4
3

F0059410

1 - Connect the cable (1) (code 5.9030.861.4) to the ART (2) (code 5.9030.730.0).
2 - Join the connector (3) of cable (2) to cable (4) (code 0.012.6655.4) and plug connector (5) into connector X18 located
internally of the right hand side console.
3 - Check that connectors (5) and X18 are securely connected.
4 - Insert the starter key and turn to the “I” (ON) position to power up the tester.

5 - Following power up, the ART performs the battery T E S T

level test. M E N U
6 - Press the key corresponding to the control unit being
tested. 1 - F r o n t s u s p e n
CAUTION 2 - R e a r L i f t
Avoid starting the engine unless required for the
purpose of diagnosis or calibrating sensors.

C H O O S E _

20-9
2. CONNECTING THE TESTER TO THE ELECTRONIC 2.2 CONNECTING THE PORTABLE COMPUTER WITH

2.2 CONNECTING THE PORTABLE COMPUTER WITH “SERDIA 3.5” SOFTWARE

TO THE ENGINE CONTROL UNIT

3 X18
5
6

F0059420

1 - Connect the cable (1) (code 5.9030.740.4/10) to the serial port of the portable computer (2).
2 - Join the connector (3) of cable (4) (code 5.9030.741.0) to the connector X18 located internally of the right hand side
console.
3 - Plug in the connectors (5) and (6).
4 - With the portable computer switched on and the Serdia program running, insert the starter key and turn to the “I” (ON)
position.

20-10
2. CONNECTING THE TESTER TO THE ELECTRONIC 2.3 CONNECTING THE PORTABLE COMPUTER WITH

2.3 CONNECTING THE PORTABLE COMPUTER WITH “EDS” SOFTWARE TO THE

TRANSMISSION CONTROL UNIT AND INFOCENTER

5
1

F0059430

2.3.1 CONNECTION TO THE TRANSMISSION CONTROL UNIT

1 - Connect the lead numbered “9141” of the interface cable (1) to the serial port of the portable computer (2).
2 - Join the connector marked “Powershift Agrotron 4.70 – 6.45” (3) of the Wilbar cable (4) (Wilbar KA 96-0529) to the
four-pin connector (5) of the interface cable (1).
3 - Join the connector (6) of cable (4) to the connector X18 located internally of the right hand side console.
4 - With the portable computer switched on and the EDS program running, insert the starter key and turn to the “I” (ON)
position.

2.3.2 CONNECTION TO THE INFOCENTER

1 - Connect the lead marked “EIC” of the interface cable (1) to the serial port of the portable computer (2).
2 - Join the connector marked “Infocenter” (3) of the Wilbar cable (4) (Wilbar KA 96-0529) to the two-pin connector (7) of
the interface cable (1).
3 - Join the connector (6) of cable (4) to the connector X18 located internally of the right hand side console.
4 - With the portable computer switched on and the EDS program running, insert the starter key and turn to the “I” (ON)
position.

20-11
PAGE INTENTIONALLY
LEFT BLANK
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)

3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF THE TRACTOR

The electronic system of the Agrotron series includes control units by which the machine functions are managed. Each
control unit is dedicated to the management of one or more systems.
The tractor's electronic system incorporates a socket used for calibration, diagnosis and programming of the control units;
connecting the All Round Tester ® (ART) or a portable computer with SERDIA and EDS diagnostics software to the socket,
the technician can program the operating parameters of the tractor according to the options available (front PTO, etc.), test
the operation of the sensors and pushbutton controls, calibrate the sensors and carry out troubleshooting procedures.
The ART can also be used to access a list of the alarms detected, which are stored as brief descriptive messages.
Through these messages, the technician can locate faults and, using the dedicated Test and Monitor menus, check the op-
eration of system components.
Using the portable computer and the SERDIA and EDS software, the technician can analyse information and alarms (if any)
recorded by the engine, transmission and INFOCENTER control units and verify the correct operation of components and
sensors governed by these units.

3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)

The function of the engine control unit is to supervise the correct operation of the engine; it receives commands from the
operator by way of the hand throttle, the accelerator pedal or the MAX, MIN and MEM functions on the rpm control keypad,
or on the armrest if fitted, and, according to the signal returned by the engine speed pickup, the coolant temperature and
fuel temperature sensors and the turbo pressure sensor, will adjust the crankshaft speed by outputting a modulated volt-
age signal (PWM) to the actuator of the injection pumps.
The engine control unit also pilots the operation of the glowplugs, activating the relative relay in response to signals re-
ceived from the coolant and fuel temperature sensors to ensure easy starting even in extreme weather conditions.
The engine control unit informs the operator of any malfunction affecting monitored components, by way of a warning light
on the Infocenter. Faults are indicated by two types of signal:
• continuously flashing light: the control unit has detected a fault in one of the engine speed control components (ac-
celerator pedal, hand throttle or keypad), though not a fault that affects the operation of the engine;
• light permanently on: the control unit has detected a serious fault and responded by switching the engine off, disabling
the starter circuit.
Connecting the portable computer with the SERDIA software installed, the technician can display the alarms affecting the
engine.
The alarms management function of the engine control unit is based on two classes of alarms, defined active and passive.
All alarms are displayed in a single window that shows information on the type of alarm detected, and the possible cause,
indicating the number of recurrences and the status (active or passive).
Detected alarms are recorded in two separate memory locations:
- Error memory 1, erasable by the technician
- Error memory 2, which maintains a log of all alarms generated, indicating how many times an alarm has cut in and
when was the most recent

20-13
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.1 ENGINE CONTROL UNIT (DEUTZ EMR2)

MX1

MX2

MX1 5 8 9 14 15 12 13 10 16 17 18 19 24 25 23 3 1 2 6 7 3 10 11 21 19 18 17 15 14 4 16 25 20 23 24 MX2
X31
6 4

2.2Kohm
5 1 1
4 2
3
1Kohm
2
1 X20
6
X8
17 1
3
4
2
2
5
7.5A

F34
X80
1
+15 2
3
RL40
+50 5
2

ST1
1
4
3
Wheel RPM output 11
RL42
1 2

ST2
Engine RPM input 12
Preheating light 19 RL42A
5
16 RL42B
F101
100A

X78
6
B37 B43 B40 Y3 B48 X18 RL41 EMR +30B
2 1 2 1 1 2 1 2 3 4 5 1 4 3 2 3 4 87 86 85 30 3 2 1

t° t° M
p +30C
7
15 14 13 12 11 10 9 8 +50

D0023000

1- Accelerator pedal position sensor 10 - Diagnostics connector

2- Engine speed keypad 11 - Turbo charge pressure sensor
3- Start enable switch (Green) 12 - Actuator
4- Engine starting relay 13 - Camshaft speed sensor (Pickup)
5- Glowplugs relay 14 - Engine coolant temperature sensor
6- Preheating device 15 - Fuel temperature sensor
7- Starter motor 16 - Infocenter
8- Lift and hand throttle console 17 - Engine ECU circuit board
9- Glowplug warning light ON relay

20-14
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.2 TRANSMISSION CONTROL UNIT

3.2 TRANSMISSION CONTROL UNIT

The function of the transmission control unit is to supervise the correct operation of the transmission; it receives com-
mands from the operator by way of the the shuttle lever, the range selection buttons and the clutch pedal, and, according
to the signals returned by the engine speed and torque sensors, will shift between the ranges selected with the controls by
piloting the operation of the 8 solenoid valves of the clutch actuators.
Connected to the control unit is a display that provides the operator with information on the current status of the trans-
mission (direction of movement, range selected, etc.) and indicates any alarms detected by way of alphanumeric codes.
Connecting the portable computer with the EDS software installed, the technician can display the alarms affecting the
transmission.
The alarms management function of the transmission control unit is based on two classes of alarms, defined active and
passive.
The EDS program displays all alarms in two windows, showing information that includes the number of the detected alarm,
its status (active or passive), the number of recurrences and the hours operation clocked by the transmission when the
alarm first occurred.

E.C.U. (PS)
65 63 20 30 1 2 11 8 57 32 55 29 5 14 39 15 16 3 40 17 21 45 36 13 56 62 4 44 24 37 38 67 22 68 23
X37
3
3.9 Ohm 1
15 3.9 Ohm 4
7.5A

3.9 Ohm 2
F17
FW
N
RV

+30
X40

14 +12V

M
1
5
M 6
Sig 2
7.5A

X33
3A

1 F35 F16
13 2
3

X34
4
12 1
2
+15 +15

EV PRESS EV.
GROUP SWITCH TEMP. NHK NLSA NLSE PROP LS/PS PS NAB X18 X12
E F C D A B 2 1 2 1 3 2 1 3 2 1 3 2 1 2 1 1 1 3 2 1 2 8 1 2 3
fN fN f
P
HK
Y2
Y3
Y4

Y1

lsa lse N

11 10 9 8 7 6 5 4 3 2 D0023010

1- Transmission ECU 7 - Gearbox output shaft speed sensor 12 - Clutch pedal position sensor
2- Gearshift lever 8 - Transmission speed sensor 13 - Clutch pedal depressed proximity
3- Diagnostics connector 9 - Transmission oil sensor
4- Speed sensor for odometer temperature sensor 14 - Transmission display
5- Proportional solenoid valve coil 10 - Engine oil low pressure switch 15 - Shuttle control lever
6- Engine speed sensor 11 - Gearshift solenoid valves

20-15
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.3 POWER LIFT CONTROL UNIT

3.3 POWER LIFT CONTROL UNIT

The function of the lift control unit is to supervise the correct operation of the hydraulic lift and the ASM system.
3.3.1 HYDRAULIC LIFT SYSTEM
The electronic system controls the movements of the lift according to the commands and the operating mode selected by
the operator using the control panel on the side console.
The operator can select six types of control:
- position control;
- draft control;
- depth control;
- wheelslip control;
- draft, wheelslip and depth control;
- transport lock.
Another function provided by the system is that of automatically activating pitch control when travelling on the highway at
speeds higher than 8 km/h with the lift control lever in the transport lock position. This operating mode reduces the pitching
motion of the tractor when running over uneven surfaces by allowing small compensating movements of the lift, using the
mounted implement as a “ballast weight”.
The transport lock can be engaged by the operator, but for reasons of safety it will be engaged automatically by the control
unit whenever the lift control is in the stop position and three minutes are allowed to elapse since the tractor was last in mo-
tion at less than 20 km/h, or whenever the ground speed of the tractor exceeds 20 km/h.
The control unit compares the command given by the operator with the signals received from the lift position sensor, the
draft sensors, the wheel speed sensor and the radar, and responds by operating a directional control valve equipped with
two proportional solenoid valves.
The control valve directs oil at high pressure to two hydraulic cylinders that raise or lower the implement mounted to the
three-point linkage.
The signals from the control console are transmitted to the lift control, and the signals from the sensors essential to the op-
eration of the system and the lift control pushbuttons on the rear fenders are connected directly to the control unit.

JX1

JX2

JX1 JX2
1 2 3 21 15 23 10 17 14 22 8 18 13 7 19 16 9 4 20 5 6 15 22

9
10 1
X18 1- Diagnostics connector
2- Rear lift Up pushbutton
1
2 3- Rear lift Down pushbutton
7.5A

2 F34
UPDX 4- Lift and hand throttle
console
+15
5- Lift control panel
6- 4WD switch
7- Differential lock switch
1
2 3 8- Lift Up solenoid valve
DWDX
9- Lift Down solenoid valve

3
2 4
EV EV 1
DW 2 1 UP
2 1 1 2 3 7 1 2 3 9 1 2 3 8 11 3 9 7 8 4 1 6 10 5 12 X14 EHR
U U U

F S F
9 8
7 6 D0017260
5

20-16
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.3 POWER LIFT CONTROL UNIT

3.3.2 ASM SYSTEM

The lift control unit also governs the ASM system which, when activated by the operator, manages the engagement and
disengagement of the four wheel drive clutch and differential lock mechanism automatically.
The parameters used to determine exclusion of the differential lock and disengagement of the four-wheel drive are:
- wheel speed;
- steering angle;
- type of braking action (one or two pedals).
The command which activates the system, and the signals from the brake pedal, wheel speed and steering angle sensors
are all routed directly to the control unit.
The control unit processes the data and, according to the status of the system and the parameter settings, activates or de-
activates the solenoid valves controlling engagement of four-wheel drive and of the differential locks.
The hydraulic lift control unit warns the operator of any malfunction in monitored components by way of a red Led (lift trans-
port lock indicator) located on the lift control console.
Faults are indicated using a system of coded flash sequences which, depending on how the control unit has been con-
figured, will either specify the precise nature of the fault (extended alarm) or simply identify the device affected (standard
alarm). Also, and likewise depending on the configuration, the unit can display only the alarm with the lowest code (rotation
of alarms deactivated), or it can display all the active alarms (rotation of alarms activated).
The ART shows the 10 most recent alarms generated, and if a further alarm is triggered, the first of the ten will be eliminated.
To verify, using the ART, whether or not an alarm detected is “active”, the technician must cancel all the alarms, turn the
starter key to the “O” (OFF) position, then make a fresh connection to the control unit.

JX1
ST2
DF 1
DT 14 JX2
+15 2
9 +30 9
GND 3
GND 12

8
1
JX2 JX1
8
1

18 23 10 16 20 11 2 13 8 20 4 5

7
1
1

7
7.5A

7.5A

F34 F34
6
5
6
1
+15 +15
7
2
8
6
1

6
5

X35 X32 X82 EV DF DT RL9 RL8

3 2 1 4 1 4 3 2 1 2 3 4 1 2 1 2 3 2 1 4 5 3 2 1 4 5
3 5 4 3 5 4
F11
20A

2 1 2 1

2 1 +15

5 4 D0017290

1- Four wheel drive (4WD) clutch solenoid valve 6- ASM switch

2- Differential lock solenoid valve 7- Differential lock switch
3- Steering angle sensor 8- 4WD switch
4- Right brake pedal switch 9- Instrument panel
5- Left brake pedal switch

20-17
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.4 INFOCENTER 2 or 3

3.4 INFOCENTER 2 or 3
The Infocenter control unit is designed and programmed to manage and display the essential information needed by the
operator to control the machine under different conditions of use, to show performance data in real time, and to activate an
indicator light warning of faults detected by the engine control unit.
The Infocenter appears as a single module incorporating one or two displays (according to the type of Infocenter installed)
which provide digital information, and analog instruments indicating items such as engine revolutions, fuel level, etc.
The instrument panel also incorporates indicator lights showing the operating status of various tractor systems, or the
presence of faults (e.g. clogged oil filter, etc.). Some of these lights are replaced on the Infocenter 3 by a digital display
showing the same alarms or items of information in the form of text messages.
The display used in both types of Infocenter provides information relating to the operation of the machine (ground speed,
wheelslip, rear and front PTO shaft speeds) and hour meter reading.
Connecting a portable computer and using the EDS program, the technician can enter basic parameters for the Infocenter
(language, etc.), test the operation of the panel indicator lights and check the inputs and outputs.

20-18
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.5 FRONT AXLE SUSPENSION CONTROL UNIT

3.5 FRONT AXLE SUSPENSION CONTROL UNIT

The function of the suspension control unit is to supervise the correct operation of the hydraulic suspension supporting the
front axle.
When the operator activates the hydraulic suspension by pressing the pushbutton on the front console, the clearance of
the front end of the tractor relative to the road surface will be controlled automatically.
With the system activated, the control unit pilots the operation of the load sensing and the up and down solenoid valves,
which continue to adjust until the signal received from the position sensor corresponds to the programmed setting.
At this point, the control unit deactivates the solenoid valves and the system remains active. When the position of the axle
shifts due to the tractor bouncing as it moves along, the control unit responds by piloting the corrections needed to return
the axle to the programmed position.
The axle suspension, used when the tractor is on the move, provides further assistance in limiting the pitching motion of the
machine, increasing its stability and improving reaction in the event of emergency braking.
All the control components of the system (on/off pushbutton, position sensor and solenoid valves) are connected directly
to the axle suspension control unit.
The only item of data not read directly by a sensor but supplied by the Infocenter, is ground speed (wheel speed), which is
used to activate or deactivate the system according to the peripheral velocity of the wheels.
The suspension control unit warns the operator of any malfunction affecting monitored components, by way of an indicator
light in the pushbutton.
Faults are indicated using a system of coded flash sequences which, depending on how the control unit has been con-
figured, will either specify the precise nature of the fault (extended alarm) or simply identify the device affected (standard
alarm).
The ART shows the 10 most recent alarms generated, and if a further alarm is triggered, the first of the ten will be eliminated.
To verify, using the ART, whether or not an alarm detected is “active”, the technician must cancel all the alarms, turn the
starter key to the “O” (OFF) position, then make a fresh connection to the control unit.

JX3
JX4

JX4 12 8 19 13 11 2 15 22 9 14 17 JX3
5 4 20 2 1
F17
7.5A

+15

1 - Front axle suspension load sensing

solenoid valve coil
5 X18 X69 H S X68 2 - Axle Down control solenoid valve coil
1 10 9 5 14 13 1 2 3 2 1 2 1 2 1
U
3 - Axle Up control solenoid valve coil
4 - Front axle suspension position sensor
S 5 - Diagnostics connector
6 - Front suspension pushbutton
5 4 3 2 1 D0017090
6

20-19
3. INTRODUCTION TO THE ELECTRONIC
SYSTEM OF THE TRACTOR 3.6 FRONT AND REAR PTO CONTROL UNIT

3.6 FRONT AND REAR PTO CONTROL UNIT

The PTO control unit is incorporated into the relays and fuses control unit. The electronic system controls the front PTO (if
installed) and rear PTO in accordance with the commands given by the operator via the pushbuttons on the right hand con-
sole.
The PTOs can be activated or deactivated by the operator, and will in any event be inhibited automatically when the engine
is switched off.
The control unit receives the command given by the operator and responds by activating the rear PTO solenoid valve,
which in turn pilots the operation of the PTO clutch.

P3
7.5A
F29

+15

PTO MODULE

P3 FZW
1 24 12 13 8 10 11 23 25 9
2
1 2
EV
PTO
2
1
3

3
F16
3A

2
1
4
PTO +15
SENS

PTODX X9 D+ B+
PTO
ST2 JX1
5 5
X10 AUTO ISO7
3 2 1 1 2 3 1 2 3 5 9 10 1 20 11 10 11 4 5 20
F10

F34

+
7.5A

7.5A

-
+15 +15
12 11 10 8 D0017270
9 7 6

1- Front and rear pto control unit 7 - Instrument panel

2- Front PTO solenoid valve 8 - PTO AUTO switch
3- Rear PTO solenoid valve 9 - Alternator
4- Rear PTO speed sensor 10 - Front PTO pushbutton (in cab)
5- ISO7 socket (implement connection) 11 - Rear PTO pushbutton (in cab)
6- Rear lift control unit 12 - Rear PTO Rx pushbutton (on fender)

20-20
4. PUTTING THE TRACTOR INTO SERVICE 4.1 INTRODUCTION

4. PUTTING THE TRACTOR INTO SERVICE

4.1 INTRODUCTION
This chapter contains all the information required to establish or restore correct operation of the tractor's various electronic
systems.
Whenever an electronic control unit of the tractor is changed or a calibration-sensitive electronic component replaced, the
tractor must be put into service as if from new.
The necessary procedures must be carried out by a skilled technician, who in turn must follow the instructions in the man-
ual precisely.

4.2 RENEWAL OF THE ENGINE CONTROL UNIT

NOTE
If possible, before renewing the engine control unit, the technician should read the program of the old control unit
and save it to a file.
If the control unit is faulty and it is not possible to read the program, contact Technical Assistance and ask for the
engine configuration file (quoting the engine serial number, which appears on the nameplate of the control unit and
on the engine data plate) and proceed to program the new unit using this file.
The accelerator pedal and hand throttle can now be calibrated, and the maximum ground speed configured.

4.2.1 READING AND SAVING DATA

1 - Connect a portable computer with the SERDIA pro-
gram installed (for details see «Connection of portable
computer with "SERDIA" software to the engine con-
trol unit»).
2 - Turn the starter key to the “I” (ON) position and start
the SERDIA program.
3 - From the “PARAMETER” menu, select the option
“OVERALL PROGRAMMING”.

4 - Click on “ECU -> file” and save the data to a floppy

disk or to the computer hard disk (c:\; d:\).
NOTE
Make certain that the file has been saved.
Files are named automatically in the following way:
0044444.hex
where the numbers “44444” correspond to the serial
number of the engine.

20-21
4. PUTTING THE TRACTOR INTO SERVICE 4.2 RENEWAL OF THE ENGINE CONTROL UNIT

4.2.2 PROGRAMMING THE CONTROL UNIT

1 - Connect a portable computer with the SERDIA pro-
gram installed (for details see «Connection of portable
computer with "SERDIA" software to the engine con-
trol unit»).
2 - Turn the starter key to the “I” (ON) position and start
the SERDIA program.
3 - From the “PARAMETER” menu, select the option
“OVERALL PROGRAMMING”.

4 - Click on “PROGRAMMING” and select the file saved

previously, or procured from Technical Assistance.

5 - When the message “DATA ACCEPTED BY ECU” ap-

pears, press Enter.

6 - Click on “SAVE IN ECU”, and when the message “DA-

TA ACCEPTED BY ECU” appears, press Enter and
exit the program.

20-22
4. PUTTING THE TRACTOR INTO SERVICE 4.2 RENEWAL OF THE ENGINE CONTROL UNIT

4.2.3 CALIBRATION OF THE ACCELERATOR PEDAL

NOTE
This operation must be carried out with the engine off
and the parking brake applied.
1 - Connect a portable computer with the SERDIA pro-
gram installed (for details see «Connection of portable
computer with "SERDIA" software to the engine con-
trol unit»), turn the starter key to the “I” (ON) position
and start the SERDIA program.
2 - From the “PARAMETER” menu, select the option
“CALIBRATION”.

3 - Select the line containing the parameter “1510:

AnalogIn1_RefLow”, apply light pressure to the ac-
celerator and release, then click on “GET VALUE” so
that the software can read the value.
4 - Click “PC->ECU”, then click “SAVE IN ECU” to save
the new parameter.

5 - Select the line containing the parameter “1511:

AnalogIn1_RefHigh”, apply light pressure to the ac-
celerator and release, then click on “GET VALUE” so
that the software can read the value.
6 - Click “PC->ECU”, then click “SAVE IN ECU” to
save the new parameter.

20-23
4. PUTTING THE TRACTOR INTO SERVICE 4.2 RENEWAL OF THE ENGINE CONTROL UNIT

4.2.4 CALIBRATION OF THE HAND THROTTLE

NOTE
This operation must be carried out with the engine off
and the parking brake applied.
1 - Connect a portable computer with the SERDIA pro-
gram installed (for details see «Connection of portable
computer with "SERDIA" software to the engine con-
trol unit»), turn the starter key to the “I” (ON) position
and start the SERDIA program.
2 - From the “PARAMETER” menu, select the option
“CALIBRATION”.

3 - Select the line containing the parameter “1530:

AnalogIn3_RefLow”, apply light pressure to the ac-
celerator and release,then click on “GET VALUE” so
that the software can read the value.
4 - Click “PC->ECU”, then click “SAVE IN ECU” to save
the new parameter.

5 - Select the line containing the parameter “1531:

AnalogIn3_RefHigh”, apply light pressure to the ac-
celerator and release, then click on “GET VALUE” so
that the software can read the value.
6 - Click “PC->ECU”, then click “SAVE IN ECU” to save
the new parameter.

20-24
4. PUTTING THE TRACTOR INTO SERVICE 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

Whenever the transmission control unit is renewed, the technician must carry out the following operations:
1 - program the version and serial number of the tractor
2 - calibrate the clutch pedal position sensor
3 - calibrate the main clutch proportional solenoid valve
The purpose of setting the type of tractor and making calibrations is to inform the components of the control unit as to the
parameters that must be used for the transmission to operate correctly.

4.3.1 SETTING THE TRACTOR VERSION AND SERIAL NUMBER

1 - Connect a portable computer with the EDS program installed (for details see «Connection of a portable computer
with “EDS” software to the transmission control unit»).
2 - Turn the starter key to the (ON) position and start the EDS program.
3 - From the introductory menu, start the transmission diagnosis program by pressing key “1” and selecting option “2”..

4 - From the main menu, select “DEST45” on the “CONTROL” menu.

20-25
4. PUTTING THE TRACTOR INTO SERVICE 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

5 - Select “END-OF-LINE PROGRAMMING” from the “CONTROL” menu..

6 - Select “CONFIG”

7 - Use the “PAGE UP” or “PAGE DOWN” functions to find the identification number of the vehicle corresponding
to the first four digits of the serial number, then press Enter to confirm the value and type the remaining four num-
bers to complete the serial number of the machine (in the example illustrated, the version is 8092 and the serial
number 0807).
8 - Proceed to calibrate the clutch pedal position sensor and the main clutch as described in the following chap-
ters..

20-26
4. PUTTING THE TRACTOR INTO SERVICE 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

4.3.2 CALIBRATION OF THE CLUTCH PEDAL POSITION SENSOR

1 - Connect a portable computer with the EDS program installed (for details see «Connection of a portable computer
with “EDS” software to the transmission control unit»).
2 - Turn the starter key to the (ON) position and start the EDS program.
3 - From the introductory menu, start the transmission diagnosis program by pressing key “1” and selecting option “2”..

4 - From the main menu, select “DEST45” on the “CONTROL” menu.

20-27
4. PUTTING THE TRACTOR INTO SERVICE 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

5 - Select “END-OF-LINE PROGRAMMING” from the “CONTROL” menu.

6 - Click on “1” to initiate the sensor calibration procedure.

7 - Click on “OK” and depress the clutch pedal slowly to full travel, then release slowly.

20-28
4. PUTTING THE TRACTOR INTO SERVICE 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

8 - At the end of the calibration procedure, a message will appear confirming calibration successfully completed; at this
point, exit the EDS program.

4.3.3 CALIBRATION OF THE MAIN CLUTCH PROPORTIONAL SOLENOID VALVE

NOTE
To carry out the calibration of the main clutch, warm the transmission oil to about 40 °C and position the tractor on
a flat tarmac surface with at least 20 metres of free space ahead.
Put the transmission in neutral by positioning the shuttle lever at “NEUTRAL”, and make certain the handbrake is
released.
1 - Connect a portable computer with the EDS program installed (for details see «Connection of a portable computer
with “EDS” software to the transmission control unit»).
2 - Turn the starter key to the (ON) position and start the EDS program.
3 - From the introductory menu, start the transmission diagnosis program by pressing key “1” and selecting option “2”.

20-29
4. PUTTING THE TRACTOR INTO SERVICE 4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT

4 - From the main menu, select “DEST45” on the “CONTROL” menu.

5 - Select “END-OF-LINE PROGRAMMING” from the “CONTROL” menu.

NOTE
Make certain that the transmission oil is at approximately 40 °C, using “DATA - PLAIN TEXT DISPLAY” from the DI-
AGNOSIS menu, and check that the shuttle lever is positioned at “NEUTRAL”.
6 - Throttle the engine to 1500 rev/min., select a ratio between 3rd M and 1st L, then click “2” to initiate the sensor cal-
ibration procedure.

20-30
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

7 - Select 3rd gear, shift the shuttle lever to the “FORWARD” position and wait for the automatic procedure to finish.
CAUTION
Do not depress the clutch pedal or move the shuttle lever during the automatic procedure, as this could cause the
program to abort and cancel.

8 - At the end of the calibration procedure, a message will appear confirming calibration successfully completed; at this
point, exit the EDS program.

4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

Whenever the lift control unit is renewed, the technician must carry out the following operations:
1 - program the type of tractor;
2 - configure no radar status;
3 - calibrate the lift position sensor: up down;
4 - check and calibrate the lift control lever.
The purpose of identifying the type of tractor and calibrating the sensors is to inform the control unit of the parameters it
must use to pilot and monitor the operation of the lift correctly.
To perform the calibration, connect the ART to the connector in the control units compartment of the cab, then select EHR+
from the “AVAILABLE TESTS” menu and proceed as described.

20-31
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

4.4.1 PROGRAMMING THE TYPE OF TRACTOR

1 - From the main menu, press “2” to bring up the P A R A M E T E R S M E N U
“PARAMETERS MENU”. = = = = = = = = = = = = = = = =

1 - S p e e d c o n s t a n t
2 - O p t i o n s

= = = = = = = = = = = = = = = =
[ E ] E x i t

2 - Press “2”. O P T I O N S
= = = = = = = = = = = = = = = =

1 - A S M 1
2 - A U T O D R O P 0
3 - 4 W D - 3 0 D E G 0
4 - R O T A T E A L A R M 1
5 - E X T D A L A R M 0
6 - S E N S I T I V . 2 5 5

7 - T R A C T O R 1
8 - E X T S E N S O R 1
9 - M I X M O D E 0

= = = = = = = = = = = = = = = =
[ E ] E x i t

3 - Press “7”. T R A C T O R T Y P E
4 - Press the key corresponding to the tractor being = = = = = = = = = = = = = = = =
serviced, and confirm by pressing “E” to memorize 1 - 8 0 - 1 0 5 H P
the information. 2 - 1 0 6 - 1 3 5 H P
5 - Press “E” twice in succession to return to the main 3 - 1 5 0 - 2 0 0 H P
menu. 4 - 2 3 0 - 2 6 0 H P

[ E ] E x i t

20-32
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

4.4.2 CONFIGURING NO RADAR STATUS

1 - From the main menu, press“2” to bring up the P A R A M E T E R S M E N U
“PARAMETERS MENU”. = = = = = = = = = = = = = = = =

1 - S p e e d c o n s t a n t
2 - O p t i o n s

= = = = = = = = = = = = = = = =
[ E ] E x i t
2 - Press “1”.
S P E E D C O N S T A N T .
= = = = = = = = = = = = = = = =

1 - R A D A R 6 5 0 0
2 - W H E E L 3 2 5 0

= = = = = = = = = = = = = = = =
[ E ] E x i t

3 - Press “1”.
R A D A R
4 - Select value “0” to configure machine without radar,
or select “6500” for machine with radar. = = = = = = = = = = = = = = = =
5 - In the event that the parameter was not set correctly,
the technician can cancel the operation by pressing
“A” and restore the previous value, whereas press-
ing “C” will confirm the new setting and cause the
“PARAMETERS” menu to reappear. A c t u a l : 6 5 0 0
6 - Press “E” to return to the main menu.
N e w :

[ A ] C a n c e l
[ C ] C o n f i r m

20-33
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

4.4.3 CALIBRATION OF THE LIFT POSITION S E T T I N G M E N U

SENSOR = = = = = = = = = =
= = = = = =
NOTE 1 - M i n H e i g t h 0 . 9 4
This operation must be carried out with the engine run- 2 - M a x H e i g t h 4 . 0 2
ning on idle, the parking brake applied and the shuttle
3 - L o c k S p e d e 2 0
lever in the neutral position.
1 - From the main menu, press “3” to bring up the 4 - S l i p a g e % 1 0
“CALIBRATIONS” menu. - - - M a i n L
e v e r - - -
5 - T r a n s p o
r t 5 . 3 6
6 - S t o p 3 . 6 6
7 - C o n t r o l 1 . 9 2
8 - F l o a t 1 . 4 5

= = = = = = = = = = = = = = = =
[ E ] E x i t

2 - Unlock the hydraulic lift by setting the control lever to M i n . H e i g h t

the “STOP” position for around two seconds (after = = = = = = = = = = = = = = = =
which, the indicator Led will stop blinking).
NOTE
If the lift control lever is already in the “STOP” position,
move it away and then back again to the “STOP” po-
sition. A c t u a l : 0 . 9 4
3 - Press “1”.
N e w : 0 . 9 2

[ D ] D e l e t e
[ E ] E x i t

4 - Press the 'Down' button to lower the lift completely M i n . H e i g h t

(as the lift links descend, the “Actual” value should = = = = = = = = = = = = = = = =
decrease continuously).
5 - When the lift has reached its lower travel limit, press
“E” to memorize the value.

A c t u a l : 0 . 9 4

N e w : 0 . 9 2

[ A ] C a n c e l
[ C ] C o n f i r m

20-34
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

6 - In the event that the operation was not carried out M a x . H e i g h t

correctly, the technician can cancel it by pressing = = = = = = = = = = = = = = = =
“A” and restore the previous value, whereas
pressing “C” will confirm the new setting and cause
the “CALIBRATIONS” menu to reappear.
7 - Unlock the lift again by shifting the control lever away
and then back again to the “STOP” position. A c t u a l : 4 . 0 2
8 - Press “2”.
N e w : 0 . 9 2

[ D ] D e l e t e
[ E ] E x i t

9 - Press the 'Up' button to raise the lift fully (as the lift M a x . H e i g h t
links ascend, the “Actual” value should increase = = = = = = = = = = = = = = = =
continuously).
10 - When the lift has reached its upper travel limit, press
the Down button until the voltage reads approxi-
mately 0.2V less than the value registering at the
travel limit, then press “E” to memorize the value. A c t u a l : 4 . 0 2

N e w : 4 . 0 4

[ A ] C a n c e l
[ C ] C o n f i r m

11 - In the event that the operation was not carried out S E T T I N G M E N U

correctly, the technician can cancel it by pressing = = = = = = = = = =
= = = = = =
“A” and restore the previous value, whereas press- 1 - M i n H e i g t h 0 . 9 4
ing “C” will confirm the new setting and cause the 2 - M a x H e i g t h 4 . 0 2
“CALIBRATIONS” menu to reappear.
3 - L o c k S p e d e 2 0
12 - Press “E” to return to the main menu.
4 - S l i p a g e % 1 0
- - - M a i n L
e v e r - - -
5 - T r a n s p o
r t 5 . 3 6
6 - S t o p 3 . 6 6
7 - C o n t r o l 1 . 9 2
8 - F l o a t 1 . 4 5

= = = = = = = = = = = = = = = =
[ E ] E x i t

20-35
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

4.4.4 CHECKING AND CALIBRATING THE LIFT CONTROL LEVER

NOTE
This operation must be carried out with the engine off and the parking brake applied.

1 - From the main menu, press “1” to bring up the M o n i t o r s M e n u

“MONITOR MENU”. = = = = = = = = = = = = = = = =
1 - L i f t
2 - C o n s o l l e
3 - A S M
4 - P o w e r S u p p l y
5 - S e n s o r s

= = = = = = = = = = = = = = = =
[ E ] E x i t

2 - Press “2”. C o n s o l l e
= = = = = = = = = = = = = = = =
C t r l L e v e r 3 . 7 0 v
S e t P o i n t 1 . 4 1 v
M a x H e i g h t 7 . 9 4 v
C t r l M o d e 7 . 7 8 v
D r o p S p e e d 7 . 5 7 v
S l i p a g e 0 . 0 3 v
B u t t . U P O F F
B u t t . D W O F F

= = = = = = = = = = = = = = = =
[ E ] E x i t

3 - Verify that the voltage output signal from the lift con- Position of Minimum Maximum
trol lever in the four positions is within range, and lever value value
press “E” twice in succession to return to the “MAIN”
Transport 4,70 6,69
menu.
Stop 3,00 4,32
Control 1,61 2,59
Float 0,72 1,61

20-36
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

4 - In the event of one or more values being out-of- S E T T I N G M E N U

range, press “3” to bring up the “CALIBRATIONS” = = = = = = = = = = = = = = = =
menu. 1 - M i n H e i g h t 0 . 9 4
2 - M a x H e i g h t 4 . 0 2
3 - L o c k S p e e d 2 0
4 - S l i p a g e % 1 0
- - - M a i n L e v e r - - -
5 - T r a n s p o r t 5 . 3 6
6 - S t o p 3 . 6 6
7 - C o n t r o l 1 . 9 2
8 - F l o a t 1 . 4 5

= = = = = = = = = = = = = = = =
[ E ] E x i t

5 - Select the number corresponding to the position of S T O P

the lever in which the value was not correct.
= = = = = = = = = = = = = = = =
NOTE
This example simulates an incorrect value in the
“STOP” position, in which case the technician presses
“6”.
A c t u a l : 3 . 6 6
CAUTION!
When an out-of-range value is detected in any one po-
sition, calibrate the values in the other operating po- N e w : 2 . 8 2
sitions as well.

[ E ] E x i t

6 - Set the lift control lever to the “STOP” position, then S T O P

press “E” to memorize the value. = = = = = = = = = = = = = = = =

A c t u a l : 3 . 6 6

N e w : 2 . 8 2

[ A ] C a n c e l
[ C ] C o n f i r m

20-37
4. PUTTING THE TRACTOR INTO SERVICE 4.4 RENEWAL OF HYDRAULIC LIFT AND ASM CONTROL UNIT

7 - In the event that the operation was not carried out S E T T I N G M E N U

correctly, the technician can cancel it by pressing = = = = = = = = = =
= = = = = =
“A” and restore the previous value, whereas 1 - M i n H e i g t h 0 . 9 4
pressing “C” will confirm the new setting and cause
2 - M a x H e i g t h 4 . 0 2
the “CALIBRATIONS” menu to reappear.
3 - L o c k S p e d e 2 0
8 - Repeat the operations described in points 5, 6 and 7
for each value found to be out of range, then press 4 - S l i p a g e % 1 0
“E” twice in succession to return to the main menu. - - - M a i n L
e v e r - - -
5 - T r a n s p o
r t 5 . 3 6
6 - S t o p 3 . 6 6
7 - C o n t r o l 1 . 9 2
8 - F l o a t 1 . 4 5

= = = = = = = = = = = = = = = =
[ E ] E x i t

20-38
4. PUTTING THE TRACTOR INTO SERVICE 4.5 RENEWAL OF THE INFOCENTER

4.5 RENEWAL OF THE INFOCENTER

Whenever the INFOCENTER is renewed, the technician must configure the operating parameters (constants).
Configuration is needed in order to inform the Infocenter of the values that must be used for the purposes of displaying data
(units of measure, and language of choice for alarm messages).

4.5.1 ENTERING CONSTANTS

1 - Connect a portable computer with the EDS program installed (for details see «Connection of a portable computer
with "EDS" software to the transmission control unit»).
2 - Turn the starter key to the “I” (ON) position and start the EDS program.
3 - From the introductory menu, start the Infocenter diagnosis program by pressing key “4” or “5”, depending on which
port the cable is connected to..

4 - When the introductory page of the program appears, press “F1” to initiate the procedure of entering the operating
constants.

20-39
4. PUTTING THE TRACTOR INTO SERVICE 4.5 RENEWAL OF THE INFOCENTER

5 - Using the arrow keys, select constant K1, press Enter, insert the new value and confirm by pressing Enter again.
6 - Repeat the procedure until all the constants have been entered, then position the cursor on the “Ende Konstan-
tenmenü” line and press Enter.

List of values to enter

Serial Constants
Model number
root K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13
80 8081 3809 20 0 210 4400 1000 3809 1000 0 6 0

90 8085 3809 20 0 210 4400 1000 3809 1000 0 6 0

(1) (2)
100 8087 3809 20 0 210 4400 1000 3809 1000 0 6 0

105 8088 3675 20 0 210 4400 1000 3809 1000 0 6 0

(1): Enter the number of hours clocked by the tractor

(2): Enter the value corresponding to the preferred language and units of measure, and specify whether or not radar is in-
stalled.

Table of constants K8
Unit of Unit of
Language measure Radar Constant Language measure Radar Constant

Danish km/h None 75 Italian km/h Installed 109

Danish km/h Installed 107 Dutch km/h None 79
French km/h None 69 Dutch km/h Installed 111
French km/h Installed 101 Portuguese km/h None 73
English km/h None 67 Portuguese km/h Installed 105
English km/h Installed 99 Spanish km/h None 71
English mph None 66 Spanish km/h Installed 103
English mph Installed 98 German km/h None 65
Italian km/h None 77 German km/h Installed 97

20-40
4. PUTTING THE TRACTOR INTO SERVICE 4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT

4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT

Whenever the front axle suspension control unit is renewed, the technician must verify that the axle suspension position
sensor is correctly deployed.
The purpose of this verification is to inform the control unit of the voltage values generated by the sensor when the sus-
pension is inactive, or at rest.
To perform the verification, connect the ART to the connector in the control units compartment of the cab, select axle sus-
pension from the “AVAILABLE TESTS” menu and proceed as described.

4.6.1 CHECKING CALIBRATION OF THE SUSPENSION POSITION SENSOR

NOTE
This operation must be carried out with the engine running on idle, the parking brake applied, the shuttle lever in
neutral and the axle suspension deactivated.

1 - From the main menu, press “1” to bring up the M o n i t o r M e n u

“MONITORS MENU”. - - - - - - - - - - - - - - - -

1 - S U S P E N S I O N
2 - P o w e r S u p p l y

[ E ] E x i t

2 - Press “1”. S u s p e n s i o n
3 - Verify that the voltage output signal from the axle - - - - - - - - - - - - - - - -
suspension position sensor (indicated under the
S t a t u s L O C K
item “POSI” is 1.9 V.
4 - In the event of the value being incorrect, proceed
with calibration of the sensor as described in the M i n - - - P o s . - - - M a x
chapter “REMOVAL AND POSITIONING OF THE 2 . 0 V 1 . 9 V 6 . 0 V
FRONT AXLE SUSPENSION POSITION SENSOR”,
section 30. L S S V 0 m A O F F
5 - Activate the axle suspension and check that the U P S V 0 m A O F F
voltage output signal from the position sensor
D W S V 0 m A O F F
(indicated under the item “POSI” is approximately
3.8 V).
B r a k e O F F
4 W h e e l D r i v e O F F
W h e e l s K m / h 0 . 0

[ E ] E x i t

20-41
PAGE INTENTIONALLY
LEFT BLANK
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

5. ALARMS
This chapter contains a list of all the alarms that can be detected by the tractor's electronic system.
To facilitate searches, the alarms are organized according to the control unit by which they are detected:
1 - List of alarms displayed by the hydraulic lift and ASM control unit.
For details of how the alarms are displayed, see the heading “Power lift control unit”.
2 - List of alarms displayed on EDS: list of alarms detected by transmission control unit.
For details of how the alarms are displayed, see the heading “Transmission control unit”.
3 - List of alarms displayed on SERDIA: list of alarms detected by engine control unit.
For details of how the alarms are displayed, see the heading “Engine control unit (DEUTZ EMR2)”.
4 - List of alarms displayed by the front axle suspension control unit.
For details of how the alarms are displayed, see the heading Front axle suspension control unit.

5.1 LIFT AND ASM CONTROL UNIT ALARMS

The hydraulic lift control unit warns the operator of any malfunction in monitored components by way of a red Led (lift trans-
port lock indicator) located on the lift control console.
Faults are indicated using a system of coded flash sequences which, depending on how the control unit has been con-
figured, will either specify the precise nature of the fault (extended alarm) or simply identify the device affected (standard
alarm).
Also, and likewise depending on the configuration, the unit can display only the alarm with the lowest code (rotation of de-
activated alarms),or it can display all the active alarms (rotation of alarms activated), whereas the ART shows the 10 most
recent alarms generated, and if a further alarm is triggered, the first of the ten will be eliminated.
To verify, using the ART, whether or not an alarm detected is “active”, the technician must cancel all the alarms, turn the
starter key to the “O” (OFF) position, then make a fresh connection to the control unit.
CAUTION
In the event of it no longer being possible to operate the lift, and alarm 11 is indicated, check whether or not the ART
will connect to the control unit. If a connection cannot be made, the problem is identifiable as a fault affecting the
EPROM, which must therefore be replaced.

20-43
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

5.1.1 LIST OF ALARMS BY EXTENDED CODE

Example of flash for code 23 (times expressed in seconds).

ON
OFF 0.3 0.3 0.3 1.2 0.2 0.2 0.2 0.2 0.2 3.0

Extended Standard Display on ART Description Page

flash flash
The control unit detects that the power input to
12 26 Supply Pos. Sens. 20-50
the lift position sensor is not correct.
The control unit detects a short circuit on the
13 13 ShortCircuitPWM control line to the lift directional control valve. 20-51

The control unit detects that either the differen-

14 53 ASM-ShortCircuit tial lock or four wheel drive solenoid valve is 20-52
short-circuiting.

16 18 HitchControlLev. The control unit detects incorrect data coming 20-53

from the lift control lever.
The control unit detects that the lift position sen-
18 22 Pos.Sens.NotConn 20-54
sor is not connected.
The control unit detects that the lift Up control
21 11 ShortCircuitEVUP solenoid valve is short-circuiting. 20-55

The control unit detects, in the absence of any

23 11 EvUpNotConnect.L energizing signal (static safety), that the lift Up 20-56
solenoid valve coil is not connected.
The control unit detects, in the presence of an
24 11 EvUpNotConnect.D energizing signal (dynamic safety), that the lift Up 20-57
solenoid valve coil is not connected.

31 12 ShortCircuitEVDW The control unit detects that the lift Down control 20-58
solenoid valve is short-circuiting.
The control unit detects, in the absence of any
33 12 EvDwDeconnecteeL energizing signal (static safety), that the lift Down 20-59
solenoid valve coil is not connected.
The control unit detects, in the presence of an
34 12 EvDwDeconnect.D energizing signal (dynamic safety), that the lift 20-60
Down solenoid valve coil is not connected.
The control unit detects that the 4WD clutch so-
41 51 ShortCircuit4WD 20-61
lenoid valve relay is short-circuiting.
The control unit detects that the 4WD clutch so-
43 51 4WD NotConnected lenoid valve relay is disconnected. 20-62

51 52 ShortCircuitDIF -OK - The control unit detects that the differential lock 20-63
solenoid valve is short-circuiting.
The control unit detects that thedifferential lock
53 52 EvDIFDeconnect. 20-64
actuator solenoid valve is disconnected.
The control unit detects that the right hand draft
62 31 NoRightDraftSens. sensor is disconnected. 20-65

20-44
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended Standard Display on ART Description Pag.

flash flash
The control unit detects that the left hand draft
63 32 NoLeftDraftSens. 20-66
sensor is disconnected.
The engine control unit detects that the signal
64 42 WheelSensNotConn. from the wheel speed pickup is either non-ex- 20-67
istent or incorrect.
The control unit detects that the radar is discon-
65 41 Radar NotConnect. nected. 20-68

67 26 5v Supply The control unit detects that the 5V power input 20-69
is not correct.
The control unit detects that the 8V power input
68 16 8v Supply 20-69
is not correct.
The control unit detects that the rate-of-drop po-
71 34 DownSpeedPotent. tentiometer is disconnected or short-circuiting. 20-70

72 23 SetPoint Potent. The control unit detects that the depth potenti- 20-71
ometer is disconnected or short-circuiting.
The control unit detects that the MIX potentiom-
73 36 CtrlMode Potent. 20-72
eter is disconnected or short-circuiting.
The control unit detects that the maximum lift
74 24 MaxHeightPotent. height potentiometer is disconnected or short- 20-73
circuiting.
The control unit detects a bad reading of data
76 54 EEPROM :OPTION 20-74
from EEPROM.
The control unit detects a bad reading of data
77 54 EEPROM : SPEED from EEPROM. 20-74

78 54 EEPROM : CALIB The control unit detects a bad reading of data 20-74
from EEPROM.
The control unit detects a bad reading of data
81 55 EEPROM : CTRL 20-75
from EEPROM.
The control unit detects a bad reading of data
82 55 EEPROM : PWM from EEPROM. 20-75

83 55 EEPROM : DRAFT The control unit detects a bad reading of data 20-75
from EEPROM.
The control unit detects a bad reading of data
84 55 EEPROM : SLIP 20-76
from EEPROM.
The control unit detects a bad reading of data
85 55 EEPROM : POS from EEPROM. 20-76

86 55 EEPROM : AB The control unit detects a bad reading of data 20-76

from EEPROM.
The control unit detects a bad reading of data
87 55 EEPROM : SFCFG 20-77
from EEPROM.
The control unit detects a bad reading of data
88 55 EEPROM : SLCFG from EEPROM. 20-77

20-45
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

5.1.2 LIST OF ALARMS BY STANDARD CODE

Example of flash for code 23 (times expressed in seconds).

ON
OFF 0,5 0,5 0,5 1,5 0,5 0,5 0,5 0,5 0,5 3,0

Standard Extended Display Description Page.

flash flash on ART
The control unit detects that the lift Up control
21 ShortCircuitEVUP 20-55
solenoid valve is short-circuiting.
The control unit detects, in the absence of any
23 EvUpNotConnect.L energizing signal (static safety), that the lift Up 20-56
11
solenoid valve coil is not connected.
The control unit detects, in the presence of an
24 EvUpNotConnect.D energizing signal (dynamic safety), that the lift Up 20-57
solenoid valve coil is not connected.
The control unit detects that the lift Down control
31 ShortCircuitEVDW solenoid valve is short-circuiting. 20-58

The control unit detects, in the absence of any

33 EvDwDeconnecteeL energizing signal (static safety), that the lift Down 20-59
12 solenoid valve coil is not connected.
The control unit detects, in the presence of an
34 EvDwDeconnect.D energizing signal (dynamic safety), that the lift 20-60
Down solenoid valve coil is not connected.

13 13 ShortCircuitPWM The control unit detects a short circuit on the 20-51

control line to the lift directional control valve.
The control unit detects that the 8V power input
16 68 8v Supply 20-69
is not correct.
The control unit detects incorrect data coming
18 16 HitchControlLev. from the lift control lever. 20-53

22 18 Pos.Sens.NotConn The control unit detects that the lift position sen- 20-54
sor is not connected.
The control unit detects that the depth potenti-
23 72 SetPoint Potent. 20-71
ometer is disconnected or short-circuiting.
The control unit detects that the maximum lift
24 74 MaxHeightPotent. height potentiometer is disconnected or short- 20-73
circuiting.
The control unit detects that the power input to
12 Supply Pos. Sens. the lift position sensor is not correct. 20-50
26
67 5v Supply The control unit detects that the 5V power input 20-69
is not correct.
The control unit detects that the right hand draft
31 62 NoRightDraftSens. 20-65
sensor is disconnected.
The control unit detects that the left hand draft
32 63 NoLeftDraftSens. sensor is disconnected. 20-66

20-46
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Standard Extended Display Description Pag.

flash flash on ART
The control unit detects that the rate-of-drop po-
34 71 DownSpeedPotent. 20-70
tentiometer is disconnected or short-circuiting.
The control unit detects that the MIX potentiom-
36 73 CtrlMode Potent. eter is disconnected or short-circuiting. 20-72

41 65 Radar NotConnect. The control unit detects that the radar is discon- 20-68
nected.
The engine control unit detects that the signal
42 64 WheelSensNotConn. from the wheel speed pickup is either non-ex- 20-67
istent or incorrect.
The control unit detects that the 4WD clutch so-
41 ShortCircuit4WD 20-61
lenoid valve relay is short-circuiting.
51
The control unit detects that the 4WD clutch so-
43 4WD NotConnected lenoid valve relay is disconnected. 20-62

51 ShortCircuitDIF -OK - The control unit detects that the differential lock 20-63
solenoid valve is short-circuiting.
52
The control unit detects that the differential lock
53 EvDIFDeconnect. 20-64
actuator solenoid valve is disconnected.
The control unit detects that either the differen-
53 14 ASM-ShortCircuit tial lock or four wheel drive solenoid valve is 20-52
short-circuiting.
The control unit detects a bad reading of data
76 EEPROM :OPTION 20-74
from EEPROM.
The control unit detects a bad reading of data
54 77 EEPROM : SPEED from EEPROM. 20-74

78 EEPROM : CALIB The control unit detects a bad reading of data 20-74
from EEPROM.
The control unit detects a bad reading of data
81 EEPROM : CTRL 20-75
from EEPROM.
The control unit detects a bad reading of data
82 EEPROM : PWM from EEPROM. 20-75

83 EEPROM : DRAFT The control unit detects a bad reading of data 20-75
from EEPROM.
The control unit detects a bad reading of data
84 EEPROM : SLIP 20-76
from EEPROM.
55
The control unit detects a bad reading of data
85 EEPROM : POS from EEPROM. 20-76

86 EEPROM : AB The control unit detects a bad reading of data 20-76

from EEPROM.
The control unit detects a bad reading of data
87 EEPROM : SFCFG 20-77
from EEPROM.
The control unit detects a bad reading of data
88 EEPROM : SLCFG from EEPROM. 20-77

20-47
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

5.1.3 LIST OF ALARMS DISPLAYED ON ART

Display Extended Standard

on ART flash flash Description Page

4WD NotConnected 43 51 The control unit detects that the 4WD clutch so- 20-62
lenoid valve relay is disconnected.
The control unit detects that the 5V power input
5v Supply 67 26 20-69
is not correct.
The control unit detects that the 8V power input
8v Supply 68 16 is not correct. 20-69

The control unit detects that either the differen-

ASM-ShortCircuit 14 53 tial lock or four wheel drive solenoid valve is 20-52
short-circuiting.

CtrlMode Potent. 73 36 The control unit detects that the MIX potentiom- 20-72
eter is disconnected or short-circuiting.
The control unit detects that the rate-of-drop po-
DownSpeedPotent. 71 34 20-70
tentiometer is disconnected or short-circuiting.
The control unit detects a bad reading of data
EEPROM : AB 86 55 from EEPROM. 20-76

EEPROM : CALIB 78 54 The control unit detects a bad reading of data 20-74
from EEPROM.
The control unit detects a bad reading of data
EEPROM : CTRL 81 55 20-75
from EEPROM.
The control unit detects a bad reading of data
EEPROM : DRAFT 83 55 20-75
from EEPROM.
The control unit detects a bad reading of data
EEPROM : POS 85 55 from EEPROM. 20-76

EEPROM : PWM 82 55 The control unit detects a bad reading of data 20-75
from EEPROM.
The control unit detects a bad reading of data
EEPROM : SFCFG 87 55 20-77
from EEPROM.
The control unit detects a bad reading of data
EEPROM : SLCFG 88 55 from EEPROM. 20-77

EEPROM : SLIP 84 55 The control unit detects a bad reading of data 20-76
from EEPROM.
The control unit detects a bad reading of data
EEPROM : SPEED 77 54 20-74
from EPROM.
The control unit detects a bad reading of data
EEPROM :OPTION 76 54 from EEPROM. 20-74

EvDIFDeconnect. 53 52 The control unit detects that the differential lock 20-64
actuator solenoid valve is disconnected.
The control unit detects, in the presence of an
EvDwDeconnect.D 34 12 energizing signal (dynamic safety), that the lift 20-60
Down solenoid valve coil is not connected.
The control unit detects, in the absence of any
EvDwDeconnecteeL 33 12 energizing signal (static safety), that the lift Down 20-59
solenoid valve coil is not connected.

20-48
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Display Extended Standard Description Page

on ART flash flash
The control unit detects, in the presence of an
EvUpNotConnect.D 24 11 energizing signal (dynamic safety), that the lift Up 20-57
solenoid valve coil is not connected.
The control unit detects, in the absence of any
EvUpNotConnect.L 23 11 energizing signal (static safety), that the lift Up 20-56
solenoid valve coil is not connected.
The control unit detects incorrect data coming
HitchControlLev. 16 18 20-53
from the lift control lever.
The control unit detects that the maximum lift
MaxHeightPotent. 74 24 height potentiometer is disconnected or short- 20-73
circuiting.
The control unit detects that the left hand draft
NoLeftDraftSens. 63 32 sensor is disconnected. 20-66

NoRightDraftSens. 62 31 The control unit detects that the right hand draft 20-65
sensor is disconnected.
The control unit detects that the lift position sen-
Pos.Sens.NotConn 18 22 20-54
sor is not connected.
The control unit detects that the radar is discon-
Radar NotConnect. 65 41 nected. 20-68

SetPoint Potent. 72 23 The control unit detects that the depth potenti- 20-71
ometer is disconnected or short-circuiting.

ShortCircuit4WD 41 51 The control unit detects that the 4WD clutch so- 20-61
lenoid valve relay is short-circuiting.
The control unit detects that the differential lock
ShortCircuitDIF -OK - 51 52 20-63
solenoid valve is short-circuiting.
The control unit detects that the lift Down control
ShortCircuitEVDW 31 12 solenoid valve is short-circuiting. 20-58

ShortCircuitEVUP 21 11 The control unit detects that the lift Up control 20-55
solenoid valve is short-circuiting.
The control unit detects a short circuit on the
ShortCircuitPWM 13 13 20-51
control line to the lift directional control valve.
The control unit detects that the power input to
Supply Pos. Sens. 12 26 the lift position sensor is not correct. 20-50

The engine control unit detects that the signal

WheelSensNotConn. 64 42 from the wheel speed pickup is either non-ex- 20-67
istent or incorrect.

20-49
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

5.1.4 ANALYSIS OF LIFT AND ASM ALARMS

Extended alarm: 12 Supply Pos. Sens.

Standard alarm: 26

DESCRIPTION
The control unit detects that the power input to the lift position sensor is not correct.

CHECK
• Check that the contacts on connector “POS SEN” and on those of the lift control unit, “JX1” and “JX2”, are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift position sensor is correct (5 V approx
measured between pin 3 (positive) and pin 1 (negative) of connector “POS SEN”).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 3 of connector “POS SEN” and to chassis
earth, and measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “POS SEN” and to chassis
earth, and measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 2 of connector “POS SEN” and to chassis earth,
and check to ensure there are no short circuits to positive (meter reading: 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
5 4

15

23 21 20
4 5 20 21 15 23 JX1

GND4

J2 TKAB2
5 2 21 22 23
7.5A

F34

+15 1 2 3 POS. SENS.

U

S
0441.9533 0.012.8672.4
D0017551

20-50
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 13 ShortCircuitPWM

Standard alarm: 13

DESCRIPTION
The control unit detects a short circuit on the control line to the lift directional control valve.

CHECK
• Check that the contacts on connectors “EV UP” and “EV DW” and on those of the lift control unit, “JX1” and “JX2”, are
firmly attached and not oxidised.
• Test the internal resistance of the Up and Down solenoids (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV UP” and to chassis earth,
and measure the resistance to check for short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV DW” and to chassis earth,
and measure the resistance to check for short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
5 4 2 1

20
4 5 20 2 1 JX1

GND4

J2 TKAB2
5 2 19 20

GND2
7.5A

F34

EV DW EV UP
2 1 2 1
+15

0441.9533 0.012.8672.4
D0017561

20-51
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 14 ASM-ShortCircuit

Standard alarm: 53

DESCRIPTION
The control unit detects that a solenoid valve operating the differential lock or four wheel drive, or the clutch relay, is short-
circuiting.

CHECK
• Check that the contacts on connectors “RL9” and “EVDF” and on those of the lift control unit, “JX1” and “JX2”, are firm-
ly attached and not oxidised.
• Check that the resistance across the coil of relay RL9 is 70 Ohm approx.
• Test the internal resistance of the differential lock actuator solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 and pin 2 of the relay socket, and measure
the resistance to verify that there are no short circuits (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV DF” and to chassis earth,
and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 8 2

20
4 5 20 8 2 JX2

GND4

J2 TKAB2
5 2 8 13

GND4 GND2
7.5A

F34
D7
EV DF 1 2
3 5 4

+15 2 1

RL9
(DT/BRAKE)
0441.9533 0.012.8672.4
D0017731

20-52
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 16 HitchControlLev.

Standard alarm: 18

DESCRIPTION
The control unit detects incorrect data coming from the lift control lever.
NOTE
In the event of the "DownSpeedPotent.", "SetPoint Potent.", CtrlMode Potent.”, MaxHeightPotent.” and “Hitch-
ControlLev." alarms being displayed simultaneously, connect a test meter to pin 11 (positive) and pin 9 (negative)
of connector “X14” on the control console and check that the voltage is between 7.5 and 8.5 V.
If the value is within range, check the continuity of the wiring and make certain there are no short circuits to earth
or to a positive leg of the power harness between the lift control unit and the lift control console.

CHECK
• Check that the contacts on connector “EHR” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift control lever is correct (8 V approx meas-
ured between pin 3 (positive) and pin 1 (negative) of connector “EHR”)
• Verify the correct operation of the control lever (for details see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EHR” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 2 of connector “EHR” and to chassis earth, and
check that there are no short circuits to positive (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 3 of connector “EHR” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed

0.012.8732.4 6 5 4

22 20 18
4 5 20 22 18 6 JX1

GND4

J2
5 2

X14 11 3 9 7 1 2 3 EHR
7.5A

F34

+15
0441.9533
D0017720

20-53
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 18 Pos.Sens.NotConn

Standard alarm: 22

DESCRIPTION
The control unit detects that the lift position sensor is not connected.

CHECK
• Check that the contacts on connector “POS SEN” and on those of the lift control unit, “JX1” and “JX2”, are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift position sensor is correct (5 V approx
measured between pin 3 (positive) and pin 1 (negative) of connector “POS SEN”)
• Verify the correct operation of the position sensor (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 3 of connector “POS SEN” and to pin 23 of con-
nector JX1, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 3 of connector “POS SEN” and to chassis
earth, and measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 3 of connector “POS SEN” and to chassis earth,
and check to ensure there are no short circuits to positive (meter reading: 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4

15

23 21 20
4 5 20 21 15 23 JX1

GND4

J2 TKAB2
5 2 21 22 23
7.5A

F34

+15 1 2 3 POS. SENS.

U

S
0441.9533 0.012.8672.4
D0017551

20-54
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 21 ShortCircuitEVUP

Standard alarm: 11

DESCRIPTION
The control unit detects that the lift Up solenoid valve is short-circuiting.

CHECK
• Check that the contacts on connector “EV UP” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the lift Up control solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV UP” and to chassis earth,
and measure the resistance to check for short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
5 4 1

20
4 5 20 1 JX1

GND4

J2 TKAB2
5 2 20

GND2
7.5A

F34

EV UP
2 1
+15

0441.9533 0.012.8672.4
D0017581

20-55
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 23 EvUpNotConnect.L

Standard alarm: 11

DESCRIPTION
The control unit detects, in the absence of any energizing signal (static safety), that the lift Up solenoid valve coil is not con-
nected.

CHECK
• Check that the contacts on connector “EV UP” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the lift Up control solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV UP” and to pin 1 o connector
“JX1”, and measure the resistance to check the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV UP” and to chassis earth,
and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 1

20
4 5 20 1 JX1

GND4

J2 TKAB2
5 2 20

GND2
7.5A

F34

EV UP
2 1
+15

0441.9533 0.012.8672.4
D0017581

20-56
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 24 EvUpNotConnect.D

Standard alarm: 11

DESCRIPTION
The control unit detects, in the presence of an energizing signal (dynamic safety), that the lift Up solenoid valve coil is not
connected.

CHECK
• Check that the contacts on connector “EV UP” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the lift Up control solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV UP” and to pin 1 of con-
nector “JX1”, and measure the resistance to check the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV UP” and to chassis earth,
and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 1

20
4 5 20 1 JX1

GND4

J2 TKAB2
5 2 20

GND2
7.5A

F34

EV UP
2 1
+15

0441.9533 0.012.8672.4
D0017581

20-57
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 31 ShortCircuitEVDW

Standard alarm: 12

DESCRIPTION
The control unit detects that the lift Down solenoid valve is short-circuiting.

CHECK
• Check that the contacts on connector “EV DW” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the lift Down control solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV DW” and to chassis earth,
and measure the resistance to check for short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 2

20
4 5 20 2 JX1

GND4

J2 TKAB2
5 2 19

GND2
7.5A

F34

EV DW
2 1
+15

0441.9533 0.012.8672.4
D0017601

20-58
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 33 EvDwDeconnect.L

Standard alarm: 12

DESCRIPTION
The control unit detects, in the absence of any energizing signal (static safety), that the lift Down solenoid valve coil is not
connected.

CHECK
• Check that the contacts on connector “EV DW” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the lift Up control solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV DW” and to pin 2 of con-
nector “JX1” , and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV DW” and to chassis earth,
and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 2

20
4 5 20 2 JX1

GND4

J2 TKAB2
5 2 19

GND2
7.5A

F34

EV DW
2 1
+15

0441.9533 0.012.8672.4
D0017601

20-59
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 34 EvDwDeconnect.D

Standard alarm: 12

DESCRIPTION
The control unit detects, in the presence of an energizing signal (dynamic safety), that the lift Down solenoid valve coil is not
connected.

CHECK
• Check that the contacts on connector “EV DW” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the lift Up control solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV DW” and to pin 2 of con-
nector “JX1” , and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV DW” and to chassis earth,
and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 2

20
4 5 20 2 JX1

GND4

J2 TKAB2
5 2 19

GND2
7.5A

F34

EV DW
2 1
+15

0441.9533 0.012.8672.4
D0017601

20-60
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 41 ShortCircuit4WD

Standard alarm: 51

DESCRIPTION
The control unit detects that the 4WD clutch solenoid valve relay is short-circuiting.
NOTE
This alarm will be displayed only when ASM is active.

CHECK
• Check that the contacts of relay “RL9” and of the connectors on the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Deselect the four wheel drive, differential lock and ASM functions with the relative switches and, with the starter key in
the “I” (ON) position, connect a test meter to pin 1 and pin 2 of the relay socket and check the voltage, which should
measure 2.5 V approx.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 and pin 2 of the relay socket and measure the
resistance to verify that there are no short circuits (meter reading: infinity).
• Replace the relay “RL9” with a new one, clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I”
(ON) position again, and if the alarm is still present, the control unit must be renewed.

0.012.8732.4
5 4 8

20
4 5 20 8 JX2

GND4

J2
5 2 8

GND4
7.5A

F34
D7

3 5 4

+15 2 1

RL9
(DT/BRAKE)
0441.9533
D0017740

20-61
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 43 4WD NotConnected

Standard alarm: 51

DESCRIPTION
The control unit detects that the 4WD clutch solenoid valve relay is disconnected.
NOTA
This alarm will be displayed only when ASM is active.

CHECK
• Check that the contacts of relay “RL9” and of the connectors on the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Deselect the four wheel drive, differential lock and ASM functions with the relative switches and, with the starter key in
the “I” (ON) position, connect a test meter to pin 1 and pin 2 of the relay socket and check the voltage, which should reg-
ister 2.5 V approx.
• Replace the relay “RL9” with a new one, clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I”
(ON) position again, and if the alarm is still present, the control unit must be renewed.

0.012.8732.4
5 4 8

20
4 5 20 8 JX2

GND4

J2
5 2 8

GND4
7.5A

F34
D7

3 5 4

+15 2 1

RL9
(DT/BRAKE)
0441.9533
D0017740

20-62
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 51 ShortCircuitDIF -OK -

Standard alarm: 52

DESCRIPTION
The control unit detects that the differential lock actuator solenoid valve is short-circuiting.

CHECK
• Check that the contacts on connector “EV DF” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the differential lock solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV DF” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 2

20
JX1 4 5 20 2 JX2

GND4

J2 TKAB2
5 2 13

GND2
7.5A

F34

EV DF
1 2
+15

0441.9533 0.012.8672.4
D0017621

20-63
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 53 EvDIFDeconnect.

Standard alarm: 52

DESCRIPTION
The control unit detects that the differential lock actuator solenoid valve is disconnected.

CHECK
• Check that the contacts on connector “EV DF” and on those of the lift control unit, “JX1” and “JX2”, are firmly attached
and not oxidised.
• Test the internal resistance of the differential lock actuator solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV DF” and to pin 2 of con-
nector “JX2”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV DF” and to chassis earth,
and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
5 4 2

20
JX1 4 5 20 2 JX2

GND4

J2 TKAB2
5 2 13

GND2
7.5A

F34

EV DF
1 2
+15

0441.9533 0.012.8672.4
D0017621

20-64
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 62 NoRightDraftSens.

Standard alarm: 31

DESCRIPTION
The control unit detects that the right hand draft sensor is disconnected.

CHECK
• Check that the contacts on connector “RIGHT DRAFT” and on those of the lift control unit, “JX1” and “JX2”, are firmly
attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the draft sensor is correct (8 V approx meas-
ured between pin 3 (positive) and pin 1 (negative) of connector “RIGHT DRAFT”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “RIGHT DRAFT” and pin 17 of
connector “JX2”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
5 4 3

21 20 17
4 5 20 21 17 3 JX1

GND4

J2 TKAB2
5 2 21 25 17
7.5A

F34
RIGHT
DRAFT
1 2 3
+15
U

F
0441.9533 0.012.8672.4
D0017631

20-65
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 63 NoLeftDraftSens.

Standard alarm: 32

DESCRIPTION
The control unit detects that the left hand draft sensor is disconnected.

CHECK
• Check that the contacts on connector “LEFT DRAFT” and on those of the lift control unit, “JX1” and “JX2”, are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the draft sensor is correct (8 V approx meas-
ured between pin 3 (positive) and pin 1 (negative) of connector “LEFT DRAFT”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “LEFT DRAFT” and pin 10 of
connector “JX2”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
5 4 3

21 20 10
4 5 20 21 10 3 JX1

GND4

J2 TKAB2
5 2 21 24 17
7.5A

F34
LEFT
DRAFT
1 2 3
+15
U

0441.9533 0.012.8672.4
D0017641

20-66
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 64 WheelSensNotConn.

Standard alarm: 42

DESCRIPTION
The engine control unit detects that the signal from the wheel speed pickup is either non-existent or incorrect.
NOTA
If, when this alarm is triggered, the Infocenter continues to indicate the ground speed, the fault will be on the line
between the Infocenter and the transmission control unit; conversely, if the speed is not indicated with the ma-
chine in motion, the problem is in the connection between the wheel sensors, the transmission control unit and the
Infocenter (for details on how to identify the fault, see transmission alarm N° 47).

CHECK
• Check that the contacts on connector “ST1” of the Infocenter, connector “X8” of the engine control unit circuit board,
connector “MX2” of the engine control unit and connectors “JX1” and “JX2” of the lift control unit, are all firmly attached
and not oxidised.
• Check with the SERDIA program that the engine control unit is receiving the ground speed signal. If the signal is being
acknowledged, renew the lift control unit.
• Connect a test meter to pin 11 of connector “ST1” and pin 19 of connector “JX2”, and measure the resistance to verify
the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 19 of connector “JX2” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 19 of connector “JX2” and to cab earth, and
check that there are no short circuits to positive (meter reading: 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4 5 4

20 19
JX1 4 5 20 19 JX2
X8
2.2Kohm
5
6

GND4

7
J2 AS3 MX2
5 2 4
7.5A

F34
3 12 9 2 11 ST1
GND

GND

WHEEL RPM OUTPUT

+30

+15

+15

0441.9533 0.012.8894.4
D0017650

20-67
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 65 Radar NotConnect.

Standard alarm: 41

DESCRIPTION
The control unit detects that the radar is disconnected.
NOTE
If, when this alarm is triggered, the Infocenter indicates a wheelslip value within normal limits (on the road, wheel-
slip should be zero), the fault will be on the line between the Infocenter and the transmission control unit; con-
versely, if an abnormally high wheelslip value is indicated with the machine in motion (e.g. 100%), the problem is in
the connection between the radar and the Infocenter.

CHECK
• Check that the contacts on connector “RADAR”, on connectors “ST1” and “ST2” of the Infocenter and on connectors
“JX1” and “JX2” of the lift control unit, are all firmly attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the radar is correct (12 V measured between
pin 3 (positive) and pin 1 (negative) of connector “RADAR”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “RADAR” and to transmission
earth, and measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “RADAR” and pin 21 of con-
nector “ST2”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Connect a test meter to pin 5 of connector “ST1” and pin 3 of connector “JX2”, and measure the resistance to verify the
continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 3 of connector “JX2” and to cab earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 3 of connector “JX2” and to chassis earth, and
check to ensure there are no short circuits to positive (meter reading: 0V.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

5 4 3 0.012.8732.4

20
JX1 4 5 20 3 JX2

AS3 ST1
21 5 RADAR OUTPUT

GND4
RADAR INPUT
2 21
AS2 ST2

J2 TKAB2 0.012.8894.4
5 2 1 10 1

GND2

RADAR
7.5A

3A

F34 F27
2 3 1

+15

0441.9533 0.012.8672.4 D0017671

20-68
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 67 5v Supply

Standard alarm: 26

DESCRIPTION
The control unit detects that the 5V power input is not correct.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 68 8v Supply

Standard alarm: 16

DESCRIPTION
The control unit detects that the 8V power input is not correct.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-69
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 71 DownSpeedPotent.

Standard alarm: 34

DESCRIPTION
The control unit detects that the rate-of-drop potentiometer is disconnected or short-circuiting.
NOTE
In the event of the "DownSpeedPotent.", "SetPoint Potent.", “CtrlMode Potent.”, “MaxHeightPotent.” and “Hitch-
ControlLev." alarms being displayed simultaneously, connect a test meter to pin 11 (positive) and pin 9 (negative)
of connector “X14” at the control console and check that the voltage is between 7.5 and 8.5 V.
If the value is within range, check the continuity of the wiring and make certain there are no short circuits to earth
or to a positive leg of the power harness between the lift control unit and the lift control console.

CHECK
• Check that the contacts on connector “X14” of the lift control console and on connectors “JX1” and “JX2” of the lift con-
trol unit are all firmly attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift control panel is correct (8 V approx
measured between pin 3 (positive) and pin 1 (negative) of connector “EHR”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 10 of connector “X14” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 10 of connector “X14” and to chassis earth, and
check to ensure there are no short circuits to positive (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 8 and pin 18 of connector “JX1”, and measure
the resistance: the reading should be between about 220 Ohm and about 1150 Ohm.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4 8 6 5 4

22 20 18
4 5 20 22 18 8 6 JX1

GND4

J2
5 2

11 3 9 7 10 X14 1 2 3 EHR
7.5A

F34
4K7
220R

+15
0441.9533
D0017680

20-70
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 72 SetPoint Potent.

Standard alarm: 23

DESCRIPTION
The control unit detects that the depth potentiometer is disconnected or short-circuiting.
NOTA
In the event of the "DownSpeedPotent.", "SetPoint Potent.", “CtrlMode Potent.”, “MaxHeightPotent.” and “Hitch-
ControlLev." alarms being displayed simultaneously, connect a test meter to pin 11 (positive) and pin 9 (negative)
of connector “X14” on the control unit, and check that the voltage is between 7.5 and 8.5 V.
If the value is within range, check the continuity of the wiring and make certain there are no short circuits to earth
or to a positive leg of the power harness between the lift control unit and the lift control console.

CHECK
• Check that the contacts on connector “X14” of the lift control console and on connectors “JX1” and “JX2” of the lift con-
trol unit are all firmly attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift control panel is correct (8 V approx
measured between pin 3 (positive) and pin 1 (negative) of connector “EHR”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 6 of connector “X14” and to cab earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 6 of connector “X14” and to chassis earth, and
check to ensure there are no short circuits to positive (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 7 and pin 18 of connector “JX1”, and measure
the resistance: the reading should be between about 220 Ohm and about 1150 Ohm.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4 7 6 5 4

22 20 18

4 5 20 22 18 7 6 JX1

GND4

J2
5 2

11 3 9 7 6 X14 1 2 3 EHR
7.5A

F34
4K7
220R

+15
0441.9533
D0017690

20-71
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 73 CtrlMode Potent.

Standard alarm: 36

DESCRIPTION
The control unit detects that the MIX potentiometer is disconnected or short-circuiting.
NOTA
In the event of the "DownSpeedPotent.", "SetPoint Potent.", “CtrlMode Potent.”, “MaxHeightPotent.” and “Hitch-
ControlLev." alarms being displayed simultaneously, connect a test meter to pin 11 (positive) and pin 9 (negative)
of connector “X14” at the control console and check that the voltage is between 7.5 and 8.5 V.
If the value is within range, check the continuity of the wiring and make certain there are no short circuits to earth
or to a positive leg of the power harness between the lift control unit and the lift control console.

CHECK
• Check that the contacts on connector “X14” of the lift control console and on connectors “JX1” and “JX2” of the lift con-
trol unit are all firmly attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift control panel is correct (8 V approx
measured between pin 3 (positive) and pin 1 (negative) of connector “EHR”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 5 of connector “X14” and to cab earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 5 of connector “X14” and to chassis earth, and
check to ensure there are no short circuits to positive (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 19 and pin 18 of connector “JX1”, and measure
the resistance: the reading should be between about 220 Ohm and about 1150 Ohm.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4 6 5 4

22 20 19 18
4 5 20 22 18 19 6 JX1

GND4

J2
5 2

11 3 9 7 5 X14 1 2 3 EHR
7.5A

F34
4K7
220R

+15
0441.9533
D0017700

20-72
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 74 MaxHeightPotent.

Standard alarm: 24

DESCRIPTION
The control unit detects that the maximum lift height potentiometer is disconnected or short-circuiting.
NOTE
In the event of the "DownSpeedPotent.", "SetPoint Potent.", “CtrlMode Potent.”, “MaxHeightPotent.” and “Hitch-
ControlLev." alarms being displayed simultaneously, connect a test meter to pin 11 (positive) and pin 9 (negative)
of connector “X14” on the control unit and check that the voltage is between 7.5 and 8.5 V.
If the value is within range, check the continuity of the wiring and make certain there are no short circuits to earth
or to a positive leg of the power harness between the lift control unit and the lift control console.

CHECK
• Check that the contacts on connector “X14” of the lift control console and on connectors “JX1” and “JX2” of the lift con-
trol unit are all firmly attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the lift control panel is correct (8 V approx
measured between pin 3 (positive) and pin 1 (negative) of connector “EHR”)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 12 of connector “X14” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, connect a test meter to pin 12 of connector “X14” and to chassis earth, and
check that there are no short circuits to positive (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 14 and pin 18 of connector “JX1”, and measure
the resistance: the reading should be between about 220 Ohm and about 1150 Ohm.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
6 5 4

14

22 20 18
4 5 20 22 18 14 6 JX1

GND4

J2
5 2

11 3 9 7 12 X14 1 2 3 EHR
7.5A

F34
4K7
220R

+15
0441.9533
D0017710

20-73
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 76 EEPROM :OPTION

Standard alarm: 54

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 77 EEPROM : SPEED

Standard alarm: 54

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 78 EEPROM : CALIB

Standard alarm: 54

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-74
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 81 EEPROM : CTRL

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 82 EEPROM : PWM

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 83 EEPROM : DRAFT

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-75
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 84 EEPROM : SLIP

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 85 EEPROM : POS

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 86 EEPROM : AB

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-76
5. ALARMS 5.1 LIFT AND ASM CONTROL UNIT ALARMS

Extended alarm: 87 EEPROM : SFCFG

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

Extended alarm: 88 EEPROM : SLCFG

Standard alarm: 55

DESCRIPTION
The control unit detects a bad reading of data from EEPROM.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-77
PAGE INTENTIONALLY
LEFT BLANK
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

5. ALARMS
5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS
The transmission control unit warns the operator of any malfunction affecting monitored components, by way of audible
signals, and messages generated in the display on the right hand front upright of the cab.
A fault is indicated by the appearance of a symbol (key) in the display, accompanied by a code and in certain instances by
an acoustic signal.
In the event of two or more alarms being activated simultaneously, the display will show only the one with the higher code.
All alarms presented on the display correspond directly to the alarm conditions detected via EDS, apart from a certain
number associated with malfunction of the connection between the control unit and the display, which are shown on the
display with the “EE” alarm code.
In addition to coded alarms, there are also conditions in which the control unit is unable to diagnose the cause of the fault;
these are identifiable from abnormalities in operation of the transmission.
Depending on the severity of the fault by which it is triggered, a given alarm can have a limiting effect on the way the trans-
mission is managed.
In many instances, where the fault is not serious, a warning appears in the display and the operation of the transmission re-
mains substantially unaffected, whereas in other cases, the warning is displayed and operation will be totally inhibited, or
in less serious cases, simply limited.

5.2.1 ABNORMALITIES NOT DETECTED BY THE TRANSMISSION CONTROL UNIT

Abnormality Pag.

EDS software unable to connect to the transmission control unit (GEN1) 20-136

Transmission slips unexpectedly from forward or reverse drive into neutral (GEN2) 20-137

Transmission continues to shift range automatically every 1 or 2 seconds (GEN3) 20-137

Momentary loss of traction with the tractor in motion (GEN4) 20-138

Transmission stays permanently in neutral (GEN5) 20-138

5.2.2 ALARMS INDICATED ON THE TRANSMISSION DISPLAY AND BY THE EDS PROGRAM

Alarm Operating
code Alarm description mode Page

11 The control unit detects errors in the main clutch calibration values. 20-84

12 The control unit detects a problem with the power input to the trans- 20-85
mission oil temperature sensor.

13 The control unit detects a problem with the power input to the tem- 20-86
perature sensor.

The control unit detects a discrepancy between the speeds sensed

at the main clutch input and at the transmission output, indicated by
14 the status of the start enable sensor (which indicates whether the 20-87
transmission is in neutral or gears are engaged)

The control unit detects that the transmission oil low pressure in-
15 20-88
dicator light is disconnected

20-79
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

Alarm Alarm description Operating Page

code mode

16 The control unit detects a short circuit to earth on the control line of 20-89
the Infocenter light indicating low transmission oil pressure

The control unit detects a short circuit to positive on the control line
17 of the Infocenter light indicating low transmission oil pressure 20-90

The control unit detects a discrepancy between the oil pressure

18 reading and the operating status of the transmission 20-91

The control unit detects the transmission display control signal

19 short-circuiting to earth 20-92

The control unit detects the transmission display control signal

20 short-circuiting to positive 20-93

The control unit detects a ground speed higher than the permissible
21 limit 20-94

The control unit detects a transmission oil temperature higher

22 than the permissible limit with the machine operating in 20-94
“FIELD” mode

The control unit detects a transmission oil temperature higher than

23 20-94
the permissible limit with the machine operating in “ROAD” mode.

24 The control unit detects the main clutch running overspeed. 20-95

The control unit detects that solenoid Y4 is either not connected or

36 Stand-by strategy 20-96
faulty.

The control unit detects that the control line of solenoid Y4 is short-
37 Stand-by strategy 20-97
circuiting to earth

The control unit detects that the control line of solenoid Y4 is short-
38 Stand-by strategy 20-98
circuiting to positive

The control unit detects that solenoid Y2 is either not connected or

39 Stand-by strategy 20-99
faulty.

The control unit detects that the control line of solenoid Y1 is

40 Stand-by strategy 20-100
short-circuiting to earth

The control unit detects that the control line of solenoid Y1

41 Stand-by strategy 20-101
is short-circuiting to positive

The control unit detects that the rpm sensor nAb is disconnected or
47 Limp-Home 20-102
short-circuiting to positive

The control unit detects that the rpm sensor nAb is short-circuiting
48 Limp-Home 20-103
to earth

The control unit detects unreliable information coming from the

49 Limp-Home 20-104
rpm sensor nAb

The control unit detects that the rpm sensor nHk is disconnected or
50 Limp-Home 20-105
short-circuiting to positive

The control unit detects that the rpm sensor nHk is short-circuiting
51 Limp-Home 20-106
to earth

The control unit detects unreliable information coming from the

52 Limp-Home 20-107
rpm sensor nHk

20-80
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

Alarm Alarm description Operating Page

code mode

53 The control unit detects that the rpm sensor nLsa is disconnected or Limp-Home 20-108
short-circuiting to positive

54 The control unit detects that the rpm sensor nLsa is short-circuiting Limp-Home 20-109
to earth

55 The control unit detects unreliable information coming from the Limp-Home 20-110
rpm sensor nLsa

56 The control unit detects that the rpm sensor nLse is disconnected or Limp-Home 20-111
short-circuiting to positive

57 The control unit detects that the rpm sensor nLse is short-circuiting Limp-Home 20-112
to earth

58 The control detects unreliable information coming from the rpm Limp-Home 20-113
sensor nLse

The control detects a conflict in the information received from the

64 clutch pedal position sensor and clutch pedal depressed sensor, Emergency drive 20-114
regarding the position of the pedal

The control unit detects that the clutch pedal position sensor is
65 disconnected or short-circuiting to earth Emergency drive 20-115

Emergency drive
The control unit detects that the clutch pedal position sensor is
66 oppure 20-116
short-circuiting to positive
TC-Shutdown

Emergency drive
The control unit detects that the power input to the
67 oppure 20-117
clutch pedal position sensor is less than the prescribed value
TC-Shutdown

Emergency drive
The control unit detects that the power input to the clutch pedal po-
68 sition sensor is higher than the correct value oppure 20-118
TC-Shutdown
Emergency drive
69 The control unit detects one or more threshold values of the clutch oppure 20-119
pedal position sensor out of range.
TC-Shutdown

The control unit detects that the calibration values of the clutch ped- Emergency drive
al have not been saved correctly due to a defect in the EEPROM
70 oppure 20-119
memory locations, or that the clutch pedal has never been calibrat-
ed TC-Shutdown

76 The control unit detects that the proportional solenoid valve oper- TC-Shutdown 20-120
ating the main clutch is disconnected

77 The control unit detects that the proportional solenoid valve oper- TC-Shutdown 20-121
ating the main clutch is short-circuiting to earth

79 The control unit detects that the forward drive solenoid valve Y3 is TC-Shutdown 20-122
disconnected

80 The control unit detects that the forward drive solenoid valve Y3 is TC-Shutdown 20-123
short-circuiting to earth

82 The control unit detects that the reverse drive solenoid valve Y1 is TC-Shutdown 20-124
disconnected

83 The control unit detects that the reverse drive solenoid valve Y1 is TC-Shutdown 20-125
short-circuiting to earth

20-81
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

Alarm Alarm description Operating Page

code mode

85 The control unit detects a problem affecting the shuttle control le- Transmission shutdown 20-126
ver.

87 The control unit detects that the type of vehicle has not been pro- TC-Shutdown 20-127
grammed correctly

89 The control unit detects an abnormal level of current drawn by the TC-Shutdown 20-128
main clutch and forward/reverse solenoid valves Y1 and Y3

90 The control unit detects an abnormal level of current drawn by the TC-Shutdown 20-129
powershift solenoid valves

The control unit detects a conflict between values read by the nLsa
91 and nHk sensors, the position of the clutch pedal and the position of TC-Shutdown 20-130
the creeper control lever

Transmission shutdown
92 The control unit has detected an abnormally high input voltage oppure 20-131
TC-Shutdown

Transmission shutdown
93 The control unit has detected an abnormally low input voltage oppure 20-131
TC-Shutdown
The control unit detects that the main clutch solenoid valve is short-
94 TC-Shutdown 20-132
circuiting to positive

The control unit detects that the forward drive solenoid valve Y3 is
95 TC-Shutdown 20-133
short-circuiting to positive

96 The control unit detects that the reverse drive solenoid valve Y1 is TC-Shutdown 20-134
short-circuiting to positive

97 The control unit detects that the transmission ECU software has not TC-Shutdown 20-135
been programmed correctly

98 The control unit detects that transmission configuration data have TC-Shutdown 20-135
not been programmed correctly.

99 The control unit detects that machine configuration data have not TC-Shutdown 20-135
been saved correctly (CHECKSUM ERROR)

EE The display detects a problem of communication with the trans- 20-136

mission control unit.

20-82
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

5.2.3 DEFINITION OF TRANSMISSION OPERATING MODES

When a fault occurs, depending on the severity, the transmission control will respond by selecting one of the following
modes:
1 - Limp-Home
2 - Stand-by strategy
3 - Emergency drive
4 - Transmission shutdown
5 - TC-Shutdown

Limp-Home
In this mode, the operation of the transmission is limited.
Whenever Limp-Home mode cuts in, the transmission reverts automatically to neutral and the powershift can no longer be
used; the gears must be shifted with the mechanical linkage only.
Forward/reverse direction can be changed only with the tractor at a complete standstill and when the shuttle control lever
has been in the neutral position for more than 1 second (or if alarm code 47 is the only one active, simply by depressing the
clutch pedal).
To bring the transmission out of this mode, the fault must be rectified and the shuttle control lever returned to the “NEU-
TRAL” position, or the clutch pedal fully depressed.

Stand-by strategy
In this operating mode, the transmission management system locks up and the powershift can no longer be used; the
gears must be shifted with the mechanical linkage only.
To bring the transmission out of this mode, the fault must be rectified and the shuttle control lever returned to the “NEU-
TRAL” position, or the clutch pedal fully depressed.

Emergency drive
In this mode, the operation of the transmission is limited.
Whenever Emergency Drive cuts in, the powershift can no longer be used; the gears must be shifted with the mechanical
linkage only.
The engagement curve of the main clutch reverts automatically to default parameters.
The main clutch can no longer be modulated by way of the clutch pedal (any pressure applied to the pedal will cause the
main clutch to engage or disengage completely).
The power supply to the solenoid valves Y1, Y2, Y3, Y4 and Y5 is cut off.
Any variation in the signal from the clutch pedal position sensor or the clutch pedal depressed sensor will cause the trans-
mission to revert to neutral.
The tractor can move off only from a completely motionless standing start, when the shuttle control lever has been in neu-
tral position for more than 1 second.
To bring the transmission out of this mode, the fault must be rectified and the shuttle control lever returned to the “NEU-
TRAL” position.

Transmission shutdown
In this mode, the operation of the transmission is completely inhibited.
When this shutdown occurs, the transmission locks up completely and reverts to neutral; the power supply to solenoid
valves Y6, Y7 and Y8 is cut off.
To bring the transmission out of this mode, the fault must be rectified and the shuttle control lever returned to the “NEU-
TRAL” position.

TC-Shutdown
In this mode, the operation of the transmission is completely inhibited.
When this shutdown occurs, the transmission locks up completely and reverts to neutral; the power supply to all the pow-
ershift solenoid valves is cut off.
To bring the transmission out of this mode, the fault must be rectified.

20-83
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

5.2.4 ANALYSIS OF ALARMS

ALARM N° 11

DESCRIPTION
The control unit detects errors in the main clutch calibration values.
ECU RESPONSE
The control unit does not limit the operation of the transmission, but sets the contact pressure on the main clutch pedal to
the default value (99.99, corresponding to the value registering at the end of the engagement ramp).

CHECK
• Perform the main clutch calibration procedure.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-84
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 12

DESCRIPTION
The control unit detects a problem with the power input to the transmission oil temperature sensor.
NOTE
This alarm could be displayed as a result of alarms 66 and 68 being activated.
ECU RESPONSE
The control unit does not limit the operation of the transmission, but sets the transmission temperature to the “Trans-
mission cold” default value (HK pedal holding time, splitter holding time, slip times).

CHECK
• Check that the contacts on connector “TEMP” and on that of the lift control unit, “ECU PS”, are firmly attached and not
oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “TEMP” and pin 24 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “TEMP” and pin 39 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With connector “ECU PS” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect
a test meter to pin 1 of connector “TEMP” and to transmission earth, and check that there is no voltage registering (me-
ter reading 0V).
• With connector “ECU PS” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect
a test meter to pin 2 of connector “TEMP” and to transmission earth, and check that there is no voltage registering (me-
ter reading 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4
1 2 21 23

45

24 39 68
21 45 23 68 1 2 39 24 ECU PS

GND4

J2 TKAB1
3 6 10 20
7.5A

7.5A

F35 F27 TEMP

2 1

+15 +30

0441.9533 0.012.8672.4
D0017121

20-85
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 13

DESCRIPTION
The control unit detects a problem with the power input to the temperature sensor.
ECU RESPONSE
The control unit does not limit the operation of the transmission, but sets the transmission temperature to the “Trans-
mission cold” default value (HK pedal holding time, splitter holding time, slip times).

CHECK
• Check that the contacts on connector “TEMP” and on that of the lift control unit, “ECU PS”, are firmly attached and not
oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “TEMP” and to transmission
earth, and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “TEMP” and to transmission
earth, and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4
1 2 21 23

45

24 39 68
21 45 23 68 1 2 39 24 ECU PS

GND4

J2 TKAB1
3 6 10 20
7.5A

7.5A

F35 F27 TEMP

2 1

+15 +30

0441.9533 0.012.8672.4
D0017121

20-86
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 14

DESCRIPTION
The control unit detects a discrepancy between the speeds sensed at the main clutch input and at the transmission output,
indicated by the status of the start enable sensor (which indicates whether the transmission is in neutral or gears are en-
gaged).
ECU RESPONSE
The control unit does not limit the operation of the transmission.

CHECK
• In the event that there are other alarms activated, relating to the main clutch speed sensor (nHk) and the engine speed
sensor (nAb), verify the cause as described under the relative alarm headings before proceeding as follows.
• Check that the contacts on connector “X80” of the start enable switch and on the lift control unit “ECU PS” are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of relay “RL40” and to engine earth, and
measure the resistance to verify the continuity of the circuit with the mechanical shift in neutral (meter reading 0 Ohm)
and a break in continuity when a gear is engaged (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4

1 2 31 21 23

45

68
21 45 23 68 1 2 31 ECU PS

0 1 2

GND4

50 15 X 30 X17

J2 MS1
3 6 31 20

GND2
7.5A

7.5A

F35 F27 +30 +50

3 1 2 5 RL40 2 1 X80

+15 +30

0441.9533 0.013.5915.4
D0022691

20-87
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 15

DESCRIPTION
The control unit detects that the transmission oil low pressure indicator light is disconnected
ECU RESPONSE.
The control unit does not limit the operation of the transmission.

CHECK
• Check that the contacts on connector “ST1” of the Infocenter and on that of the lift control unit, “ECU PS”, are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 7 of connector “ST1” and pin 5 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• If the Infocenter installed is a type 2, check that the lamp of the transmission oil low pressure indicator is not burnt out.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4

1 2 5 21 23

45

68
21 45 23 68 1 2 5 ECU PS

GND4

J2 AS6
3 6 6
31

ST1
2 7 9 3 12
7.5A

7.5A

F35 F27
GND

GND
+30
GEAR BOX PRESSURE
+15

+15 +30

0441.9533 0.012.8894.4
D0017060

20-88
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 16

DESCRIPTION
The control unit detects a short circuit to earth on the control line of the Infocenter light indicating low transmission oil pres-
sure.
ECU RESPONSE
The control unit does not limit the operation of the transmission.

CHECK
• Check that the contacts on connector “ST1” of the Infocenter and on that of the lift control unit, “ECU PS”, are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position and connector “ST1” unplugged, connect a test meter to pin 5 of connector
“ECU PS” and to cab earth, and measure the resistance to verify whether or not there are short circuits to earth (meter
reading: infinity).
• If no short circuit to earth is discovered, fit a new Infocenter.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4

1 2 5 21 23

45

68
21 45 23 68 1 2 5 ECU PS

GND4

J2 AS6
3 6 6
31

ST1
2 7 9 3 12
7.5A

7.5A

F35 F27
GND

GND
+30
GEAR BOX PRESSURE
+15

+15 +30

0441.9533 0.012.8894.4
D0017060

20-89
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 17

DESCRIPTION
The control unit detects a short circuit to positive on the control line of the Infocenter light indicating low transmission oil
pressure
ECU RESPONSE.
The control unit does not limit the operation of the transmission.

CHECK
• Check that the contacts on connector “ST1” of the Infocenter and on that of the lift control unit, “ECU PS”, are firmly at-
tached and not oxidised.
• With the “ST1” connector unplugged from the Infocenter and the starter key in the “I” (ON) position, connect a test me-
ter to pin 5 of connector “ECU PS” and to cab earth, and check that there is no voltage registering (meter reading 0V).
• If there is no voltage, fit a new Infocenter.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4

1 2 5 21 23

45

68
21 45 23 68 1 2 5 ECU PS

GND4

J2 AS6
3 6 6
31

ST1
2 7 9 3 12
7.5A

7.5A

F35 F27
GND

GND
+30
GEAR BOX PRESSURE
+15

+15 +30

0441.9533 0.012.8894.4
D0017060

20-90
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 18

DESCRIPTION
The control unit detects a discrepancy between the oil pressure reading and the operating status of the transmission
ECU RESPONSE
The control unit does not limit the operation of the transmission, but indicates the problem via the Infocenter

CHECK
• In the event that there are other alarms activated, relating to the engine rpm sensors (nLse), verify the cause as de-
scribed under the relative alarm headings before proceeding as follows.
• Check that the contacts on the “PRESS. SWITCH” transmission oil pressure sensor and connector “ECU PS” of the lift
control unit are firmly attached and not oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “I” (ON), position, check that the power input to the clutch pedal position sensor is correct
(12V measured between pin 1 (positive) of connector “PRESS. SWITCH” and transmission earth)
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “PRESS. SWITCH” and pin 29
of connector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Check the pressure in the hydraulic circuit of the transmission system.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4

1 2 29 21 23

45

68
21 45 23 68 1 2 29 ECU PS

GND4

J2 TKAB1
3 6 7 11
31

PS
1
7.5A

7.5A

F35 F27
1
LS/PS

2 1 PRESS.
+15 +30 SWITCH
P
HK

0441.9533 0.012.8672.4
D0017071

20-91
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 19

DESCRIPTION
The control unit detects the transmission display control signal short-circuiting to earth
ECU RESPONSE
The control unit does not limit the operation of the transmission, but displays an error message “EE” and sounds a con-
tinuous beep
NOTE
Alarm code 19, detectable only by way of the EDS program.

CHECK
• Check that the contacts on connector “X40” of the display and on that of the lift control unit, “ECU PS”, are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position and connector “X40” unplugged, connect a test meter to pin 14 of con-
nector “ECU PS” and to cab earth, and measure the resistance to verify whether or not there are short circuits to earth
(meter reading: infinity).
• If no short circuit to earth is discovered, fit a new display.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4
1 2 14 21 23

45

68
21 45 23 68 1 2 14 ECU PS

GND4

J2 J3 AS5
3 6 6 3 1 5
7.5A

7.5A

F35 F27
3A

F16

X40
1 5 6 2
+12V

Sig

+15 +30 +15

0441.9533 0443.7875
D0017080

20-92
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 20

DESCRIPTION
The control unit detects the transmission display control signal short-circuiting to positive.
ECU RESPONSE
The control unit does not limit the operation of the transmission, but displays an error message “EE” and sounds a con-
tinuous beep.
NOTE
Alarm code 20, detectable only by way of the EDS program.

CHECK
• Check that the contacts on connector “X40” of the display and on that of the lift control unit, “ECU PS”, are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position and connector “X40” unplugged, connect a test meter to pin 14 of connector
“ECU PS” and to cab earth, and check that there is no voltage registering (meter reading: 0V).
• If there is no voltage, fit a new display.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

0.012.8732.4
1 2 14 21 23

45

68
21 45 23 68 1 2 14 ECU PS

GND4

J2 J3 AS5
3 6 6 3 1 5
7.5A

7.5A

F35 F27
3A

F16

X40
1 5 6 2
+12V

Sig

+15 +30 +15

0441.9533 0443.7875
D0017080

20-93
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 21

DESCRIPTION
The control unit detects a ground speed higher than the permissible limit
ECU RESPONSE
The control unit does not limit the operation of the transmission, but sounds a continuous beep until ground speed returns
within the permissible limits.

CHECK
• Reduce ground speed.

ALARM N° 22

DESCRIPTION
The control unit detects a transmission oil temperature higher than the permissible limit with the machine operating in
“FIELD” mode.
ECU RESPONSE
The control unit does not limit the operation of the transmission, but when the alarm is activated, five beeps will be sounded
in succession, and a single beep every two minutes thereafter.

CHECK
• Reduce the load on the transmission.
• Switch off the engine.

ALARM N° 23

DESCRIPTION
The control unit detects a transmission oil temperature higher than the permissible limit with the machine operating in
“ROAD” mode.
ECU RESPONSE
The control unit does not limit the operation of the transmission, and does not display any alarm message.

CHECK
• Reduce ground speed
• fault code is not shown on the display
• temperature monitoring only if configured
• counter increments, if over temperature is pending (mark for duration)
• fault code erasable only with a special diagnostic service tool (security fault memory)

20-94
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 24

DESCRIPTION
The control unit detects the main clutch running overspeed.
ECU RESPONSE
The control unit does not limit the operation of the transmission.

CHECK
• Reduce ground speed immediately.

20-95
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 36

DESCRIPTION
The control unit detects that solenoid Y4 is either not connected or faulty.
ECU RESPONSE
The control unit limits operation to "STAND-BY STRATEGY” mode.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin E and pin F of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin E of connector “EV GROUP” and pin 11 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-96
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 37

DESCRIPTION
The control unit detects that the control line of solenoid Y4 is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to "STAND-BY STRATEGY” mode.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin E and pin F of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin E
of connector “EV GROUP” and to the frame earth, and measure the resistance to check for short circuits to earth
(meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin F
of connector “EV GROUP” and to the frame earth, and measure the resistance to check for short circuits to earth
(meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin E and pin F of connector “EV GROUP”, and
measure the resistance to verify that the wires are not short-circuiting one to another (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-97
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 38

DESCRIPTION
The control unit detects that the control line of solenoid Y4 is short-circuiting to positive
ECU RESPONSE
The control unit limits operation to "STAND-BY STRATEGY” mode.
NOTE
His alarm could be displayed as a result of alarm 90 being activated.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “I” (ON) position, connect a test meter to pin E of connector “EV GROUP” and to transmission
earth, and check that there is no voltage registering (meter reading 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-98
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 39

DESCRIPTION
The control unit detects that solenoid Y2 is either not connected or faulty
ECU RESPONSE
The control unit limits operation to "STAND-BY STRATEGY” mode.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin C and pin F of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin C of connector “EV GROUP” and pin 57 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-99
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 40

DESCRIPTION
The control unit detects that the control line of solenoid Y2 is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to "STAND-BY STRATEGY” mode.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin C and pin F of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin C
of connector “EV GROUP” and to the frame earth, and measure the resistance to check for short circuits to earth
(meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin F
of connector “EV GROUP” and to the frame earth, and measure the resistance to check for short circuits to earth
(meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin C and pin F of connector “EV GROUP”, and
measure the resistance to verify that the wires are not short-circuiting one to another (meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-100
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 41

DESCRIPTION
The control unit detects that the control line of solenoid Y2 is short-circuiting to positive
ECU RESPONSE
The control unit limits operation to "STAND-BY STRATEGY” mode.
NOTE
This alarm could be displayed as a result of alarm 90 being activated.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “I” (ON) position, connect a test meter to pin C of connector “EV GROUP” and to transmission
earth, and check that there is no voltage registering (meter reading 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-101
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 47

DESCRIPTION
The control unit detects that the rpm sensor nAb is disconnected or short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NAB” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NAB”).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of
the“NAB” connector and to transmission earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NHK” and to pin 16 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 16 21 23

45

68
21 45 23 68 1 2 16 3 ECU PS

GND4

J2 TKAB1
3 6 11 12 13
7.5A

7.5A

F35 F27
NAB
3 2 1

+15 +30

0441.9533 0.012.8672.4
D0017361

20-102
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 48

DESCRIPTION
The control unit detects that the rpm sensor nAb is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NAB” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NHK” and to transmission
earth, and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 16 21 23

45

68
21 45 23 68 1 2 16 3 ECU PS

GND4

J2 TKAB1
3 6 11 12 13
7.5A

7.5A

F35 F27
NAB
3 2 1

+15 +30

0441.9533 0.012.8672.4
D0017361

20-103
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 49

DESCRIPTION
The control detects unreliable information coming from the rpm sensor nAb
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NAB” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NAB”).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
1 2 3 16 21 23

45

68
21 45 23 68 1 2 16 3 ECU PS

GND4

J2 TKAB1
3 6 11 12 13
7.5A

7.5A

F35 F27
NAB
3 2 1

+15 +30

0441.9533 0.012.8672.4
D0017361

20-104
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 50

DESCRIPTION
The control unit detects that the rpm sensor nHk is disconnected or short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NHK” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NHK”).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of con-
nector “NHK” and to transmission earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NHK” and to pin 62 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 21 23

45

62 68

21 45 23 68 1 2 62 3 ECU PS

GND4

J2 TKAB2
3 6 1 1 2 6
7.5A

7.5A

3A

F35 F27 F16

3 2 1 NHK

+15 +30 +15

0441.9533 0.012.8672.4
D0017341

20-105
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 51

DESCRIPTION
The control unit detects that the rpm sensor nHk is short-circuiting to earth.
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NHK” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NHK” and to transmission
earth, and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 21 23

45

62 68

21 45 23 68 1 2 62 3 ECU PS

GND4

J2 TKAB2
3 6 1 1 2 6
7.5A

7.5A

3A

F35 F27 F16

3 2 1 NHK

+15 +30 +15

0441.9533 0.012.8672.4
D0017341

20-106
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 52

DESCRIPTION
The control detects unreliable information coming from the rpm sensor nHk
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NHK” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NHK”).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed

0.012.8732.4
1 2 3 21 23

45

62 68

21 45 23 68 1 2 62 3 ECU PS

GND4

J2 TKAB2
3 6 1 1 2 6
7.5A

7.5A

3A

F35 F27 F16

3 2 1 NHK

+15 +30 +15

0441.9533 0.012.8672.4
D0017341

20-107
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 53

DESCRIPTION
The control unit detects that the rpm sensor nLsa is disconnected or short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NLSA” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NLSA”).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of con-
nector “NLSA” and to transmission earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NLSA” and to pin 40 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 40 21 23

45

68
21 45 23 68 1 2 40 3 ECU PS

GND4

J2 TKAB1
3 6 11 14 13
7.5A

7.5A

F35 F27
NLSA
3 2 1
fN

+15 +30
ISE

0441.9533 0.012.8672.4
D0017381

20-108
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 54

DESCRIPTION
The control unit detects that the rpm sensor nLsa is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NLSA” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NLSA” and to transmission
earth, and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 40 21 23

45

68
21 45 23 68 1 2 40 3 ECU PS

GND4

J2 TKAB1
3 6 11 14 13
7.5A

7.5A

F35 F27
NLSA
3 2 1
fN

+15 +30
ISE

0441.9533 0.012.8672.4
D0017381

20-109
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 55

DESCRIPTION
The control detects unreliable information coming from the rpm sensor nLsa
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NLSA” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is correc
(12V measured between pin 3 (positive) and pin 1 (negative) of connector “NLSA”).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 40 21 23

45

68
21 45 23 68 1 2 40 3 ECU PS

GND4

J2 TKAB1
3 6 11 14 13
7.5A

7.5A

F35 F27
NLSA
3 2 1
fN

+15 +30
ISE

0441.9533 0.012.8672.4
D0017381

20-110
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 56

DESCRIPTION
The control unit detects that the rpm sensor nLse is disconnected or short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NLSE” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NLSE”).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of con-
nector “NLSE” and to transmission earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NLSE” and to pin 17 of con-
nector “ECU PS” , and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 17 21 23

45

68

21 45 23 68 1 2 17 3 ECU PS

GND4

J2 TKAB1
3 6 11 15 13
7.5A

7.5A

F35 F27
3 2 1 NLSE
f

N
+15 +30

0441.9533 0.012.8672.4
D0017541

20-111
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 57

DESCRIPTION
The control unit detects that the rpm sensor nLse is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NLSE” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “NLSE” and to transmission
earth, and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 17 21 23

45

68

21 45 23 68 1 2 17 3 ECU PS

GND4

J2 TKAB1
3 6 11 15 13
7.5A

7.5A

F35 F27
3 2 1 NLSE
f

N
+15 +30

0441.9533 0.012.8672.4
D0017541

20-112
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 58

DESCRIPTION
The control detects unreliable information coming from the rpm sensor nLse
ECU RESPONSE
The control unit limits operation to “LIMP-HOME” mode, and at the first attempt to shuttle in either direction, the trans-
mission will revert to neutral, emitting a continuous beep.

CHECK
• Check that the contacts on connector “NLSE” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “I” (ON) position, check that the power input to the transmission output speed sensor is cor-
rect (12V measured between pin 3 (positive) and pin 1 (negative) of connector “NLSE”).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 3 17 21 23

45

68

21 45 23 68 1 2 17 3 ECU PS

GND4

J2 TKAB1
3 6 11 15 13
7.5A

7.5A

F35 F27
3 2 1 NLSE
f

N
+15 +30

0441.9533 0.012.8672.4
D0017541

20-113
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 64

DESCRIPTION
The control detects a conflict in the information received from the clutch pedal position sensor and clutch pedal depressed
sensor, regarding the position of the pedal
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded.

CHECK
• In the event that there are other alarms activated, relating to the clutch pedal position sensor, verify the cause as de-
scribed under the relative alarm headings before proceeding as follows.
• Check that the contacts on connector “X33” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• Perform the clutch pedal position sensor calibration procedure.
• Verify the correct operation of the clutch pedal depressed proximity sensor (for details see section 40)
• Verify the correct positioning of the clutch pedal depressed proximity sensor.
• Verify the correct operation of the clutch pedal position sensor (for details see section 40)
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 4 21 23

45

44 68

21 45 23 68 1 2 4 44 ECU PS

GND4

J2 J3 AS6 AS3
3 6 6 8 4 9
7.5A

7.5A

F35 F27
3A

F16 X33
1 2 3

+15 +30 +15

0441.9533 0.012.8894.4
D0017400

20-114
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 65

DESCRIPTION
The control unit detects that the clutch pedal position sensor is disconnected or short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded.

CHECK
• Check that the contacts on connector “X34” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the clutch pedal position sensor is correct (5V
measured between pin 1 (positive) and pin 2 (negative) of connector “X34”).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 2 of con-
nector “X34” and to transmission earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 4 of connector “X34” and to pin 38 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 21 23

45

24 37 38 68

21 45 23 68 1 2 38 37 24 ECU PS

GND4

J2 AS6
3 6 3 2 1
7.5A

7.5A

F35 F27 X34

4 1 2

+15 +30

0441.9533 0.012.8894.4
D0017430

20-115
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 66

DESCRIPTION
The control unit detects that the clutch pedal position sensor is short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded. In the event that one or more of alarms 85, 92 and 93 should also be activated, the transmission will be switched
to “TC-SHUTDOWN” mode.
NOTE
This alarm could be displayed as a result of alarms 12 and 68 being activated.

CHECK
• Check that the contacts on connector “X34” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the clutch pedal position sensor is correct (5V
measured between pin 2 (positive) and pin 1 (negative) of connector “X34”).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of con-
nector “X34” and to cab earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 4 of connector “X34” and to pin 38 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 21 23

45

24 37 38 68

21 45 23 68 1 2 38 37 24 ECU PS

GND4

J2 AS6
3 6 3 2 1
7.5A

7.5A

F35 F27 X34

4 1 2

+15 +30

0441.9533 0.012.8894.4
D0017430

20-116
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 67

DESCRIPTION
The control unit detects that the power input to the clutch pedal position sensor is lower than the correct value
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded. In the event that one or more of alarms 85, 92 and 93 should also be activated, the transmission will be
switched to “TC-SHUTDOWN” mode.
NOTE
This alarm could be displayed as a result of alarm 69 being activated.

CHECK
• In the event that there are other alarms activated, relating to the clutch pedal position sensor or the transmission oil tem-
perature sensor, verify the cause as described under the relative alarm headings before proceeding as follows.
• Check that the contacts on connector “X34” of the clutch pedal position sensor, connector “TEMP” of the transmission
oil temperature sensor, and connector “ECU PS” of the transmission control unit, are all firmly attached and not ox-
idised.
• With the starter key in the “I” (ON) position, check that the power input to the clutch pedal position sensor is correct (5V
measured between pin 2 (positive) and pin 1 (negative) of connector “X34”).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 21 23

45

24 37 38 39 68

21 45 23 68 1 2 38 37 24 39 ECU PS

GND4

J2 AS6 TKAB1
3 6 3 2 1 10 20
7.5A

7.5A

F35 F27 X34 TEMP

4 1 2 2 1

+15 +30

0441.9533 0.012.8894.4 0.012.8672.4

D0017441

20-117
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 68

DESCRIPTION
The control unit detects that the power input to the clutch pedal position sensor is higher than the correct value
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded. In the event that one or more of alarms 85, 92 and 93 should also be activated, the transmission will be
switched to “TC-SHUTDOWN” mode.
NOTE
This alarm could be displayed as a result of alarm 12 or 68 being activated.

CHECK
• In the event that there are other alarms activated, relating to the clutch pedal position sensor or the transmission oil tem-
perature sensor, verify the cause as described under the relative alarm headings before proceeding as follows.
• Check that the contacts on connector “X34” of the clutch pedal position sensor, connector “TEMP” of the transmission
oil temperature sensor, and connector “ECU PS” of the transmission control unit, are all firmly attached and not ox-
idised.
• With the starter key in the “I” (ON) position, check that the power input to the clutch pedal position sensor is correct (5V
measured between pin 2 (positive) and pin 1 (negative) of connector “X34”).
• Verify the correct operation of the sensor (for technical details, see section 40).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 21 23

45

24 37 38 39 68

21 45 23 68 1 2 38 37 24 39 ECU PS

GND4

J2 AS6 TKAB1
3 6 3 2 1 10 20
7.5A

7.5A

F35 F27 X34 TEMP

4 1 2 2 1

+15 +30

0441.9533 0.012.8894.4 0.012.8672.4

D0017441

20-118
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 69

DESCRIPTION
The control unit detects one or more threshold values of the clutch pedal position sensor out of range.
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded. In the event that one or more of alarms 85, 92 and 93 should also be activated, the transmission will be
switched to “TC-SHUTDOWN” mode.

CHECK
• Perform the clutch pedal sensor calibration procedure.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

ALARM N° 70

DESCRIPTION
The control unit detects that the calibration values of the clutch pedal have not been saved correctly due to a defect in the
EEPROM memory locations, or that the clutch pedal has never been calibrated
ECU RESPONSE
The control unit limits operation to “EMERGENCY DRIVE” mode, the transmission reverts to neutral and a continuous beep
is sounded. In the event that one or more of alarms 85, 92 and 93 should also be activated, the transmission will be switched
to “TC-SHUTDOWN” mode.
NOTE
This alarm could be displayed as a result of alarm 64 being activated.

CHECK
• Perform the clutch pedal sensor calibration procedure.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-119
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 76

DESCRIPTION
The control unit detects that the proportional solenoid valve operating the main clutch is disconnected
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “EV PROP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• Test the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “EV PROP” and to pin 56 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EV PROP” and to pin 13 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• With the starter key in the “I” (ON) position, check that the power input to the proportional solenoid valve is correct (12V
measured between pin 2 (positive) of connector “EV PROP” and transmission earth)
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-120
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 77

DESCRIPTION
The control unit detects that the proportional solenoid valve operating the main clutch is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “EV PROP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• Test the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin 2 of con-
nector “EV PROP” and to transmission earth, and measure the resistance to verify whether or not there are short circuits
to earth (meter reading: infinity).
• With the starter key in the “I” (ON) position, check that the power input to the proportional solenoid valve is correct (12V
measured between pin 2 (positive) of connector “EV PROP” and transmission earth)
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-121
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 79

DESCRIPTION
The control unit detects that the forward drive solenoid valve Y3 is disconnected.
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin A and pin D of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin D of connector “EV GROUP” and pin 32 of con-
nector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-122
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 80

DESCRIPTION
The control unit detects that the forward drive solenoid valve Y3 is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin A and pin D of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin D
of connector “EV GROUP” and to the transmission earth, and measure the resistance to check for short circuits
to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin A
of connector “EV GROUP” and to the transmission earth, and measure the resistance to check for short circuits
to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin 2 and pin
3 of connector “EV GROUP”, and measure the resistance to verify that the wires are not short-circuiting one to another
(meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-123
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 82

DESCRIPTION
The control unit detects that the reverse drive solenoid valve Y1 is disconnected
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin A and pin B of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin B of connector “EV GROUP” and to pin 55 of
connector “ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-124
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 83

DESCRIPTION
The control unit detects that the reverse drive solenoid valve Y1 is short-circuiting to earth
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “EV GROUP” and connector “ECU PS” of the transmission control unit are firmly
attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin A and pin B of connector “EV GROUP” on the
transmission, and measure the resistance of the solenoid (for details, see section 40).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin A
of connector “EV GROUP” and to the transmission earth, and measure the resistance to check for short circuits
to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin B of con-
nector “EV GROUP” and to transmission earth, and measure the resistance to verify whether or not there are short cir-
cuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin A and pin
B of connector “EV GROUP”, and measure the resistance to verify that the wires are not short-circuiting one to another
(meter reading: infinity).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-125
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 85

DESCRIPTION
The control unit detects a problem affecting the shuttle control lever.
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.

CHECK
• Check that the contacts on connector “X37” and on connector “ECU PS” of the transmission control unit are firmly at-
tached and not oxidised.
• Verify the correct operation of the shuttle lever (for details see section 40).
• With the starter key in the “I” (ON) position, check that the power input to the shuttle control lever is correct (12V meas-
ured between pin 3 (positive) of connector “X37” and cab earth)
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter in alternation
to pin 1, pin 2, pin 3 and pin 4 of connector “X37“ and to cab earth, and measure the resistance to verify whether or not
there are short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of con-
nector “X37” and in alternation to pin 2, pin 3 and pin 4, and measure the resistance to verify whether or not there are
short circuits (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin 2 of con-
nector “X37” and in alternation to pin 3 and pin 4, and measure the resistance to verify whether or not there are short cir-
cuits (meter reading: infinity).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin 3 of con-
nector “X37” and to pin 4, and measure the resistance to verify whether or not there are short circuits (meter reading: in-
finity).
• With the starter key in the “I” (ON) position, connect a test meter in alternation to pin 1, pin 2 and pin 4 of connector “X37“
and to cab earth, and check that there is no voltage registering (meter reading 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 20 21 23

45

63 65 68

21 45 23 68 1 2 63 65 20 ECU PS

GND4

J2 AS4
3 6 20 18 21 19

X37
7.5A

7.5A

F35 F27 3 1 4 2
3.9 Ohm

3.9 Ohm

3.9 Ohm

FW

RV
N

+15 +30

0441.9533 0443.8656
D0017500

20-126
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 87

DESCRIPTION
The control unit detects that the type of vehicle has not been programmed correctly
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode.

CHECK
• Reprogram the control unit, entering the correct tractor model data, and repeat the calibration procedure for the main
clutch and the clutch pedal.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-127
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 89

DESCRIPTION
The control unit detects an abnormal level of current drawn by the main clutch solenoid valves and the forward and reverse
solenoid valves Y1 and Y3
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.
NOTE
This alarm could be displayed as a result of alarms 94, 95 and 96 being activated.

CHECK
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin B
of connector “EV GROUP” and to the transmission earth, and measure the resistance to check for short circuits
to earth (meter reading: infinity).
Repeat the test on pin D for connector “EVGROUP” and on pin 1 of connector “EVPROP”.
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin A of
connector “EV GROUP” and the transmission earth and check that there is no voltage (meter reading: 0V).
Repeat the test on pin D for connector “EVGROUP” and on pin 1 of connector “EVPROP”.
• With the starter key in the “I” (ON) position, connect a test meter to pins 23 and 68 and measure the voltage (meter read-
ing: 12V)
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed..

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-128
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 90

DESCRIPTION
The control unit detects an abnormal level of current drawn by the powershift solenoid valves Y2, Y4.
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.
NOTE
This alarm could be displayed as a result of alarms 38 and 41 being activated.

CHECK
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin F of con-
nector “EV GROUP”, and measure the resistance to verify whether or not there are short circuits to earth (meter reading:
infinity).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 8 of con-
nector “EV GROUP” and check that there is no voltage registering (meter reading: 0V).
• With the starter key in the “I” (ON) position, check that the power input to the solenoid valves is correct (12V measured
between pin F (positive) of connector “EV GROUP” and transmission earth)
• With the starter key in the “I” (ON) position, connect a test meter to pins 23 and 68 and measure the voltage (meter read-
ing: 12V)
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 32 11 13 21 23

45

55 57 68

21 45 23 68 1 2 11 8 57 32 13 55 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 17 21 16
7.5A

7.5A

F35 F27
E F C D A B EV GROUP
Y2
Y3
Y4

Y1

+15 +30

0441.9533 0.012.8672.4
D0017281

20-129
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 91

DESCRIPTION
The control unit detects a conflict between values read by the nLsa and nHk sensors, the position of the clutch pedal and
the position of the creeper engagement lever
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral.

CHECK
• Check that the creeper engagement lever is in the correct position and the sensor correctly placed.
• Verify the correct operation of the creeper engagement sensor (for details, see section 40).
• Make certain that connectors “NHK” and “NAB” have not been switched.
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin A of con-
nector “EV GROUP”, and measure the resistance to verify whether or not there are short circuits to earth (meter reading:
infinity).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of
connector “EV PROP” and the transmission earth and check that there is no voltage (meter reading: 0V).
• Check the transmission hydraulic system
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-130
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 92

DESCRIPTION
The control unit has detected an abnormally high input voltage
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral. In the event that one
or more of alarms 64, 65, 66, 67, 68, 69 or 70 should also be activated, the transmission will be switched to “TC-SHUT-
DOWN” mode.
NOTE
This alarm is activated generally when the alternator charging voltage is irregular, and can be tripped only by a fault
affecting the alternator itself.

CHECK
• Check, with the engine off, that the battery voltage is within the prescribed range (normal voltage 12V - 13.5V).
• Check, with the engine running, that the battery voltage is within the prescribed range. In this instance the problem may
be attributable to a fault in the ECU, which must therefore be replaced with a new unit, otherwise the trouble is being
caused by incorrect operation of the alternator voltage regulator.

ALARM N° 93

DESCRIPTION
The control unit has detected an abnormally low input voltage
ECU RESPONSE
The control unit limits operation to “TRANSMISSION-SHUTDOWN” mode and the transmission reverts to neutral. In the
event that one or more of alarms 64, 65, 66, 67, 68, 69 or 70 should also be activated, the transmission will be switched to
“TC-SHUTDOWN” mode.
NOTE
This alarm is activated generally when the battery voltage is less than 10V and can be tripped by an excessive cur-
rent draw when the engine is started, or if the battery is damaged or cannot be recharged by the alternator.
Accordingly, this alarm can be displayed only as a passive alarm, using the EDS program. Should the alarm be dis-
played among the active alarms, the ECU must be renewed.

CHECK
• See if the alarm is indicated as an active alarm; if so, the ECU must be renewed.
• Check, with the engine off, that the battery voltage is as prescribed (higher than 12V); if not, install a new battery.
NOTE
Lower voltages can register after the tractor has been standing idle for an extended period; this does mean nec-
essarily that the battery needs replacing.
• Check first whether or not the battery voltage returns to normal with the engine running. In this instance the problem
may be attributable to the battery being discharged or damaged; if not, and the voltage remains lower than the pre-
scribed minimum, the trouble is being caused by incorrect operation of the alternator.
NOTE
In extreme cases, when the battery is seriously damaged (short-circuiting), the alternator may not be able to re-
charge the cells or generate sufficient voltage. Before changing the alternator, verify its correct or incorrect op-
eration by connecting a new battery.

20-131
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 94

DESCRIPTION
The control unit detects that the main clutch solenoid valve is short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.
NOTE
This alarm could be displayed as a result of alarm 89 being activated.

CHECK
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 1 of con-
nector “EV PROP” and the transmission earth and check that there is no voltage (meter reading: 0V).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 2 of con-
nector “EV PROP” and the transmission earth and check that there is no voltage (meter reading: 0V)).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-132
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 95

DESCRIPTION
The control unit detects that the forward drive solenoid valve Y3 is short-circuiting to positive.
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.
NOTE
This alarm could be displayed as a result of alarm 89 being activated.

CHECK
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin A of con-
nector “EV GROUP” and the transmission earth and check that there is no voltage (meter reading: 0V).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin D of con-
nector “EV GROUP” and the transmission earth and check that there is no voltage (meter reading: 0V).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-133
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 96

DESCRIPTION
The control unit detects that the reverse drive solenoid valve Y1 is short-circuiting to positive
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode and the transmission reverts to neutral, emitting a continuous
beep.
NOTE
This alarm could be displayed as a result of alarm 89 being activated.

CHECK
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin A of con-
nector “EV GROUP” and the transmission earth and check that there is no voltage (meter reading: 0V)).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin B of con-
nector “EV GROUP” and the transmission earth and check that there is no voltage (meter reading: 0V)).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

0.012.8732.4
1 2 8 11 13 21 23

45

32 55 56 57 68

21 45 23 68 1 2 11 8 57 32 13 55 56 ECU PS

GND4

J2 TKAB1
3 6 5 1 6 16 21 17 22
7.5A

7.5A

F35 F27
EV GROUP EV PROP
E F C D A B 2 1
U

+15 +30
Y2
Y3
Y4

Y1

Prop

0441.9533 0.012.8672.4
D0017611

20-134
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° 97

DESCRIPTION
The control unit detects that the transmission ECU software has not been programmed correctly
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode.

CHECK
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

ALARM N° 98

DESCRIPTION
The control unit detects that transmission configuration data have not been programmed correctly.
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode.

CHECK
• Reprogram the control unit, entering the correct tractor model data, and repeat the calibration procedure for the main
clutch and the clutch pedal.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

ALARM N° 99

DESCRIPTION
The control unit detects that machine configuration data have not been saved correctly (CHECKSUM ERROR)
ECU RESPONSE
The control unit limits operation to “TC-SHUTDOWN” mode.

CHECK
• Reprogram the control unit, entering the correct tractor model data, and repeat the calibration procedure for the main
clutch and the clutch pedal.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-135
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM N° EE

DESCRIPTION
The display detects a problem of communication with the transmission control unit.

CHECK
• Connecting a portable computer to the transmission control unit and using the EDS program, check whether or not
alarms 19 and/or 20 have been logged, and if so, follow the procedures described for these alarms.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

ALARM GEN1

DESCRIPTION
EDS software unable to connect to the transmission control unit.

CHECK
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position, and try connecting to the transmission con-
trol unit.
• Check the integrity of the transmission ECU power supply fuses F27 and F35
• With the starter key in the “O” (OFF) position, check that the power input to the control unit is correct (starter key in the
“I” (ON) position, 12V measured between pin 23 and pin 68 (positive) and pin 1 and pin 2 (negative) of connector “ECU
PS”).
• With the starter key in the “I” (ON) position, check that the power input to the control unit is correct (starter key in the “I”
(ON) position, 12V measured between pin 21 and pin 45 (positive) and pin 1 and pin 2 (negative) of connector “ECU PS”).
• With the starter key in the “O” (OFF) position and connector “ECU PS” unplugged, connect a test meter to pin 8 of con-
nector “X18” and to cab earth, and measure the resistance to verify whether or not there are short circuits to earth (meter
reading: infinity).
• With the starter key in the “I” (ON) position and connector “ECU PS” unplugged, connect a test meter to pin 8 of con-
nector “X18” and to cab earth, and check that there is no voltage (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 8 of connector “X18” and pin 15 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• If the fault cannot be traced and rectified through this procedure, fit a new control unit.

20-136
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM GEN2

DESCRIPTION
Transmission slips unexpectedly from forward or reverse drive into neutral.
ECU RESPONSE
The display indicates forward drive, reverse drive and neutral status simultaneously, and a continuous beep is sounded.

CHECK
• Reprogram the control unit, entering the correct tractor model data, and repeat the calibration procedure for the main
clutch and the clutch pedal.
• Check the wiring, following the procedures described for alarms 53, 54, 55, 56, 57 and 58.
• Check the pressure in the hydraulic circuit of the transmission system.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

ALARM GEN3

DESCRIPTION
The transmission continues to shift range automatically every 1 or 2 seconds
ECU RESPONSE
None

CHECK
• Reprogram the control unit, entering the correct tractor model data, and repeat the calibration procedure for the main
clutch and the clutch pedal.
• Check the wiring, following the procedures described for alarms 36, 37, 38, 39, 40 and 41.
• Check the wiring, following the procedures described for alarms 53, 54, 55, 56, 57 and 58.
• Check the pressure in the hydraulic circuit of the transmission system.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

20-137
5. ALARMS 5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS

ALARM GEN4

DESCRIPTION
Momentary loss of traction with the tractor in motion
ECU RESPONSE
None

CHECK
• Reprogram the control unit, entering the correct tractor model data, and repeat the calibration procedure for the main
clutch and the clutch pedal.
• Check the wiring, following the procedures described for alarms 53, 54, 55, 56, 57 and 58.
• Check the pressure in the hydraulic circuit of the transmission system.
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the control unit must be renewed.

ALARM GEN5

DESCRIPTION
The transmission stays in neutral

CHECK
• Check that the contacts on connector “X80” of the start enable switch and on connector “ECU PS” of the lift control unit
are firmly attached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of relay “RL40” and to engine earth, and
measure the resistance to verify the continuity of the circuit with the mechanical shift in neutral (meter reading 0 Ohm)
and a break in continuity when a gear is engaged (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of relay “RL40 and to pin 31 of connector
“ECU PS”, and measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• Clear all alarms, turn the starter key first to “O” (OFF) and then back to the “I” (ON) position again, and if the alarm is still
present, the transmission control unit must be renewed.

20-138
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

5. ALARMS
5.3 LIST OF ALARMS DISPLAYED BY SERDIA
The engine control unit informs the operator of any malfunction affecting monitored components, both audibly and visually
(fault warning light) by way of the Infocenter.
Faults are indicated by the light using two types of visual warning:
1 - fault warning light flashing: this type of indication informs the operator that one of the components in the engine sys-
tem is faulty, but normal operation of the engine remains unaffected. The engine continues to operate normally.
2 - fault warning light permanently on: this type of indication informs the operator that one of the components in the en-
gine system is faulty, and continuing to work under these conditions could result in serious damage to the engine.
When this type of alarm occurs, the engine generally switches off and it will not be possible to operate the starter until
the fault has been rectified.

5.3.1 ALARMS DISPLAYED USING THE SERDIA PROGRAM

Alarm Alarm description Page

code
The engine control unit detects that the signal from the engine
1 20-141
pickup is either non-existent or incorrect
2 Alarm code available but not utilised –
The engine control unit detects that the signal from the wheel speed
3 20-142
pickup is either non-existent or incorrect.
4 Alarm code available but not utilised –
The control unit detects that the connection to the accelerator pedal position sensor is either
5 20-143
non-existent or short-circuiting.
The control unit detects that the connection to the hand throttle position sensor is either
6 non-existent or short-circuiting. 20-144

7 The engine control unit has detected that the engine turbo charge pressure signal is either 20-145
non-existent or unreliable.
8 Alarm code available but not utilised –

9 The engine control unit has detected that the coolant temperature signal is either 20-146
non-existent or unreliable.
10 Alarm code available but not utilised –

The engine control unit has detected that the fuel temperature signal is either
11 20-147
non-existent or unreliable.
30 Alarm code available but not utilised –

31 The engine control unit has detected a coolant temperature higher than 20-148
the alarm threshold.
32 Alarm code available but not utilised –
34 Alarm code available but not utilised –
The engine control unit detects that the engine is or has been running overspeed (above 3100
35 rpm). 20-149

36 The engine control unit has detected a fuel temperature higher than 20-150
the alarm threshold.
40 Alarm code available but not utilised –

41 The engine control unit has detected a coolant temperature higher than 20-151
the alarm threshold.

20-139
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

Alarm Alarm description Page

code
42 Alarm code available but not utilised –
44 Alarm code available but not utilised –
The engine control unit has detected that the actuator position signal does not match
50 the requirement. 20-152

52 The engine control unit has detected that the reference signal for the position of the actuator 20-153
does not match the requirement.
The engine control unit has detected that the difference between the command and the
53 20-154
response of the actuator is greater than 10%.
59 Alarm code available but not utilised –
60 Alarm code available but not utilised –
62 Alarm code available but not utilised –
63 Alarm code available but not utilised –
The engine control unit has detected the absence of a connection to the accelerator pedal po-
67 20-155
sition sensor or a signal out of range.
68 Alarm code available but not utilised –

70 Alarm code available but not utilised –

71 Alarm code available but not utilised –

74 Alarm code available but not utilised –

76 The engine control unit has detected an error in writing the parameters. 20-156

77 The engine control unit has detected an error in reading the program memory during the 20-156
normal control cycle.
The engine control unit has detected an error in reading the work memory during the
78 20-156
normal control cycle.
The engine control unit detects an actuator power input outside the
80 specified parameters. 20-156

83 The control unit detects that the power input to the accelerator pedal or 20-157
hand throttle position sensor is either non-existent or incorrect.
The control unit detects that the power input to the turbo charge pressure sensor
84 20-158
is non-existent or incorrect.
85 Alarm code available but not utilised –
86 The engine control unit detects that its internal temperature is too high. 20-159
87 The engine control unit detects that atmospheric pressure is outside the permitted limits. 20-159
The engine control unit has detected a discrepancy between the parameters written in
90 EEPROM. 20-159

93 The engine control unit has detected a “Stack Overflow” error during execution of the 20-160
program.
94 The engine control unit has detected an internal error. 20-160

20-140
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

5.3.2 ANALYSIS OF ALARMS

SERDIA ALARM N° 1

DESCRIPTION
The engine control unit detects that the signal from the engine pickup is either non-existent or incorrect.

CHECK
• Check that the engine speed pickup is installed correctly and at the specified distance from the pulse wheel
• Check that the internal resistance of the sensor is correct (for details, see section 40)
• Check that the contacts on connector “B40” and on connector “MX1” of the engine control unit are firmly attached and
not oxidised.
• Check for electrical continuity between pin 1 of connector “B40” and pin 12 of connector “MX1”.
• Check for electrical continuity between pin 2 of connector “B40” and pin 13 of connector “MX1”.

0.012.8732.4
13
12
10

2
14
1

10 12 13 MX1 1 2 14 MX2

GND4

MS1 J1
16 28 7
0.013.5915.4
7.5A

F30
G18
12 13

+15

B40 1 2

0421.3172 0441.9533
D0022701

20-141
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 3

DESCRIPTION
The engine control unit detects that the signal from the wheel speed pickup is either non-existent or incorrect.

CHECK
• Using the ART, check that the lift control unit is receiving the wheel speed signal, or if it has detected the “WheelSen-
sorDisc” alarm corresponding to flash code 42 (standard) or 64 (text).
If the lift control unit detects the alarm, check out the system following the procedure described for “WheelSensorDisc”.
• If the control unit is receiving and acknowledging the signal correctly, check for electrical continuity between pin 3 of
connector “ISO7” and pin 6 of connector “X8”.
• Check that the circuit board attached to connector “X8” is not damaged (for details, see section 40).
• Check for electrical continuity between pin 5 of connector “X8” and pin 7 of connector “MX2”.
• Connect a test meter to pin 5 and pin 6 of the circuit board attached to connector “X8” and, using the diode test, check
that the diode is operational (negative prod on pin 6, positive prod on pin 5).
• Connect a test meter to pin 5 and pin 6 of the circuit board attached to connector “X8” and+ measure the resistance,
which should read 2200 Ohm approx (negative prod on pin 6, positive prod on pin 5).
• Check on page 24 of the “Configuration” menu that the value of “1301:VelocityFactor” is 130.
• If the fault persists, reprogram or renew the control unit.

20-142
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 5

DESCRIPTION
The control unit detects that the connection to the accelerator pedal position sensor is either non-existent or short-
circuiting.

CHECK
• Check that the contacts on connector “MX2” of the control unit and connector “X31” are firmly attached and not ox-
idised.
• Check that the power input to the accelerator pedal position sensor is correct (5 Vdc approx measured between pin 1
(positive) and pin 2 (negative) of connector “X31”).
• With connector “MX2” unplugged from the engine control unit, check for electrical continuity between pin 4 of con-
nector “X31” and pin 24 of connector “MX2”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 4 of connector “X31” and to cab earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With connector “MX2” plugged into the engine control unit and the starter key in the “I” (ON) position, connect a test me-
ter to pin 4 of connector “X31” and to cab earth, and check that there is no voltage registering (meter reading 0V).
• Check that the resistance characteristics of the accelerator pedal position sensor are correct (for technical details see
section 40)..

0.012.8732.4
1 2

14 23 24 25

14 1 2 23 25 24 MX2

GND4

J1 AS6
7 11 9 10
7.5A

F30

X31 2 1 4
+15

0441.9533 0.012.8894
D0017161

20-143
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 6

DESCRIPTION
The control unit detects that the connection to the hand throttle position sensor is either non-existent or short-circuiting.
NOTE
This procedure is described for versions without armrest. If an armrest control is installed, carry out the procedure
starting from the connector of the hand throttle position sensor located internally of the armrest.

CHECK
• Check that the contacts on connector “MX2” of the control unit and connector “EMR” are firmly attached and not ox-
idised.
• Check that the power input to the accelerator pedal position sensor is correct (5 Vdc approx measured between pin 3
(positive) and pin 1 (negative) of connector “EMR”).
• With connector “MX2” unplugged from the engine control unit, check for electrical continuity between pin 2 ofcon-
nector “EMR” and pin 20 of connector “MX2”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “EMR” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With connector “MX2” plugged into the engine control unit and the starter key in the “I” (ON) position, connect a test me-
ter to pin 2 of connector “EMR” and to cab earth, and check that there is no voltage registering (meter reading 0V).
• Check that the resistance characteristics of the hand throttle position sensor are correct (for technical details see sec-
tion 40)..

0.012.8732.4
1 2

14 20 23 25

14 1 2 23 20 25 MX2

GND4

EMR
1 2 3

J1
7
7.5A

F30

+15

0441.9533
D0017170

20-144
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 7

DESCRIPTION
The engine control unit has detected that the engine turbo charge pressure signal is either non-existent or unreliable.

CHECK
• Check for electrical continuity between pin 1 of connector “B48” and pin 23 of connector “MX1”.
• Check for electrical continuity between pin 4 of connector “B48” and pin 24 of connector “MX1”.
• Check for electrical continuity between pin 3 of connector “B48” and pin 25 of connector “MX1”.
• Verify the correct operation of the sensor (for technical details, see section 40).
• Check that the power input to the sensor is correct (5 Vdc approx measured between pin 3 (positive) and pin 1 (negative)
of connector “B48”).
• With connector “MX1” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect a test
meter to pin 2 of connector “B48” and to engine earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in position “O” (OFF), connect a test meter to pin 2 of connector “B48” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity)

0.012.8732.4

25
10 24

23
2
14
1

10 23 24 25 MX1 1 2 14 MX2

GND4
MS1 J1
17 29 27 7
0.013.5915.4
7.5A

F30
G18
23 24 25

+15

B48 1 4 3 2

p
0421.3172 0441.9533
D0023020

20-145
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 9

DESCRIPTION
The engine control unit has detected that the coolant temperature signal is either non-existent or unreliable.

CHECK
• Check for electrical continuity between pin 1 of connector “B43” and pin 9 of connector “MX1”.
• Check for electrical continuity between pin 2 of connector “B43” and pin 8 of connector “MX1”.
• Check that the temperature sensor functions correctly and does not give a false reading; use an infrared thermometer
and compare the reading with the value received from the sensor by the engine control unit.
• Check that the coolant level is within normal limits.
• Check with the Serdia program that the parameters “510 CoolantTempWarn” (normal value: 122 °C) and “514 Cool-
antTempEcy” (normal value: 130 °C) are correct.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With connector “MX1” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect a test
meter to pin 1 of connector “B43” and to engine earth, and check that there is no voltage registering (meter reading 0V).
• With connector “MX1” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect a test
meter to pin 2 of connector “B43” and to engine earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “B43” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “B43” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).

0.012.8732.4

10
9
8 2
14
1

10 9 8 MX1 1 2 14 MX2

GND4

MS1 J1
24 22 7
0.013.5915.4
7.5A

F30
G18
9 8

+15
B43 1 2

0421.3172 t° 0441.9533
D0022721

20-146
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 11

DESCRIPTION
The engine control unit has detected that the fuel temperature signal is either non-existent or unreliable.

CHECK
• Check for electrical continuity between pin 1 of connector “B37” and pin 5 of connector “MX1”.
• Check for electrical continuity between pin 2 of connector “B37” and pin 8 of connector “MX1”.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With connector “MX1” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect a test
meter to pin 1 of connector “B37” and to engine earth, and check that there is no voltage registering (meter reading 0V).
• With connector “MX1” unplugged from the engine control unit and the starter key in the “I” (ON) position, connect a test
meter to pin 2 of connector “B37” and to engine earth, and check that there is no voltage registering (meter reading 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “B37” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “B37” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).

0.012.8732.4

10
8
5 2
14
1

10 5 8 MX1 1 2 14 MX2

GND4
MS1 J1
15 22 7
0.013.5915.4
7.5A

F30
G18
15 8

+15

B37 1 2

t°
0421.3172 0441.9533
D0022711

20-147
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 31

DESCRIPTION
The engine control unit has detected a coolant temperature higher than the alarm threshold.

CHECK
• Check with the Serdia program that the parameter “510 CoolantTempWarn” is correct (normal value: 122 °C).
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “B43” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).

0.012.8732.4

10
9
8 2
14
1

10 9 8 MX1 1 2 14 MX2

GND4

MS1 J1
24 22 7
0.013.5915.4
7.5A

F30
G18
9 8

+15
B43 1 2

0421.3172 t° 0441.9533
D0022721

20-148
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 35

DESCRIPTION
The engine control unit detects that the engine is or has been running overspeed (above 3300 rpm).
NOTE
This alarm is activated generally when, with the tractor on a down gradient, the engine is made to operate as a
brake and forced to run at higher speed.
Generally, this alarm will disappear automatically when the tractor returns to level ground.
In this case, there is no need to make any checks.

CHECK
• Check with the Serdia program that the parameter “21 Speed over” is correct (normal value: 3300 rpm).
• Check that the engine speed pickup sensor functions correctly and does not give a false reading; use an external sen-
sor and compare the reading obtained with the value received from the pickup by the engine control unit.
• Check that the injection pumps control rod slides freely.
• Check that the internal resistance values for the actuator are correct (for details see section 40).
• Check that the parameter “1 TeethPickUp1” is correct (normal value=44).

20-149
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 36

DESCRIPTION
The engine control unit has detected a fuel temperature higher than the alarm threshold.

CHECK
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “B43” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity)..

0.012.8732.4

10
9
8 2
14
1

10 9 8 MX1 1 2 14 MX2

GND4

MS1 J1
24 22 7
0.013.5915.4
7.5A

F30
G18
9 8

+15
B43 1 2

0421.3172 t° 0441.9533
D0022721

20-150
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 41

DESCRIPTION
The engine control unit has detected a coolant temperature higher than the alarm threshold.

CHECK
• Check that the coolant level is within normal limits.
• Check with the Serdia program that the parameter “514 CoolantTempEcy” (normal value: 130 °C) is correct.
• Verify the correct operation of the sensor (for technical details, see section 40).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “B43” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).

0.012.8732.4

10
9
8 2
14
1

10 9 8 MX1 1 2 14 MX2

GND4

MS1 J1
24 22 7
0.013.5915.4
7.5A

F30
G18
9 8

+15
B43 1 2

0421.3172 t° 0441.9533
D0022721

20-151
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 50

DESCRIPTION
The engine control unit has detected that the actuator position signal does not match the requirement.

CHECK
• Check that the contacts on connector “Y3” and on the control unit “MX1” are firmly attached and not oxidised.
• Check for electrical continuity between pin 4 of connector “Y3” and pin 19 of connector “MX1”.
• Check that the internal resistance values for the actuator are correct (for details see section 40).
• With the starter key in the “I” (ON) position and the engine 'off', connect a test meter to pin 4 of connector “Y3” and to
engine earth, and check that there is no voltage registering (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 4 of connector “Y3” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• If the fault persists, renew the actuator.

0.012.8732.4

10 19
18
17
2
16
1
15
14

10 14 15 17 19 18 16 MX1 1 2 14 MX2

GND4
MS1 J1
4 6 10 11 19 7
0.013.5915.4

GND2
G18
7.5A

14 15 17 19 18 F30

+15
1 2 3 4 5 Y3

0429.3172 0441.9533
D0022741

20-152
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 52

DESCRIPTION
The engine control unit has detected that the reference signal for the position of the actuator does not match the re-
quirement.

CHECK
• Check that the contacts on connector “Y3” and on the control unit “MX1” are firmly attached and not oxidised.
• Check for electrical continuity between pin 5 of connector “Y3” and pin 18 of connector “MX1”.
• Check that the internal resistance values for the actuator are correct (for details see section 40).
• With the starter key in the “I” (ON) position and the engine 'off', connect a test meter to pin 5 of connector “Y3” and to
engine earth, and check that there is no voltage registering (meter reading: 0V).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 5 of connector “Y3” and to engine earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• If the fault persists, renew the actuator.

0.012.8732.4

10 19
18
17
2
16
1
15
14

10 14 15 17 19 18 16 MX1 1 2 14 MX2

GND4
MS1 J1
4 6 10 11 19 7
0.013.5915.4

GND2
G18
7.5A

14 15 17 19 18 F30

+15
1 2 3 4 5 Y3

0429.3172 0441.9533
D0022741

20-153
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 53

DESCRIPTION
The engine control unit has detected that the difference between the command and the response of the actuator is greater
than 10%.

CHECK
• Check that the internal resistance values for the actuator are correct (for details see section 40).
• Check that the injection pumps control rod slides freely.
• Check that the fuel injection pumps have not seized.
• Check that the contacts on connector “Y3” and on the control unit “MX1” are firmly attached and not oxidised.
• Check for electrical continuity between pin 4 of connector “Y3” and pin 19 of connector “MX1”.
• Check for electrical continuity between pin 5 of connector “Y3” and pin 18 of connector “MX1”.

0.012.8732.4

10 19
18
17
2
16
1
15
14

10 14 15 17 19 18 16 MX1 1 2 14 MX2

GND4
MS1 J1
4 6 10 11 19 7
0.013.5915.4

GND2
G18
7.5A

14 15 17 19 18 F30

+15
1 2 3 4 5 Y3

0429.3172 0441.9533
D0022741

20-154
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 67

DESCRIPTION
The engine control unit has detected the absence of a connection to the accelerator pedal position sensor or a signal out
of range.

CHECK
• Check that the contacts on connector “MX2” of the control unit and connector “X31” are firmly attached and not ox-
idised.
• Check that the resistance characteristics of the accelerator pedal position sensor are correct (for technical details see
section 40).
• Check that the power input to the accelerator pedal position sensor is correct (5 Vdc approx measured between pin 1
(positive) and pin 2 (negative) of connector “X31”).
• Check for electrical continuity between pin 4 of connector “X31” and pin 24 of connector “MX2”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 4 of connector “X31” and to cab earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• With connector “MX2” plugged into the engine control unit and the starter key in the “I” (ON) position, connect a test me-
ter to pin 4 of connector “X31” and to cab earth, and check that there is no voltage registering (meter reading 0V).

0.012.8732.4
1 2

14 23 24 25

14 1 2 23 25 24 MX2

GND4

J1 AS6
7 11 9 10
7.5A

F30

X31 2 1 4
+15

0441.9533 0.012.8894
D0017161

20-155
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 76

DESCRIPTION
The engine control unit has detected an error in writing the parameters.

CHECK
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• Repeat the data entry procedure, and if the problem persists, contact Technical Assistance.

SERDIA ALARM N° 77

DESCRIPTION
The engine control unit has detected an error in reading the program memory during the normal control cycle.

CHECK
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• If the problem persists, contact Technical Assistance.

SERDIA ALARM N° 78

DESCRIPTION
The engine control unit has detected an error in reading the work memory during the normal control cycle.

CHECK
• Note down the values of the parameters “3895 RAMTestAddr” and “3896 RAMTestPattern”
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• If the problem persists, contact Technical Assistance.

SERDIA ALARM N° 80

DESCRIPTION
The engine control unit detects an actuator power input outside the specified parameters.

CHECK
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• See if the alarm is still indicated; if so, contact Technical Assistance.

20-156
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 83

DESCRIPTION
The control unit detects that the power input to the accelerator pedal or hand throttle position sensor is either non-existent
or incorrect.
NOTE
If an armrest control is installed, check the hand throttle power input starting from the connector located internally
of the armrest.

CHECK
• Check that the power input to the accelerator pedal and hand throttle position sensors is correct (5 Vdc approx meas-
ured between pin 1 (positive) and pin 2 (negative) of connector “X31” or pin 1 (positive) and pin 3 (negative) of connector
“EMR”).
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• See if the alarm is still indicated; if so, contact Technical Assistance.

0.012.8732.4
1 2

14 20 23 24 25

14 1 2 23 25 24 20 MX2

GND4 EMR
1 2 3

J1 AS6
7 11 9 10
7.5A

F30

+15
X31 2 1 4

0441.9533 0.012.8894
D0017201

20-157
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 84

DESCRIPTION
The control unit detects that the power input to the turbo charge pressure sensor is non-existent or incorrect.

CHECK
• Check that the power input to the turbo charge pressure sensor is correct (5 Vdc approx measured between pin 3 (pos-
itive) and pin 1 (negative) of connector “B48”).
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• See if the alarm is still indicated; if so, contact Technical Assistance

0.012.8732.4

25
10 24

23
2
14
1

10 23 24 25 MX1 1 2 14 MX2

GND4
MS1 J1
17 29 27 7
0.013.5915.4
7.5A

F30
G18
23 24 25

+15

B48 1 2 3 2

p
0421.3172 0441.9533
D0022731

20-158
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 86

DESCRIPTION
The engine control unit detects that its internal temperature is too high.

CHECK
• Turn the starter key to “O” (OFF) and wait a few minutes for the engine to cool down.
Turn the key back to “I” (ON) and check that the alarm does not reoccur.
• If the alarm reoccurs, contact Technical Assistance.

SERDIA ALARM N° 87

DESCRIPTION
The engine control unit detects that atmospheric pressure is outside the permissible limits.

CHECK
• Turn the starter key to “O” (OFF) and wait a few minutes.
Turn the key back to “I” (ON) and check that the alarm does not reoccur.
• If the alarm reoccurs, contact Technical Assistance.

SERDIA ALARM N° 90

DESCRIPTION
The engine control unit has detected a discrepancy between the parameters written in EEPROM.

CHECK
• Check that the parameter values to be written in the control unit EEPROM are correct and consistent with one another.
• Send the parameters to the control unit again.
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• If the problem persists, contact Technical Assistance.

20-159
5. ALARMS 5.3 LIST OF ALARMS DISPLAYED BY SERDIA

SERDIA ALARM N° 93

DESCRIPTION
The engine control unit has detected a “Stack Overflow” error during the execution of the program.

CHECK
• Note down the values of the parameters “3897 CStackTestFreeBytes” and “3898 IStackTestFreeBytes”
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• If the problem persists, contact Technical Assistance.

SERDIA ALARM N° 94

DESCRIPTION
The engine control unit has detected an internal error.

CHECK
• Contact Technical Assistance.

20-160
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

5. ALARMS
5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS
The suspension control unit warns the operator of any malfunction affecting monitored components, by way of an indicator
light in the pushbutton.
Faults are indicated using a system of coded flash sequences which, depending on how the control unit has been con-
figured, will either specify the precise nature of the fault (extended alarm) or simply identify the device affected (standard
alarm).
To verify, using the ART, whether or not an alarm detected is “active”, the technician must cancel all the alarms, turn the
starter key to the “O” (OFF) position, then make a fresh connection to the control unit.
All alarms with the exception of those indicated by the light incorporated into the pushbutton (Alarms 21 and 22) have the
effect of deactivating and inhibiting the system completely.

5.4.1 LIST OF ALARMS BY TEXT CODE

Extended Standard Display

flash flash on ART Description Page

11 11 As. SV Fa. or NC The control unit detects that the front axle 'up' 20-164
valve solenoid is not connected
The control unit detects that the front axle 'down'
12 12 De. SV Fa. or NC 20-165
valve solenoid is not connected
The control unit detects that the front axle load
13 13 LS. SV Fa. or NC sensing valve solenoid is not connected 20-166

15 15 PO. SE. Fa. or NC The control unit detects that the front suspen- 20-167
sion position sensor is disconnected.
The control unit detects that the power input to
16 16 PW. S. Fa. or NC the front suspension position sensor is not cor- 20-168
rect.

17 17 Battery V. High The control unit has detected that the battery 20-169
voltage is too high.
The control unit has detected that the battery
19 19 Battery V. Low 20-170
voltage is too low (less than10V).
The control unit has detected that the activation
21 21 SC LAMP Ind. and faults indicator light is short-circuiting. 20-171

The control unit has detected that the activation

22 22 LAMP Ind. Disc. and faults indicator light is burnt out or discon- 20-172
nected.

24 11 ALL. CC EV UP The control unit detects a short circuit in the con- 20-173
trol line of the front axle 'up' solenoid.
The control unit detects a short circuit in the con-
25 12 ALL. CC EV DW 20-174
trol line of the front axle 'down' solenoid.
The control unit detects a short circuit in the con-
26 13 ALL. CC EV LS trol line of the front axle load sensing solenoid. 20-175

20-161
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

5.4.2 LIST OF ALARMS BY STANDARD CODE

Standard Extended Display Description Page

flash flash on ART
The control unit detects that the front axle 'up'
11 As. SV Fa. or NC 20-164
valve solenoid is not connected.
11
The control unit detects a short circuit in the con-
24 ALL. CC EV UP trol line of the front axle 'up' solenoid. 20-173

12 De. SV Fa. or NC The control unit detects that the front axle 'down' 20-165
valve solenoid is not connected.
12
The control unit detects a short circuit in the con-
25 ALL. CC EV DW 20-174
trol line of the front axle 'down' solenoid.
The control unit detects that the front axle load
13 LS. SV Fa. or NC sensing valve solenoid is not connected. 20-166
13
26 ALL. CC EV LS The control unit detects a short circuit in the con- 20-175
trol line of the front axle load sensing solenoid.
The control unit detects that the front suspen-
15 15 PO. SE. Fa. or NC 20-167
sion position sensor is disconnected.
The control unit detects that the power input to
16 16 PW. S. Fa. or NC the front suspension position sensor is not cor- 20-168
rect.
The control unit has detected that the battery
17 17 Battery V. High voltage is too high. 20-169

The control unit has detected that the battery

19 19 Battery V. Low voltage is too low (less than10V). 20-170

21 21 SC LAMP Ind. The control unit has detected that the activation 20-171
and faults indicator light is short-circuiting.
The control unit has detected that the activation
22 22 LAMP Ind. Disc. and faults indicator light is burnt out or discon- 20-172
nected.

20-162
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

5.4.3 LIST OF ALARMS DISPLAYED BY ART

Display Standard Extended Description Page

on ART flash flash
The control unit detects a short circuit in the con-
ALL. CC EV DW 12 25 20-174
trol line of the front axle 'down' solenoid.
The control unit detects a short circuit in the con-
ALL. CC EV LS 13 26 trol line of the front axle load sensing solenoid. 20-175

ALL. CC EV UP 11 24 The control unit detects a short circuit in the con- 20-173
trol line of the front axle 'up' solenoid.
The control unit detects that the front axle 'down'
De. SV Fa. or NC 12 12 20-165
valve solenoid is not connected
The control unit detects that the front axle load
LS. SV Fa. or NC 13 13 sensing valve solenoid is not connected 20-166

As. SV Fa. or NC 11 11 The control unit detects that the front axle 'up' 20-164
valve solenoid is not connected
The control unit detects that the front suspen-
PO. SE. Fa. or NC 15 15 20-167
sion position sensor is disconnected.
The control unit has detected that the activation
LAMP Ind. Disc. 22 22 and faults indicator light is burnt out or discon- 20-172
nected.
The control unit has detected that the activation
SC LAMP Ind. 21 21 and faults indicator light is short-circuiting. 20-171

The control unit detects that the power input to

PW. S. Fa. or NC 16 16 the front suspension position sensor is not cor- 20-168
rect.
The control unit has detected that the battery
Battery V. High 17 17 voltage is too high. 20-169

Battery V. Low 19 19 The control unit has detected that the battery 20-170
voltage is too low (less than10V).

20-163
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

5.4.4 ANALYSIS OF ALARMS

ALARM N° 11 As. SV Fa. or NC

DESCRIPTION
The control unit detects that the front axle 'up' valve solenoid is not connected.

CHECK
• Test the internal resistance of the solenoid (the resistance value must be other than infinity).
• Check that the contacts on connector “JX3” of the control unit and connector “H” of the front axle up valve solenoid are
firmly attached and not oxidised.
• Check for electrical continuity between pin 2 of connector “H” and pin 1 of connector “JX3”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “H” and to chassis earth, and
measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
20 5 4 1

JX3 1 20 4 5
FE1
8 GND4
3

FE2 J2
1 7 7

H
7.5A

2 1
F17

+15

0443.7849 0441.9533
D0017210

20-164
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 12 De. SV Fa. or NC

DESCRIPTION
The control unit detects that the front axle 'down' valve solenoid is not connected.

CHECK
• Test the internal resistance of the solenoid (the resistance value must be other than infinity).
• Check that the contacts on connector “JX3” of the control unit and connector “S” of the front axle down valve solenoid
are firmly attached and not oxidised.
• Check for electrical continuity between pin 2 of connector “S” and pin 2 of connector “JX3”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 to connector “S” and to chassis earth, and
measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
20 5 4 2

JX3 2 20 4 5
FE1
8 GND4
3

FE2 J2
2 7 7

S
7.5A

2 1
F17

+15

0443.7849 0441.9533
D0017220

20-165
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 13 LS. SV Fa. or NC

DESCRIPTION
The control unit detects that the front axle load sensing valve solenoid is not connected.

CHECK
• Test the internal resistance of the solenoid (the resistance value must be other than infinity).
• Check that the contacts on connector “JX3” of the control unit and connector “X68” of the front axle load sensing valve
solenoid are firmly attached and not oxidised.
• Check for electrical continuity between pin 2 of connector “X68” and pin 2 of connector “JX3”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 1 of connector “X68” and to chassis earth, and
measure the resistance to verify the continuity of the circuit (meter reading: 0 Ohm).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
2 20 5 4

2 JX4 20 4 5 JX3

FE1
3
8 GND4

FE2 J2
3 7 7

X68
7.5A

2 1 F17

+15

0443.7849 0441.9533
D0017230

20-166
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 15 PO. SE. Fa. or NC

DESCRIPTION
The control unit detects that the front suspension position sensor is disconnected.

CHECK
• Check that the contacts on connector “X69” of the front axle suspension position sensor and connector “JX4” of the
control unit are firmly attached and not oxidised.
• With the starter key in the “I” (ON) position, check that the power input to the front suspension position sensor is correct
(8 Vdc approx measured between pin 3 (positive) and pin 1 (negative) of connector “X69”).
• Check for electrical continuity between pin 14 of connector “JX4” and pin 2 of connector “X69”.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “X69” and to transmission earth,
and measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• Verify the correct operation of the sensor (for technical details, see section 40).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
14 17 9 20 5 4

17 14 9 JX4 20 4 5 JX3

FE1
3
8 GND4

FE2 J2
4 5 6 7
7.5A

1 2 3 X69 F17
U

+15
S

0443.7849 0441.9533
D0017240

20-167
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 16 PW. S. Fa. or NC

DESCRIPTION
The control unit detects that the power input to the front suspension position sensor is not correct.

CHECK
• With the starter key in the “I” (ON) position, check that the power input to the front suspension position sensor is correct
(8 Vdc approx measured between pin 3 (positive) and pin 1 (negative) of connector “X69”).
• Turn the starter key first to “O” (OFF) and then back to the “I” (ON) position.
• See if the alarm is still indicated; if so, the ECU must be renewed.

0443.7850 0.012.8732.4
14 17 9 20 5 4

17 14 9 JX4 20 4 5 JX3

FE1
3
8 GND4

FE2 J2
4 5 6 7
7.5A

1 2 3 X69 F17
U

+15
S

0443.7849 0441.9533
D0017240

20-168
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 17 Battery V. High

DESCRIPTION
The control unit has detected that the battery voltage is too high.
NOTE
This alarm is activated generally when the alternator charging voltage is irregular, and can be tripped only by a fault
affecting the alternator itself.
CAUTION
Never connect the ART with the engine running when this alarm is indicated, as the instrument could be
damaged.

CHECK
• Check, with the engine off, that the battery voltage is within the prescribed range (normal voltage 12V - 13.5V).
• Check, with the engine running, that the battery voltage is within the prescribed range. In this instance the problem may
be attributable to a fault in the ECU, which must therefore be replaced with a new unit, otherwise the trouble is being
caused by incorrect operation of the alternator voltage regulator.

20-169
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 19 Battery V. Low

DESCRIPTION
The control unit has detected that the battery voltage is too low (less than 10V).
NOTE
This alarm is activated generally when the battery voltage is less than 10V and can be tripped by an excessive cur-
rent draw when the engine is started, or if the battery is damaged or cannot be recharged by the alternator.
Accordingly, this alarm can be displayed only as a passive alarm by the ART. Should the alarm be displayed among
the active alarms, the ECU must be renewed.

CHECK
• See if the alarm is indicated as an active alarm; if so, the ECU must be renewed.
• Check, with the engine off, that the battery voltage is as prescribed (higher than 12V); if not, install a new battery.
NOTE
Lower voltages can register after the tractor has been standing idle for an extended period; this does mean nec-
essarily that the battery needs replacing.
• Check first whether or not the battery voltage returns to normal with the engine running. In this instance the problem
may be attributable to the battery being discharged or damaged; if not, and the voltage remains lower than the pre-
scribed minimum, the trouble is being caused by incorrect operation of the alternator.
NOTE
In extreme cases, when the battery is seriously damaged (short-circuiting), the alternator may not be able to re-
charge the cells or generate sufficient voltage. Before changing the alternator, verify its correct or incorrect op-
eration by connecting a new battery.

20-170
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 21 SC LAMP Ind.

DESCRIPTION
The control unit has detected that the activation and faults indicator light is short-circuiting.

NOTE
This alarm is displayed only by the ART. The operator or technician may become aware of the problem simply due
to the fact that the lamp does not light up when the front axle suspension is activated or deactivated.

CHECK
• Check that the contacts on connector “5” of the activating switch and connector “JX4” of the control unit are firmly at-
tached and not oxidised.
• With the starter key in the “O” (OFF) position, connect a test meter to pin 10 of connector “5” and to cab earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• If the fault persists, renew the control unit..

0443.7850
20 5 4 8 12

5 4 20 JX3 12 8 JX4

FE1
3 8 10 9
0.012.8732.4

GND4

J2 AS1 AS3
7 3 21 12 3
7.5A

F17

5 9 10 1 5
+15

0441.9533 0.012.8894.4
D0017250

20-171
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 22 LAMP Ind. Disc.

DESCRIPTION
The control unit has detected that the activation and faults indicator light is burnt out or disconnected.
NOTE
This alarm is displayed only by the ART. The operator or technician may become aware of the problem simply due
to the fact that the lamp does not light up when the front axle suspension is activated.

CHECK
• Check the condition of the indicator lamp.
• Check that the contacts on connector “5” of the activating switch and connector “JX4” of the control unit are firmly at-
tached and not oxidised.
• With the starter key in the “I” (ON) position, activate the axle suspension and check that the control unit is supplying
power to the indicator light, connecting a test meter to pin 9 and pin 10 of connector “5” (voltage 12V).
• Check for electrical continuity between pin 10 of connector “5” and pin 8 of connector “JX4”.
• Check for electrical continuity between pin 9 of connector “5” and the cab earth.
• If the fault persists, renew the control unit.

0443.7850
20 5 4 8 12

5 4 20 JX3 12 8 JX4

FE1
3 8 10 9
0.012.8732.4

GND4

J2 AS1 AS3
7 3 21 12 3
7.5A

F17

5 9 10 1 5
+15

0441.9533 0.012.8894.4
D0017250

20-172
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 24 ALL. CC EV UP

DESCRIPTION
The control unit detects a short circuit in the control line of the front axle 'up' solenoid.

CHECK
• Check that the contacts on connector “JX3” of the control unit and connector “H” of the front axle up valve solenoid are
firmly attached and not oxidised.
• Test the internal resistance of the solenoid (the resistance value must be other than 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “H” and to chassis earth, and
measure the resistance to verify that there are no short circuits to earth (meter reading: infinity).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
20 5 4 1

JX3 1 20 4 5
FE1
8 GND4
3

FE2 J2
1 7 7

H
7.5A

2 1
F17

+15

0443.7849 0441.9533
D0017210

20-173
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 25 ALL. CC EV DW

DESCRIPTION
• The control unit detects a short circuit in the control line of the front axle 'down' solenoid.

CHECK
• Check that the contacts on connector “JX3” of the control unit and connector “S” of the front axle down valve solenoid
are firmly attached and not oxidised.
• Test the internal resistance of the solenoid (the resistance value must be other than 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “S” and to chassis earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
20 5 4 2

JX3 2 20 4 5
FE1
8 GND4
3

FE2 J2
2 7 7

S
7.5A

2 1
F17

+15

0443.7849 0441.9533
D0017220

20-174
5. ALARMS 5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE ALARMS

ALARM N° 26 ALL. CC EV LS

DESCRIPTION
The control unit detects a short circuit in the control line of the front axle load sensing solenoid.

CHECK
• Check that the contacts on connector “JX3” of the control unit and connector “X68” of the front axle load sensing valve
solenoid are firmly attached and not oxidised.
• Test the internal resistance of the solenoid (the resistance value must be other than 0 Ohm).
• With the starter key in the “O” (OFF) position, connect a test meter to pin 2 of connector “X68” and to chassis earth, and
measure the resistance to ensure there are no short circuits to earth (meter reading: infinity).
• If the fault persists, renew the control unit.

0443.7850 0.012.8732.4
2 20 5 4

2 JX4 20 4 5 JX3

FE1
3
8 GND4

FE2 J2
3 7 7

X68
7.5A

2 1 F17

+15

0443.7849 0441.9533
D0017230

20-175
PAGE INTENTIONALLY
LEFT BLANK
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 1. GENERAL INTRODUCTION

6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System)

1. GENERAL INTRODUCTION
The electronic components in the AGROTRON are tested and programmed by means of the Electronic Diagnosis System
(EDS) from DEUTZ-FAHR.
The existing version of the EDS consists of an interface cable and an adapter cable as well as of an installation disk with the
corresponding programs.
The PC program and the cables are distributed via:

SAME-DEUTZ-FAHR ITALIA S.p.A.

Viale F. CASSANI, 15
24047 TREVIGLIO (BG) - ITALIA

1.1 FUNCTIONAL SCOPE

The EDS software includes the following subprograms:
• POWERSHIFT (not used for this tractor) and POWERSHUTTLE transmission
- Diagnosis
- Readout of the gear box error memory
- Programming of the gear box, e.g. upon replacement of the box (end-of-line programming)
- Calibration of the sensor at the clutch pedal (end-of-line programming)
- Evaluation of the contact pressure of the main clutch (only for power shuttle)
• Agrotronic-hD (not used for this tractor)
- Diagnosis
- Readout of the AGROTRONIC-hD box error memory
- Calibrate valves
• Infocenter
- Diagnosis
- Programming of the constant values
• Spring-suspended front axle (not used for this tractor)
- Diagnosis
- Readout of the control box error memory
- Reading resp. loading of the control box standard data (parameters) converter

20-177
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 1. GENERAL INTRODUCTION

1.2 HARDWARE REQUIREMENTS

Converter
Serial K-line
line
Control box

Hardware Setup

1.2.1 INTERFACE CABLE (SERIAL)

The depicted interface cable is plugged into the serial interface (COM 1 or COM 2) of the computer and connected with the
corresponding connectors of the adapter cable.
1 - Plug (designation ”EIC”) for connection to the serial interface (RS 232) at the computer for diagnosis INFOCENTER.
2 - Plug (designation ”9141”) for connection to the serial interface (RS 232) at the computer for diagnosis POWERSHIFT-
and POWERSHUTTLE-transmission, AGROTRONIC-hD and spring-suspended front axle.
3 - Plug for 12 V supply of the interface cable for connection to the cigar lighter.
4 - Diagnosis plug for AGROTRONIC-hD, gear box control and spring-suspended front axle, 4-pole.
5 - Diagnosis plug for INFOCENTER, 2-pole.
6 - Adapter for diagnosis POWERSHIFT transmission, old version.

20-178
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 1. GENERAL INTRODUCTION

1.2.2 ADAPTER CABLE FOR CENTRAL DIAGNOSIS INTERFACE

The depicted adapter cable is plugged into the diagnosis interface in the fuse box and connected with the corresponding
connectors of the PC interface cable.
8 - Central plug 14-pole for connection in the fuse box
9 - Diagnosis plug for ”Agrotronic-hD”, 4-pole
10 - Diagnosis plug for ”Infocenter”, 2-pole
11 - Diagnosis plug ”Powershift Agrotron 4.70 – 6.45”, 4-pole
12 - Diagnosis plug ”Spring-suspended front axle”, 4-pole
13 - Diagnosis plug ”Electronic motor control”, 4-pole
14 - Diagnosis plug for ”Full powershift Agrotron 160-200”, 3-pole
15 - Diagnosis connection for ”MOBI-DIG (ZF)”, 4-pole
NOTE. Both free cable ends are not used.

1.2.3 SYSTEM REQUIREMENTS

The applied computer (notebook, laptop or portable system) needs to fulfill the following requirements in order to install
and execute EDS:
• IBM compatible personal computer with at least a 80486 processor.

CAUTION!
For the use of SERDIA – SERvice DIAgnosis program for the electronic motor control from DEUTZ AG – a Pentium‘-
processor is recommended.
• Main memory (RAM) at least 640 kB
• Disk drive 3,5” for 1,44 MB floppy disks (HD)
• Hard disk with at least 2,5 MB of free memory space
• at least one serial interface COM 1 (RS 232)
• Operating system MS-DOS from version 6.xx on
• An additional serial/k-line converter is required for the communication with the diagnosis interface (included in the
scope of supply of the company Wilbär).

20-179
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 1. GENERAL INTRODUCTION

1.2.4 SOFTWARE INSTALLATION

IMPORTANT!
The EDS program needs to be installed and executed in the DOS mode of the computer in order to prevent mal-
functions! The installation has to be carried out according to the installation instructions included in the scope of
supply.
The installation procedure valid according to the current release is shown step by step in the subsequent description:
• Start computer in DOS mode (C:\_)
• Insert floppy disk in drive A
• Change to drive A (A:\_) by means of entering A: and pressing of the ENTER-key
• The automatic installation procedure is launched by means of entering install
Hereby a new subdirectory (C:\EDS) is created on the hard disk in which the EDS program will be installed. During the
installation process the user is assisted by instructions on the screen.
• After succesful installation the EDS program is launched automatically.
• The program is terminated by selecting Option 8 (C:\EDS_)
• The subdirectory EDS is quit (C:\_) by means of entering cd. (resp. cd\).

1.3 STARTING AND TERMINATING OF THE EDS PROGRAM

IMPORTANT!
If Windows 95/Windows 3.1 is installed as operating system the EDS program needs to be launched
in DOS mode (in case of Win’95 via the MS-DOS input prompt icon). Otherwise malfunctions may
occur during the diagnosis!

1.3.1 STARTING OF THE EDS PROGRAM

• Start computer in DOS mode (C:\_)
• Change into the subdirectory EDS (C:\EDS:>_) by means of entering CD EDS.
• The program is launched by entering EDS; the initial menu appears with the following select options:

Fig. 1 - Initial Menu

Within the initial menu, pressing one of the numerical keys (1 to 7) determines which component (e.g. Agrotronic-hD+ASM)
is supposed to be checked and on which computer interface (COM 1 or COM 2) the signals arrive.

20-180
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 1. GENERAL INTRODUCTION

1.3.2 TERMINATING OF THE EDS PROGRAM

• The initial menu (see figure) appears again after terminating the selected subprogram (e.g. Agrotronic-hD+ASM)
• The EDS program is quit by means of selecting Option 8.
• The display C:\EDS:>_ shows that the operating system is still located in the subdirectory EDS which is quit by entering
cd.., causing DOS to return to the root directory.
• If EDS was launched in DOS mode under Windows 95 (via the MS-DOS input prompt), entering EXIT causes Windows
to close the DOS window and return to the Windows desktop.

20-181
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 2. TRANSMISSION DIAGNOSIS

2. TRANSMISSION DIAGNOSIS
DEST is a program for diagnosis and end-of-line programming of the transmission control units DEST 38 and DEST 45. It
consists of a main menu in which the corresponding control unit is selected and the actual diagnosis programs.
The user interface of this program is realized according to the SAA standard. This means for the user:
• a uniform menu prompting system
• an online help available at any time
• mouse-support
• operation via hotkeys (designated by highlighted characters)

2.1 THE MAIN MENU

On start-up of DEST (compare part 1.1.3: ”Starting and terminating of the EDS program”) the last selected diagnosis con-
trol is started automatically. The corresponding diagnosis program must be quit in order to return to the main menu (DEST
38 – menu item File > End; DEST 39/45 – menu item File > main menu). From the DEST 38 diagnosis it is always possible
to return to the main menu.

2.1.1 SCREEN AND MENU STRUCTURE

Fig. 2 - Menu structure

The screen setup with the main menu is identical for the transmission diagnosis programs; in the diagnosis programs DEST
38, 39/45 the menu line is merely supplemented by the menu item Diagnosis. Left at the top in the menu line the current pro-
gram level is indicated, e.g. MAIN MENU. The rotating dash left beside it signalizes to the user that the program is working
correctly on the lowest level. If this dash stands still an error has occured and the program must be restarted.
The user activates the menu by means of pressing the ALT key or the F10 key and may select a submenu by means of the
cursor keys. The same goal is accomplished by means of pressing the ALT key and one of the hotkeys assigned to every
menu item simultaneously.
This hotkey is a highlighted character for every menu item (e.g. the ”F” for the menu item File, invoked with the combination
ALT + F).
The menu may be quit by means of the ESC key (resp. the ALT key).

2.1.2 FILE
• File >End
Terminates the program; altered settings (language, colour palette and interface in use) are stored. If the program is ter-
minated directly after quitting DEST 38 the start menu of DEST 38 is invoked automatically on the next start-up; oth-
erwise the main menu reappears.

20-182
6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 2. TRANSMISSION DIAGNOSIS

2.1.3 CONTROL

Fig. 3 - Control
• Control > DEST38
Launches the diagnosis program DEST 38 after a confirmation.

CAUTION!
Colour, language and interface settings cannot be taken over!
• Control > DEST39
Launches the diagnosis program DEST 39 after a confirmation.

CAUTION!
This program cannot be started if there is no file dest39.ini existing!

• Control > DEST45

Launches the diagnosis program DEST 45 after a confirmation and takes over the current settings.

2.1.4 OPTIONS)
• Options > Colour palette
Selection of various colour palettes for the screen display.

Fig. 4 - Menu Colour

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6. OPERATOR’S MANUAL EDS (Electronic Diagnosis System) 2. TRANSMISSION DIAGNOSIS

• Options > Language (Lingua)

Changes the communication language between user and program.

Fig. 5 - Menu Change language

• Selection of the serial interface COM1

for the communication between control device and PC.

• Options >Interface COM 2)

Selection of the serial interface COM2 for the communication between control device and PC.

• Options > Simulated communication

This menu item is disabled due to safety reasons; the selection Simulation is not stored.

2.2 ONLINE HELP

The diagnosis program DEST offers the user help at any time about the current environment (context help) as well as help
about the current key assignment. All help texts are stored as text files to be displayed at any time during the running pro-
gram. Future supplements or changes of these texts can be carried out without problems by means of a text editor.
The user of the diagnosis program DEST has the opportunity to invoke an online help within the program context at any
time:
• by means of pressing the F1 key
• by means of pressing ALT + H
• by means of clicking on the << HELP >> button with the mouse
The online help basically describes the operation of the currently active window. Further texts (e.g. a detailed description
of specific control device data) can also be included.
The possible key combinations in the context are shown by means of pressing the F9 key.

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6. EDS (Electronic Diagnosis System)

3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45

3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS WITH DEST 45

As a preparatory measure the connection between tractor and computer needs to be established so as to check the trans-
mission control by means of DEST 45 resp. to be able to carry out the end-of-line programming.

Fig. 23 - Interface cable and adapter cable

The interface cable and the adapter cable are serving for this purpose (see figure).
1 - Connect plug (2) of the interface cable with the designation ”9141” to the computer (COM interface)
2 - Connect plug (3) of the interface cable for the 12 V supply to the cigar lighter
3 - Connect the 4-pole plug (4) of the interface cable to the plug (11) – designation ”powershift Agrotron 4.70-6.45” – of
the adapter cable
4 - Insert the central plug (8) of the adapter cable into the central diagnosis interface in the fuse box
5 - Switch ON ignition
6 - Start the computer and call the EDS program (compare item A 1.3 – Launching and terminating of the EDS program)
7 - Call Option 1 in the initial menu
8 - Make sure that the right diagnosis program (DEST 345) is invoked. On the right side in the upper frame of the screen
DEST 45 needs to be displayed, and below e.g. DEST 45 – V 2.2 – 16.12.97. If necessary change to the main menu and
launch DEST 45 via the menu item Control > DEST 45.

CAUTION!
Before starting the diagnosis verify that the proper interface (COM 1 or COM 2) is selected in the menu item Op-
tions!

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3.2 DEST 45 PROGRAM DESCRIPTION

3.2.1 FILE >MAIN MENU

Fig. 24 - File >Main menu

• File > Main menu

Selecting this menu item quits the active control and calls the main menu in which the user can select the next control
to be diagnosed or quit the program. All current settings are saved and upon the next start-up the main menu reap-
pears.
• File > End
The menu item ”End” saves the settings selected under the menu item ”options” (colour palette, language and selected
interface) and terminates the diagnosis program.
Upon the next start-up of the diagnosis program the settings are automatically taken over and the diagnosis program
DEST 45 is called.

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3.2.2 MENU DIAGNOSIS

• Diagnosis > Read error memory
The menu item ”Read error memory ” opens a window divided into two parts in which the contents of the error memory
are displayed in chronological order.

Fig. 25 - Read error memory

The double frame and the highlighted lines ”Read error memory” resp. ”Error description” show which part of the win-
dow is currently active.
In the left part of the window the current operating-hours of the transmission-E-box (not to be compared with the op-
erating hours of the infocenter!) and the number of the various errors detected by the transmission-E-box are displayed.
Below the errors stored in the E-box are indicated. In the column ”Errors” the respective error codes are listed. The col-
umn ”active” indicates the corresponding error status. ”Y” stands for yes; i.e. the error is currently active – resp. ”N” for
no; i.e. the error is currently not active. The third column ”Number” indicates how many times the respective error has
occured. The information under ”Operating-hours” indicates when the respective error has occured.
The user can select an error with the cursor keys and cause a detailed error description to be displayed on the right side
of the screen by means of clicking on OK or pressing ENTER. The error text can be scrolled by means of the cursor keys
if it exceeds the size of the right window.
Pressing of ESC or C reactivates the left screen window.
If the left window is active, all errors can be saved in a text file with their detailed description by means of pressing F2.
In addition to the error descriptions the current operating-hours counter, the identification data, the current date as well
as the vehicle identification number and the number of the electronic box are saved. However, vehicle identification
number and number of the electronic box can only be saved if the corresponding entry in the EEPROM is valid.

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• Diagnosis > Delete error memory (Cancellazione memoria errori)

“Delete error memory” opens a window which prompts the user to confirm the deletion of the error memory.

Fig. 26 - Delete error memory

• Diagnosis > HEX data display

This menu item is not relevant for diagnosis, as only internal data in hexadecimal notation are displayed here.
On selection of the menu item HEX data display a window appears, in which the user can enter up to four hexadecimal
addresses (see figure). In addition to the address data the user has to enter the number of bytes (maximum 12) he wants
to read at this start address. On confirmation with OK their contents are dumped on the screen.

Fig. 27 - HEX data display

With << + >> / << - >> the start addresses are incremented resp. decremented by one.
With << ++ >> / << — >> the start addresses are increased resp. decreased by 12 (decimal).
With << CONT >> the contents are read continually (default). Selection of this button causes the label to change to ”<<
STAT >>”. Reselection toggles again.
Pressing the key ESC (or ALT + C) quits this menu item.

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• Diagnosis > Plaintext data display

CAUTION!
After selecting the menu item ”End-of-line programming” the ignition on the vehicle needs to be switched off
and on again in order to update all data in the window ”Plaintext data display”!
Plain text data display opens a window in which the data are converted and displayed in their corresponding physical
units. The structure and contents of the window are shown in the figure below.
By pressing the key ”T” it is possible to toggle between continuous display and static display.
The current status is indicated left at the top of the window as CONT (for continuous display) resp. STAT (for static dis-
play).

Fig. 28 - Plaintext data display

It is possible to switch between the individual windows for digital inputs, digital outputs, sensor errors and internal var-
iables by means of the select fields (buttons) << DIG_IN >>, << DIG_OUT >>, << ERRORS >> and << INTERNAL >> (al-
so compare ”DEST 38 program description”). The window for speeds/drive information is always visible.
Possible errors are indicated in each individual window.
In case of continuous display a rotating dot indicates which variable resp. which value is currently being refreshed.
Charts with descriptions about matching internal pin assignments and for the contacts of the E-box for the respective
windows can be called by means of pressing the keys F3 and F4.
Pressing the key ESC (or C) quits this menu item.
• << DIG_IN >> Digital inputs
Upon selecting << DIG_IN >> a list of the digital inputs appears on the right side of the screen together with their cor-
responding addresses and values. So in the continuous display mode (CONT) it is possible to check whether the re-
spective signal is being transferred in to the E-box.
Tip plus Powershift plus at the gear lever
Tip minus Powershift minus at the gear lever
FS neutral Drive switch (power-shuttle lever) in neutral position
FS forward Drive switch (power-shuttle lever) in forward position
FS reverse Drive switch (power-shuttle lever) in reverse position
System pressure 18 bar system pressure switch
HK pedal switch Proximity switch at main clutch pedal
Pin code 1 Set to value 1 if type of transmission is T7100
Pin code 2 Set to value 1 if type of transmission is T7200
Gear sync transm Starter inhibit switch at control console
Starter inhibit Push-button switch at drive switch (POWER-SHUTTLE lever)

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• << DIG_OUT >> Digital outputs

Upon selecting << DIG_OUT >> a list of the ”digital outputs” appears on the right side of the screen together with their
corresponding addresses and values. So in the continuous display mode (CONT) it is possible to display the output sig-
nals of the E-box.

Fig. 29 - Digital outputs

• << ERRORS >> Sensor errors)

Upon selecting << ERRORS >> a list of the sensor errors appears on the right side of the screen.

Fig. 30 - Sensor errors

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• << INTERNAL >> Internal variables

Upon selecting << INTERNAL >> a list of the ”internal variables” appears on the right side of the screen together with
their values and physical units. All displayed values are calculated by the E-box.

Fig. 31 - Internal variables

HK pressure Pressure at the main clutch (calculated by means of measuring the current which flows to the pro-
portional valve)
HK contact pres Contact pressure of the main clutch evaluated during end-of-line programming
HK pedal position Position of the clutch pedal (calculated from the voltage level of the angle sensor at the clutch pedal)

• Diagnosis > Set output ports

CAUTION!
• Due to safety reasons this menu item can only be selected when the engine has stopped!
• If the menu item ”End-of-line programming” has been previously executed the ignition on the vehicle needs
to be switched off and on again once. Otherwise the digital outputs cannot be activated!

Fig. 32 - Select output ports

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Via the menu item ”Select output ports” it is possible to set or reset the individual digital outputs. After calling the menu item
”Select output ports” a window appears in which the data of the individual outputs of the transmission-E-box are dis-
played. The outputs are indicated line by line.
Column 1: In this column the components activated by the respective output are indicated.
Column 2: In this column the internal addresses (pins) of the digital outputs are indicated.
Column 3: This column indicates the current status of the output: Hereby the indication ”1” signifies that the output is set
and therefore a signal (voltage) is existing at the corresponding pin of the E-box. The indication ”0” signifies that the output
is not set and therefore no signal is existing. Highlighted fields in different colours show to the user those outputs which are
connected to the E-box and therefore are ready to be activated.
Column 4: In this column the user can select one of the connected outputs by means of the cursor keys, i.e. the desired
field is highlighted in a different colour. This output status can be toggled (activated resp. deactivated) by pressing the EN-
TER key. The output will be set in the E-box and subsequently be read in again by the DEST program. Due to safety reasons
the changes which have been carried out will be reset to the normal state after the menu item ”Activate outputs” has been
quit.
Column 5: In this column the errors of the digital outputs are shown. Thereby the letters”KM”signify a short circuit to
ground and ”LU” stands for a line interruption.

• Diagnosis > EEPROM read/write

This menu item allows the user to read and edit the customer area contents of the EEPROM. On selection a window ap-
pears in which the contents are shown (see figure). The user can alter individual characters with the help of the cursor
keys and confirm these changes with <<OK>> (ALT + O or ENTER). Subsequent to every writing process into the EEP-
ROM customer area an identification (date) is saved which can be read later on via the menu item Control > Information.
This menu item can be quit by means of pressing the ESC key (or ALT + C).

Fig. 33 - EEPROM read/write

The first nine characters of the customer area are highlighted in a different colour. The menu item ”End-of-line program-
ming” fills in the vehicle identification number into this area.
In case of storing the contents of the error memory into a file DEST 45 checks whether the first four characters of the EEP-
ROM customer area correspond to a valid vehicle identification prenumber. If this is the case the vehicle identification
number and the corresponding number of the electronic box will also be stored into the file. Otherwise both values cannot
be stored.
Due to the aforementioned reasons this area should not be edited by the user himself. Therefore, upon opening the window
the cursor is located at the position on the right beside it.

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• Diagnosis > Operating-hours counter

This menu item enables the user to read and edit the contents of the electronic operating-hours counter. Subsequent
to the initial input a window is opened in order to confirm the data. The input itself is to be carried out with decimal values
in hours.

Fig. 34- Operating-hours counter

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3.2.3 CONTROL
The submenu ”Control” contains the menu items ”Information” and ”End-of-line programming”

Fig. 35 - Control

• Control > Information

The menu item ”Information” indicates in a window the operating-hours, the EEProm login data, the control unit login
data as well as the control unit identification data. These data cannot be edited.

Fig. 36 - Information

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• Control > End of line programming

CAUTION!
After terminating the menu item ”Activate outputs” the ignition on the vehicle needs to be switched off and on
again before the menu item ”End-of-line programming” can be selected. Otherwise the call is aborted by
prompting the error message ”Select transmission version not possible!”.
The menu item ”End-of-line programming” opens a divided window for the purpose of configuration of the trans-
mission box and for adjustment of the clutch. In the upper window area the configuration data is displayed. In the lower
area the user can find instructions for the end-of- line programming.

Fig. 37 - End-of-line programming

First the program reads the 8 digit vehicle identification number from the EEPROM. If the first four digits correspond to
a valid vehicle identification prenumber the configuration data are read directly from the box. If the configuration data
of the box are consistent to the corresponding data of the vehicle identification prenumber all data (transmission ver-
sion, type of transmission, vehicle configuration, electronic box and vehicle identification number) will be displayed. If
they are not consistent only the read out data from the control unit will be displayed. In addition, a warning will appear
with instructions to reconfigure the box. The same applies if the vehicle identification prenumber read from the EEP-
ROM is invalid.
The vehicle configuration can be changed by means of selecting the button << CONFIG >> or the letter ”F”. At first the
vehicle identification prenumber (the first four digits of the vehicle identification number) is highlighted in a different col-
our. The vehicle identification number defined for the corresponding type of vehicle can be selected from a table stored
in the program by means of the cursor keys. The configuration data belonging to the respective type of tractor are al-
tered simultaneously.
Before these data are stored by pressing the ENTER key it is obligatory to compare the pre-set speed version (30 / 40
km/h or 50 km/h) with the actual speed version of the tractor. If these do not match the proper speed version has to be
set by means of pressing the cursor keys again.

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Fig. 38 - Select vehicle identification number

After pressing the ENTER key the last four digits of the vehicle identification number will be highlighted in a different col-
our. Here the user has to fill in the serial number of the tractor which is stored in the EEPROM by pressing the ENTER
key.

Fig. 39 - Clutch adjustment

Subsequently the transmission box will be configured with the corresponding data by activating << OK >> or pressing
ENTER. In addition, the entire vehicle identification number will be written into the first nine bytes of the EEPROM cus-
tomer area. If the configuration is completed the clutch can be adjusted by means of << 1 >>. If the instructions are ex-
ecuted the clutch adjustment is terminated with << OK >> (or ENTER) causing a message to appear whether the clutch
adjustment was carried out succesfully or not.

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6. EDS (Electronic Diagnosis System) 3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45

Determination of the contact pressure of the main clutch

In order to insure engaging without a jerk upon automatical reversing, the components transmission control unit (E-box),
proportional valve and main clutch are to be coordinated by means of determining the contact pressure.

Fig. 40 - Determination of contact pressure

CAUTION!
As the vehicle starts moving on its own during the process, take care that there is sufficiently free space in front of
the tractor!

Fig. 41 - Safety note

The determination of the contact pressure is started by means of << 2 >>. For this purpose the followinf works need to be
carried out:
• Remedy all pending errors at the power-shuttle system
• Warm up the tractor (transmission oil temperature at least 40 ×C).
• Place the tractor on a solid leveled surface and move the drive switch into the neutral position. Let the engine run.
• Create a safety area with a size of at least 5 meters in front of the tractor which nobody is allowed to enter!
• Engage the gear (T7100 = 2. Gear; T7200 = 3. Gear).

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• Connect the computer, boot the system and call ”Control > End-of-line programming”. The determination of the con-
tact pressure is started by means of << 2 >>.
• Further instructions can be directly taken from the <<HELP>> file stored in the computer. After quitting the help file the
determination of the contact pressure is carried on according to the instruction.
• During the calibration process the pressure in the main clutch upon which frictional connection occurs is determined.
Hereby the tractor moves about 0,5 m forward on ist own. Simultaneously the E-box detects the ”speed at the output
of the main clutch” and terminates the determination of the contact pressure.
> Contact pressure T 7200 5,0 – 8,0 bar
> Contact pressure T 7100 6,0 – 9,0 bar
• The determined value is stored in the transmission control unit (E-box) by means of switching the ignition off and on
again and can be looked up in the plain text display under << INTERNAL >>.

Leaving end-of-line programming:

The end-of-line mode is quit by pressing C (or ESC). The determined values are stored in the EEPROM by means of switch-
ing the ignition off and on again.

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3.2.4 OPTIONS
The option menu offers the user the possibility to alter the program environment. All settings executed under this menu
item are saved when the program is terminated.

Fig. 42 - Options

• Options > Colour palette

In this menu item settings for the appropriate screen colours can be selected. All possible palettes can be selected by
means of the cursor keys and be shown in a preview. The selected colour palette is retained by means of pressing EN-
TER.

Fig. 43 - Change colours

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• Options > Language

In the submenu ”Options – Language” another language can be selected. After confirming with ENTER (resp. ALT + O)
all screen texts are displayed in the selected language.

Fig. 44 - Change language

• Options > Interface COM 1

By selecting one of the two menu items the communication with the box is carried out via the corresponding interface.
The selected interface is marked.
Only an interface actually available on the computer can be selected!

• Options > Simulated communication

Selecting this menu item causes allows most of the program functions to be called without a connection to a trans-
mission control unit. For this purpose the program EDS simulates the communication between computer and trans-
mission box. However not all the functions are currently executable with simulated control.

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3.3 ERROR CODES POWER-SHUTTLE /DEST 45

Legend error code list T7x00 V/R-auto EST 45
Validity: V410 (IV) version

General
In case of a multiple error only the error code with the highest external error number will be displayed on the screen. Si-
multaneously the error symbol ”wrench” appears on the display. The external error numbers are sorted according to the
severity of the required reaction upon an error.

Rough sub-division of the external error number

0 ...9 reserved for operation indications
10 ...99 Operation mode normal, operation mode stand-by strategy, operation mode limp home, operation mode emer-
gency operation, operation mode vehicle shut-down (except for EE), operation mode permanent neutral

Abbreviations
• LU Line interruption
• KM Short circuit to ground
• K+ Short circuit to vehicle electrical system plus general
• Nmot Speed at powershift gear input (=nLSE)
• nLSA Speed at powershift gear output
• nHK Speed at main clutch output
• nAB Speed at output, ground speed
• HK Main clutch
• HKPed Main clutch pedal
• ED Digital input
• EU Analog input voltage (U)
• ER Analog input resistance (R)
• EF Frequency input (F)
• AU Voltage output (U) (plus supply sensor system)
• VMG Ground supply transmitter (sensor system)
• VMGA Ground supply transmitter analog (sensor system)
• ADM Digital output ground
• AIP Current output (I) proportional
• VPS Plus supply (actuator system)

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3.4 DISPLAY POWERSHUTTLE

Error code Drive program Significance/function

Non-critical error, tractor can be operated normally.

10-20 Normal driving
Start-up / change of directions possibly delayed or only by jerks.

Ground speed too high.

21 Normal driving Reduce ground speed until error code disappears.
If the error code is not disappearing contact a DEUTZ-FAHR workshop.

Transmission oil temperature too high.

22 Normal driving Reduce tractor load until error code disappears.
If the error code is not disappearing contact a DEUTZ-FAHR workshop.

27-41 Limited driving Powershift are blocked.

Powershifts are blocked.

47-58 Stand-by program Conditions for starting upon change of directions:
(Limp home) Commutator switch at least 1 second in neutral position upon standstill of
tractor.

Powershifts are blocked.

Driving clutch is not working – driving only possible by means of change of di-
rections switch.
64-70 Emergency program Commutator switch at least 1 second in neutral position upon standstill of
tractor.
Contact a DEUTZ-FAHR workshop immediately and have the error be elim-
inated.

76-99 No driving possible Contact the DEUTZ-FAHR after-sales service.

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 3.5 ERROR CODE LIST WITH DESCRIPTION

Code Error location/error cause System reaction possible remedy Remarks

• Generally upon
”new” electronic system
Operation mode NORMAL Carry out/repeat • Self-preservation
EEPROM end-of-line data invalid HK adjustment
11 • Reserve value
(contact pressure)
Default contact pressure • Checks or plausibility invalid
• Both EEPROM blocks defective no
automatic restoration possible
Check cabling
EDS (Electronic Diagnosis System)

Default value: cold (HK pedal holding

time, splitter holding time, slip times) • Possible sequence error from:
Check temperature sensor
12 Temperature sensor LU, K+ • K+ HK sensor
Check sensor supply
• K+ sensor supply AU1
No change of operation mode Check vehicle electr. system voltage
Default value: cold (HK pedal holding Check cabling
• Possible sequence error from:
time, splitter holding time, slip times) Check temperature sensor
13 Temperature sensor KM • K+ HK sensor
Check sensor supply
No change of operation mode • K+ sensor supply AU1
Check vehicle electr. system voltage
Check cabling
Synchronous neutral switch Check neutral switch • Self-preservation
14 plausibility No change of operation mode (Start interlock switch) • Plausibility circuit
(Start interlock switch) Check speed sensor/cabling • Nhk-SyncN-Nab
Nab, Nhk

Check cabling • Diagnosis only if

Warning light LU
15 (Oil pressure/HK overspeed) No change of operation mode configured
Check lamp in disconnected state LU can only be diagnosed

Check cabling • Diagnosis only if configured

Warning light KM
16 (Oil pressure/HK overspeed) No change of operation mode • KM can only be diagnosed in
Check supply warning light
disconnected state
•Diagnosis only if configured
Warning light K+ Check cabling
17 No change of operation mode • KM can only bediagnosed in
(Oil pressure/HK overspeed) Check supply warning light connected state

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POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
Check oil pressure switch
• Is only diagnosed if Nmot > Nmot

20-204
Warning light is lighting Check cabling
18 System pressure plausibility threshold
No change of operation mode Check system pressure • Switch closed if pressure Is existing
Check speed sensor Nmot
On display ”EE”, permanent beep Check cabling
19 Signal line display KM • Error code is not used
No change of operation mode Check display
On display ”EE”, permanent beep Check cabling
20 Signal line display K+ • Error code is not used
No change of operation mode Check display
Permanent beep as long as
EDS (Electronic Diagnosis System)

21 Speed limit exceeded overspeed is existing Reduce driving speed • Diagnosis only if configured
No change of operation mode
• Temperature monitoring only if con-
figured
Upon exceeding 5x beep, Reduce load • Error code upon exceeding of max.
22 Temperature exceeded
subsequently 1x beep every 2 min. Shut down engine permissible upper limit temperature
• Indication ”temperature warning” is
independent of EC priority
Operation mode STAND-BY Check cabling • Possibly sequence error from
27 Characteristic line valve LU STRATEGY Check valve LU VPS2
(Powershift blocked) Check valve supply (VPS2) • Only for T7200

Operation mode Check cabling • Possibly sequence error from LU

28 Characteristic line valve KM STAND-BY STRATEGY Check valve VPS2
(Powershift blocked) Check valve supply (VPS2) • Only for T7200
• Possibly sequence error from LU
VPS2
Operation mode Check cabling
STAND-BY STRATEGY • Self preservation
29 Characteristic line valve K+ Check valve
• Can also lead to error ”VPS2-
(Powershift blocked) Check valve supply (VPS2) Plausi” (Int. EC:47)
• Only for T7200
• Only for T7200
Operation mode Check cabling
30 Retaining valve 2 LU STAND-BY STRATEGY Check valve • Possibly sequence error from
LU VPS2
(Powershift blocked) Check valve supply (VPS2)
• LU can only be diagnosed in
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Only for T7200
Check cabling • Possibly sequence error from
Operation mode
STAND-BY STRATEGY LU VPS2
31 Retaining valve 2 KM Check valve
• KM can only be diagnosed in dis-
(Powershift blocked) Check valve supply (VPS2) connected state
• Self preservation
• Only for T7200
• Possibly sequence error from
LU VPS2
Operation mode Check cabling
32 Retaining valve 2 K+ STAND-BY STRATEGY Check valve • Self preservation
EDS (Electronic Diagnosis System)

(Powershift blocked) • Can also lead to error

Check valve supply (VPS2)
”VPS2-Plausi” (Int. EC:47)
• K+ can only be diagnosed in con-
nected state
• Only for T7200
Operation mode Check cabling • Possibly sequence error from
33 Retaining valve 1 LU STAND-BY STRATEGY Check valve LU VPS2
(Powershift blocked) Check valve supply (VPS2) • LU can only be diagnosed in dis-
connected state
• Only for T7200
Operation mode Check cabling • Possibly sequence error from
LU VPS2
34 Retaining valve 1 KM STAND-BY STRATEGY Check valve
(Powershift blocked) • KM can only be diagnosed in dis-
Check valve supply (VPS2) connected state
• Self preservation
• Only for T7200
• Possibly sequence error from
LU VPS2
Operation mode Check cabling
STAND-BY STRATEGY • Self preservation
35 Retaining valve 1 K+ Check valve
(Powershift blocked) Check valve supply (VPS2) • Can also lead to error ”VPS2- Plau-
si” (Int. EC:47)
• K+ can only be diagnosed in con-
nected state

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POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Possibly sequence error from
Operation mode Check cabling LU VPS2

20-206
36 Transfer valve 2 LU STAND-BY STRATEGY Check valve • LU can only be diagnosed in dis-
(Powershift blocked) Check valve supply (VPS2) connected state (toggling only upon
defined peed ratio)

Check cabling • Possibly sequence error from LU

Operation mode VPS2
STAND-BY STRATEGY Check valve
37 Transfer valve 2 KM • LU can only be diagnosed in
(Powershift blocked) Check valve supply disconnected state
(VPS2)
• Self preservation
• Possibly sequence error from LU
EDS (Electronic Diagnosis System)

Check cabling
Operation mode VPS2
STAND-BY STRATEGY Check valve
38 Transfer valve 2 K+ • Can also lead to error
(Powershift blocked) Check valve supply “VPS2-Plausi” (CE int.: 47)
(VPS2)
• Self preservation
Check cabling • Possibly sequence error from LU
Operation mode VPS2
STAND-BY STRATEGY Check valve
39 Transfer valve 1 LU • LU can only be diagnosed in
(Powershift blocked) Check valve supply disconnected state (toggling only
(VPS2) upon defined speed ratio)
• Possibly sequence error from LU
Check cabling VPS2
Operation mode
STAND-BY STRATEGY Check valve • LU can only be diagnosed in
40 Transfer valve 1 KM
Check valve supply disconnected state (toggling only
(Powershift blocked) upon defined speed ratio) Self pres-
(VPS2)
ervation
• Possibly sequence error from
Operation mode Check cabling LU VPS2
41 Transfer valve 2 K+ STAND-BY STRATEGY Check valve • Can also lead to error
(Powershift blocked) Check valve supply (VPS2) “VPS2-Plausi” (CE int.: 47)
• Self preservation
• Upon reversing demand neutral
Check cabling shifting, permanent beep
47 nAB speed transmitter LU, K+ Operation mode LIMP-HOME
Check speed sensor • Upon reversing standstill is not ab-
solutely required!
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Upon reversing demand neutral
Check cabling shifting, permanent beep
48 nAB speed transmitter KM Operation mode LIMP-HOME
Check speed sensor • Upon reversing standstill is not ab-
solutely required!
• Inadmissible speed discontinuity
from transmitter failure threshold to
Operation mode LIMP-HOME
nAB speed transmitter gradient Ignition off/on • Upon reversing demand neutral
49 Check cabling
(Plausibility) standstill threshold shifting, permanent beep
Check speed sensor
• Upon reversing standstill is not ab-
solutely required!
Check cabling
EDS (Electronic Diagnosis System)

• Upon reversing demand neutral

50 nHK speed transmitter LU, K+ Operation mode LIMP-HOME
Check speed sensor shifting, permanent beep
Check cabling • Upon reversing demand neutral
51 nHK speed transmitter KM Operation mode LIMP-HOME
Check speed sensor shifting, permanent beep
• Inadmissible speed discontinuity
Ignition off/on from transmitter failure threshold to
nHK speed transmitter standstill threshold
52 gradient (Plausibility) Operation mode LIMP-HOME Check cabling
Check speed sensor • Upon reversing demand neutral
shifting, permanent beep
Check cabling • Upon reversing demand neutral
53 nLSA speed transmitter LU, K+ Operation mode LIMP-HOME
Check speed sensor shifting, permanent beep
Check cabling • Upon reversing demand neutral
54 nLSA speed transmitter KM Operation mode LIMP-HOME
Check speed sensor shifting, permanent beep
• Inadmissible speed discontinuity
Ignition off/on from transmitter failure threshold to
nLSA speed transmitter standstill threshold
55 gradient (Plausibility) Operation mode LIMP-HOME Check cabling
Check speed sensor • Upon reversing demand neutral
shifting, permanent beep
Check cabling • Upon reversing demand neutral
56 nMOT speed transmitter LU, K+ Operation mode LIMP-HOME
Check speed sensor shifting, permanent beep
Check cabling • Upon reversing demand neutral
57 nMOT speed transmitter KM Operation mode LIMP-HOME
Check speed sensor shifting, permanent beep

20-207
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Inadmissible speed discontinuity
Ignition off/on from transmitter failure threshold to

20-208
nMOT speed transmitter standstill threshold
58 gradient (Plausibility) Operation mode LIMP-HOME Check cabling
Check speed sensor • Upon reversing demand neutral
shifting, permanent beep
Ignition off/on
End-of-line programming • Switch point out of tolerance range
Carry out/repeat
• Self preservation
Neutral shifting permanent beep
• Upon neutral shifting
Clutch pedal sensory Check/adjust mechanical tolerance,
64 system plausibility Operation mode EMERGENCY OP- • HK pedal switch is closed with
ERATION Of the HK pedal sensory system
EDS (Electronic Diagnosis System)

Sensor/switch HK pedal in idle position

HK pedal adjustment Check cabling
• HK pedal sensor signal:
Check HK switch Idle: LOW
Check sensor supply stepped: HIGH
Check sensor/switch LU, KM, K+
• Upon neutral shifting
Check cabling permanent beep
Neutral shifting • Possibly sequence error from:
Clutch pedal sensoryl Check sensor mounting
65 Operation mode LU sensor supply (AU1)
system LU, KM Check sensor
EMERGENCY OPERATION • Limit values:
Check sensor supply Umin approx. 0,5V
Umax approx. 4,5V
• Possibly sequence error from:
Neutral shifting
Clutch pedal sensory Check cabling • EMERGENCY K+ temperature sen-
66
system K+ Operation mode EMERGENCY OPER- Check sensor mounting sor or OPERATION K+ sensor sup-
ATION
ply AU1
• Upon neutral shifting permanent
Check sensor beep
66 • Limit values:
Check sensor supply
Umin approx. 0,5V
Umax approx. 4,5V
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Upon neutral shifting permanent
beep
Check cabling
Neutral shifting • Possibly sequence error from:
Check cabling del sensore temperatura Vehicle electrical system
67 Sensor supply undervoltage Operation mode / sensore frizione undervoltage
EMERGENCY OPERATION Check cabling at temperature sensor/ • Can also lead to sequence errors
clutch sensor
• Temperature sensor
Clutch sensory system
• Upon neutral shifting permanent
beep
Neutral shifting
• Possibly sequence error from:
EDS (Electronic Diagnosis System)

Operation mode Check cabling

K+ HK sensor
68 Sensor supply overvoltage EMERGENCY OPERATION Check cabling at temperature K+ temperature sensor
Check cabling at temperature sensor/clutch sensor
• Can also lead to sequence errors
sensor/clutch sensor
• Temperature sensor
Clutch sensory system
Ignition off/on • Self preservation
Clutch pedal sensory system Neutral shifting
End-of-line programming • Programmed thresholds not logical
69 plausibility Operation mode
End-of-line data Carry out/repeat HK pedal (Idle position, switch point,
EMERGENCY OPERATION
adjustment disengaged)
• Self preservation
• Generally upon ”new” electronic
Neutral shifting Ignition off/on system
70 EEPROM end-of-line Operation mode End-of-line programming • Both EEPROM blocks are defective
EMERGENCY OPERATION Carry out/repeat HK pedal adjust- (invalid checksum), no automatic
ment restoration possible
Can also lead to errors ”HK sensor/
switch plausibility” (int. code 6)
• Self preservation
Neutral shifting Check cabling • Possibly sequence error of LU
76 Proportional valve LU Operation mode Check valve VPS1!
SHUT DOWN VEHICLE Check valve supply (VPS1) • Upon neutral shifting permanent
beep
Neutral shifting Check cabling • Self preservation
77 Proportional valve KM Operation mode Check valve • Upon neutral shifting permanent
SHUT DOWN VEHICLE Check valve supply (VPS1) beep

20-209
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Self preservation
Neutral shifting Check cabling

20-210
• Possibly sequence error of LU VPS1!
79 Forward valve LU Operation mode Check valve
SHUT DOWN VEHICLE Check valve supply (VPS1) • Upon neutral shifting
permanent beep
Neutral shifting Check cabling • Self preservation
80 Forward valve KM Operation mode Check valve • Upon neutral shifting
SHUT DOWN VEHICLE Check valve supply (VPS1) permanent beep
Check cabling • Self preservation
Neutral shifting
Check valve • Possibly sequence error of LU VPS1
82 Reverse valve LU Operation mode
EDS (Electronic Diagnosis System)

SHUT DOWN VEHICLE Check valve supply • Upon neutral shifting

(VPS1) permanent beep
Check cabling • Self preservation
Operation mode
83 Reverse valve KM Check valve • Upon neutral shifting
SHUT DOWN VEHICLE
Check valve supply (VPS1) permanent beep
Neutral shifting • Self preservation
Combining error drive switch Check cabling
85 Operation mode • Upon neutral shifting
(LU, KM, K+) Check drive switch
SHUT DOWN VEHICLE permanent beep
Check pin code • Self preservation
Ignition off/on • Pin code is evaluated only
Pin code not corresponding
87 to type of vehicle Operation mode Check end-of-line data, carry out upon initialisation
PERMANENT NEUTRAL end-of-line programming (type of • Defectice pin code.
(T7100/T7200)
vehicle, vehicle version) Wrong type of vehicle/version pro-
Check cabling grammed
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
• Self preservation
• Upon neutral shifting
permanent beep
• EC also defective with term30
Check cabling (KM, K+)
• LU VPS can also lead to sequence
Neutral shifting Check voltage at VPS 1 errors F-/R-/prop.-SV)
89 VPS1 plausibility (KM, K+) Operation mode Check voltage at term30 • Possibly sequence error resulting
SHUT DOWN VEHICLE Check cabling delle valvole from counter supply (K+) at F/R
F/R (K+) valve upon power on
• Possibly sequence error from LU
proportional valve
EDS (Electronic Diagnosis System)

• Possibly sequence error from:

Safety processor not programmed
• Self preservation
• Upon neutral shifting
permanent beep
Check cabling (KM, K+) • EC also defective with term30
Neutral shifting Check voltage at VPS 2 • LU VPS2 can only be detected via
90 VPS2 plausibility (KM, K+) Operation mode Check voltage at term30 sequence errors
PERMANENT NEUTRAL Check cabling di • Possibly sequence error resulting
GV/HV/MVKI (K+) from counter supply (K+) at GV/HV/
MVKl upon power on
• Possibly sequence error from:
Safety processor not programmed
Engage/disengage creep
speed lever
Check cabling at •HK plausibility only if configured
Neutral shifting proportional valve (K+) •Self preservation
91 HK plausibility circuit Operation mode Check proportional valve •Plausibility circuit: Nisa-HK-Nhk
SHUT DOWN VEHICLE Check HK •For T72 creep speed lever
Check speed sensory system Position”N” is possible!
Nlsa, Nhk
Check hydraulic system
Neutral shifting Ignition off/on
Vehicle electrical system
92 overvoltage Operation mode Check vehicle electrical system
SHUT DOWN VEHICLE Check cabling

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POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks
Neutral shifting Ignition off/on
Vehicle electrical system

20-212
93 Operation mode Check vehicle electrical system
undervoltage
SHUT DOWN VEHICLE Check cabling
• Self preservation
Neutral shifting • Upon neutral shifting
Check cabling
94 Proportional valve K+ Operation mode permanent beep
SHUT DOWN VEHICLE Check valve
• Can also lead to error ”VPS1-
plausibility” (int. EC 46)
• Self preservation
Neutral shifting • Upon neutral shifting
EDS (Electronic Diagnosis System)

Check cabling
95 Forward valve K+ Operation mode permanent beep
SHUT DOWN VEHICLE Check valve
• Can also lead to error ”VPS1-
plausibility” (int. EC 46)
• Self preservation
Neutral shifting • Upon neutral shifting
Check cabling
96 Reverse valve K+ Operation mode permanent beep
Check valve
SHUT DOWN VEHICLE • Can also lead to error ”VPS1-
plausibility” (int. EC 46)
• Error can only occur upon wrongly
programmed application controls
(not upon standard controls)
• Wrong parameterization of:
• Slip_configuration
• _LS_Plausi_Konfig
• _PC_Konfig
• _Diag_Disable
97 Application error Operation mode Check application data
PERMANENT NEUTRAL • _Syncn_Plausi_Disable
• _Kplp_Plausi_Disable
• GP-ID invalid
• KD-ID invalid
• FD-ID invalid
• KUNDE_KD_FD invalid
• GP-KD-vers. Invalid
• GP-FD-vers. invalid
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 Code Error location/error cause System reaction possible remedy Remarks

Ignition off/on • Customer programming (customer,

Operation mode version) invalid, not existing
98 Configuration error Check/carry out end-of-line pro-
PERMANENT NEUTRAL • Basic program not suitable for end-
gramming (customer, version)
of-line programming - by customer
• Self preservation
EEPROM end-of-line data Operation mode Ignition off/on • Checksum of the EEPROM config-
99
defective (vehicle configuration) PERMANENT NEUTRAL Repeat end-of-line programming uration data defective. No vehicle
version can be selected.
EDS (Electronic Diagnosis System)

20-213
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 3.6 OTHER INFORMATIONS
Error consequence/System reaction possible error cause possible remedy

20-214
EST45 is not running up Check supply paths LU, KM
no display activation resp. display ”EE” Communication line defective Check fuse (term15, term30)
Power supply defective Check communication line (LU)
Ignition off/on, repeat
EST45 is not running up
Check supply paths LU, KM
Diagnosis tool cannot establish connection Communication line defective
Check fuse (term15, term30)
Power supply defective
Check communication line (LU)
Wrong vehicle version selected upon Check/correct end-of-line programmed
EDS (Electronic Diagnosis System)

Upon starting/reversing powershift end-of-line programming vehicle version in programmazione fine linea
gear shifts over to neutral (jerk can be observed). Speed sensor Nmot and Nlsa defective Check cabling speed sensor Nmot and Nlsa
display: ”N”, FR-arrows flashing, no error
code, permanent beep Fault in hydraulic system Check speed sensors Nmot and Nlsa
(neutral by reversing monitoring) Check hydraulic system
Wrong vehicle version selected upon end-of- Check/correct end-of-line programmed
line programming vehicle version
Automatic shifting upward/downward in Speed sensor Nmot and Nlsa defective, Check cabling speed sensors Nmot and Nlsa
interchanged
the splitter, shifting noise every 1-2 sec. Transfer valves GV1/GV2 interchanged Check cabling transfer valves GV1/GV2
Check speed sensors Nmot and Nlsa
Fault in hydraulic system (pressure
modulation by GV toggling) Check hydraulic system

Wrong vehicle version selected upo Check/correct end-of-line programmed

end-of-line programming vehicle version
Short traction force interruption during
driving with Closed drive train Speed sensor Nmot and Nlsa defective Check cabling speed sensors Nmot and Nlsa
(LS pressure modulation) Fault in hydraulic system (pressure modulation Check speed sensors Nmot and Nlsa
by GV toggling) Check hydraulic system
Check starting block signal
Automatic starting not possible, vehicle remains in neutral Starting block signal not existing (LU, KM, K+)
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 3.7 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7100

ram switches:
neutral switch (outside)
starting block switch
(inside/only with powershift)
switches for
street/field display proportional valve
(only with power shuttle)
locking magnet
for street/field
shifting 18 bar system pressure switch
EDS (Electronic Diagnosis System)

solenoid valves for:

power take off (outside)
differential lock (inside)

speed output
power take off

speed output
electro-hydraulic powershift gear
gear shift output n Lsa
speed output
output/ground speet solenoid valve temperature speed output
n Ab all-wheel drive transmission powershift gear
oil input/engine speed
n Mot; n Lse
speed output
driving clutch (gear shift input)
n HK (only with power shuttle)

20-215
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100

20-216
Cannon Bayonet
Hydraulic pressure plug-socket
retaining valve Main pressure valve
18 bar
EDS (Electronic Diagnosis System)

Pressure-reducing valve
10 bar Pressure
control valve

Release valve

Pilot valve

Two-way valve
forward/neutral/reverse
Pilot valve

Solenoid valves Y1 – Y4:

Y1 = M VR ;solenoid valve reverse
Y2 = G V1;transfer valve 1
Y3 = M VV;solenoid valve forward
Y4 = G V2;transfer valve 2
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 3.9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T-7200

speed output ram switches:

powershift gear input/engine speed neutral switch (outside)
n Mot; n Lse starting block switch electro-hydraulic
(inside/only with powershift) gear shift
electrical connection
proportional valve forward/reverse
EDS (Electronic Diagnosis System)

(only with power shuttle) control block

18 bar system
pressure switch
solenoid valves for:
power take off (outside)
differential lock (inside)

speed output
power take off

speed output temperature

driving clutch (gear shift input)
n HK (only with power shuttle) solenoid valve transmission electrical connection
all-wheel drive oil
speed output speed output
output/ground powershift gear output
speed n Ab N Lsa

20-217
POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
 3.10 ELECTRO-HYDRAULIC GEAR SHIFT T-7200 / T-7300

20-218
Gear shift
valve A/B; F/G Safety valve Retaining valve C/D
Magnet Y6 Magnet Y7
Retaining valve A/B; F/G forward; MVV reverse
Bleed Valve
Safety valve
EDS (Electronic Diagnosis System)

Magnet Y3 Reversing piston

Clutch C/D
Retaining valve 2; HV2

Release Valve Magnet Y4

Clutch A/B; F/G
Retaining valve 1; HV1
Pressure
control valve Magnet Y1
Clutch A/B; F/G
Retaining valve 1; GV1

Two-step valve Magnet Y5

Field/street characteristik MVK
Two-way valve
field or street Magnet Y2
characteristic Clutch C/D Release valve for
Transfer valve 2; GV2 neutral position
Shift pressure
valve 18 Bar
Transfers valve C/D pilot
Pressure valve 10 bar

4-G EA R PO W ER SH IFT C O N TR O L U N IT FO RW A R D -R EVER SE C O N TR O L B LO C K

POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45
EDS (Electronic Diagnosis System) POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45

3.11 ERROR ANALYSIS

Interchanging of electrical connectors at the transmission T-7100 L and T-7200 L
Various sensors/solenoid valves/switches at the transmission are located very close to each other and are equipped with
the same type of connector. At these locations the electrical mating connectors at the cable harness cannot be layed in a
way which ensures that accidental interchanging may be absolutely excluded.
The following consideration shows the consequences if electrical connectors are interchanged:

3.11.1 VA SOLENOID VALVE AND TEMPERATURE SENSOR T-7100 L AND T-7200 L

Both elements are equipped with Jet-Tronic connectors; distance approx. 75 mm with T-7100 and 55 mm with T-7200.
VA plug on temperature sensor and VA – SV ”OFF”
• All-wheel ”OFF” ‡ 12V voltage at temperature sensor
• Error code on display
• Electronic system shifts gear to permanent neutral
Vehicle cannot be moved any more!

VA plug on temperature sensor and VA – SV ”ON”

• All-wheel ”ON” ‡ 0V voltage at temperature sensor
• Error code on display; temperature sensor defective
• Hard gear shifts (5V supply in electronic system is overloaded, but short circuit proof)

Temperature sensor plug on VA – SV

• Error code on display; temperature sensor defective
• Hard gear shifts

3.11.2 SV DIFFERENTIAL LOCK AND SV POWER TAKE OFF CLUTCH T-7100 L AND T-7200 L
Both valves are equipped with Jet-Tronic connectors; distance approx. 40 mm

Plug differential lock on SV power take off valve

• Interchanged functions upon switch actuation in cabin
• Power take off stub is running upon diff. ”ON”
Upon ZW clutch ”ON” and differential lock ”OFF” the differential lock is engaged. Critical driving state with regard to safety,
e.g. when driving in a curve, etc.

3.11.3 SPEED SENSORS INPUT/OUTPUT WITH T-7100 L

AMP superseal 3-pole connectors at both sensors, distance approx. 80 mm

Plug output on input sensor and vice versa

(both plugs are connected!)

Upon powershift step L and H

• Error is not detected
• LS transmission in neutral

Upon powershift step M

• Error is not detected
No consequences

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EDS (Electronic Diagnosis System) POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45

Only one plug is connected

OUTPUT not connected
• Error code on display
Standby driving possible
INPUT not connected
• Error code on display
• Plausibility
Standby driving possible

3.11.4 LOCKING MAGNET FIELD/STREET AND TEMPERATURE SENSOR T-7100 L

Both elements are equipped with Jet-Tronic connectors; distance approx. 115 mm
Locking magnet plug on temperature sensor

3.11.5 PLUG DRIVING CLUTCH NHK ON OUTPUT/GROUND SPEED NAB AND VICE VERSA
WITH T-7200 L (both plugs are connected)
• Tractor is starting for a short time
• Error message ”91” on display: Powershift gear in neutral

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

4. PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER

As a preparatory measure the connection between tractor (infocenter) and computer needs to be established so as to
check the infocenter by means of the EDS program resp. to change the constant values. The interface cable and the adapt-
er cable are serving for this purpose (see figure).

Fig. 51 - Interface cable and adapter cable

1 - Connect plug (1) of the interface cable with the designation ”EIC” to the computer (COM interface).
2 - Connect plug (3) of the interface cable for the 12 V supply to the cigar lighter
3 - Connect the 2-pole plug (4) of the interface cable to the plug (10) – designation ”Info center” – of the adapter cable
4 - Insert the central plug (8) of the adapter cable into the central diagnosis interface in the fuse box
5 - Switch on ignition
6 - Start the computer and call the EDS program (compare item A 1.3 – Launching and terminating of the EDS program)
7 - Make sure that the right option is called in the initial menu:
Option 4 -> plug (2) with the designation ”9141” to interface COM 1
Option 5 -> plug (2) with the designation ”9141” to interface COM 2
NOTE. Agrotron tractors with the vehicle identification numbers up to 80xx 1999 (i.e. green cabin) usually are not
equipped with a central diagnosis interface.

To be able to check the Infocenter however, with these tractors it is necessary to connect the 2-pole plug of the interface
cable directly with the diagnosis terminal of the Infocenter. The diagnosis terminal is located in the cable harness at the
backside of the Infocenter.

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

4.1 PROGRAM DESCRIPTION

4.1.1 MAIN MENU
After selecting Option 4 resp. Option 5 (depending on the computer interface) the main menu appears:

Fig. 52 - Main menu

In the upper part of the window information about the selected interface (COM 1, COM 2) as well as information about the
hardware version (Infocenter) and the software can be found.
The lower part of the window contains the select menu for the subprograms of the Infocenter diagnosis. The cursor is flash-
ing behind “function”.
The respective subprograms can be called by means of pressing the specified key:
• F1 launches the subprogram “Change constant values”
• F2 launches the subprogram “Diagnosis printout”
• F3 launches the subprogram “Test mode”
• END terminates the Infocenter diagnosis program and calls the EDS initial menu.

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

4.1.2 F1 – CONSTANTS CHANGE

By pressing the key F1 an additional window headlined “display and program constants” appears:

Fig. 53 - Display and program constants

It is possible to compare the stored constants in the Infocenter with the help of the constant list (see item 3, resp. vehicle
workshop manual).
• Procedure for changing constant values:
Select the desired constant value by means of the cursor keys (the corresponding line is highlighted)
- Press the ENTER key. By doing so, another window appears in which the new value can be entered.
- Press the ENTER key again to confirm the change and return to the constant values menu.
When the proper values are assigned to all constants, the main menu is called again by selecting the bottom line “End
constant values menu” (and pressing ENTER).

CAUTION!
The realized changes are only saved after terminating the diagnosis program and subsequently switching the ig-
nition off and on again.

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

4.1.3 F2 – DIAGNOSIS PRINT

Upon pressing the key F2 the diagnosis printout menu appears:
• Printer ready?
• ESC = No, abort
• Return = Yes, printout
Press the ESC key (keyboard top left) to abort the procedure and to return to the main menu.
Press the ENTER key (Return) to start the diagnosis printout:

Fig. 54 - Diagnosis printout

The data from “production date” are only valid for the supplier of the INFOCENTER.

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

4.1.4 F3 – TEST MODE

Upon pressing the key F3 the test mode appears. At the lower screen edge the test mode menu is displayed:

It is possible to do the following by pressing the key:

• F1 Check the inputs into the INFOCENTER.
• F2 Set (activate) the outputs of the INFOCENTER.
• F3 Check the LCDs (upon INFOCENTER 2 and 3).
• F5 Check the analog inputs into the INFOCENTER.
• F6 Check the pointer instruments.
• END Leave the test mode; subsequently the main menu appears.

TEST MODE > F1 CHECK INPUTS

Upon pressing the key F1 the following window appears:
(The representation shows the example of an INFOCENTER 2 in the AGROTRON 150. The ignition is switched ON.)

Fig. 56 - Check inputs

• Check inputs > parking brake

The signal input of the hand brake control switch at plug X 130, pin 8 of the INFOCENTER (only for INFOCENTER 3) is
tested.
- Locking brake actuated: Indication hand brake ON
- Locking brake released: Indication hand brake OFF
• Check inputs > Air filter
The signal input of the negative pressure switch air filter at plug X 131, pin 8 of the INFO-CENTER (only for INFOCENTER
3) is tested.
- Ignition on, indication air filter OFF
- Start engine, connect cable of negative pressure switch, indication air filter ON

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

• Check inputs > Transm.fl.press.

The signal input of the system pressure switch at plug X 130, pin 7 of the INFOCENTER (only for INFOCENTER 3) is test-
ed.
- Engine off, ignition on: Indication transmission oil pressure ON
- Start engine: Indication transmission oil pressureOFF
• Check inputs > air pressure
The signal input of the pressure transducer at plug X 131, pin 17 of the INFOCENTER (only for INFOCENTER 3) is tested.
Engine off, ignition on, indication pressurized air gauge > 7 bar:
- Indication pressurized air off
Ignition on, reduce boiler pressure to < 5 bar by repeated braking:
- Indication pressurized air ON

• Check inputs > eng. oil level

This function cannot be tested as it is not realized (transmitter not existing).

• Check inputs > Preheat

The signal input of the preheating time control unit at plug X 131, pin 19 of the INFOCENTER (only for INFOCENTER 3)
is tested.
- Ignition ON, during preheating process indication ON, subsequently indication OFF.
• Check inputs > Front PTO
The signal input of the switch front power take-off at plug X 131, pin 10 of the INFOCENTER is tested.
- Ignition ON, indication FRONT power take-off OFF
- Start engine, front power take-off ON, indication front power take-off ON

• Check inputs > Rear PTO

The signal input of the switch rear power take-off at plug X 131, pin 11 of the INFOCENTER is tested.
- Ignition ON, indication rear power take-off OFF
- Start engine, rear power take-off ON, indication rear power take-off ON

• Check inputs > road lights

The signal input of the switch dipped beam at plug X 130, pin 4 of the INFOCENTER is tested .
- Ignition ON, switch dipped beam OFF, indication dipped beam OFF
- Ignition ON, switch dipped beam ON, indication dipped beam ON

• Check inputs > turn signal 2

The signal input of the multifunctional switch at plug X 131, pin 2 of the INFOCENTER is tested.
With connected trailer the indication changes between flashing indicator 2 on and flashing indicator 2 off in the rhythm
of the flashing.

• Check inputs > turn signal

The signal input of the multifunctional switch at plug X 131, pin 4 of the INFOCENTER is tested.
- Ignition on, flashing indicator not actuated indication flashing indicator off
- Ignition on, actuate flashing indicator indication changes between flashing indicator on and off.

• Check inputs > high beam

The signal input of the multifunctional switch at plug X 131, pin 16 of the INFOCENTER is tested.
- Ignition ON, Indication: Main beam OFF
- Switch ON main beam (flash light) Indication: Main beam ON

Press the ENTER key to return to the TEST MODE.

TEST MODE > F2 SET OUTPUTS
Upon pressing the key F2 the following window appears:

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

Fig. 57 - Set outputs

The last line “End output menu” is marked by a bar. Press the cursor keys to move the bar to the desired function and start
the function by pressing ENTER.

• Set outputs > Lamp test

All LEDs (light emitting diodes) in the INFOCENTER are tested.
- Indication: All LEDs are lighting up.
For terminating the test step select “Reset outputs” and press the RETURN key.
- Indication: All LEDs are extinguishing.

• Set outputs > Warning lamp

The central warning light in the INFOCENTER 3 is tested.
- Indication: The warning light is lighting up.
For terminating the test step select “Reset outputs” and press the RETURN key.
- Indication: The warning light is extinguishing.

• Set outputs > Beep

The acoustic alarm - beep - in the INFOCENTER 3 is tested.
- Indication: The acoustic alarm - beep – is sounding.
For terminating the test step select “Reset outputs” and press the RETURN key.
- Indication: Beep stops.

• Set outputs > true ground speed

With this test step a signal is transmitted from the output of the true ground speed (plug X130 pin 5) to pin 1 of the signal
socket.
- Indication: Ground frequency on.
Now a voltage signal is existing at the 7-pole signal socket. Measuring is possible between pin 1 (true ground speed sig-
nal) and pin 7 (ground).
- Setpoints with ground frequency on: approx. 0,8 V (DC)
with ground frequency off: approx. 8 V (DC)

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

• Set outputs > theor. ground speed

With this test step a signal is transmitted from the output of the theoretical ground speed (plug X130 pin 11) to pin 2 of
the signal socket.
- Indication: Wheel frequency ON.
Now a voltage signal is existing at the 7-pole signal socket. Measuring is possible between pin 2 (theoretical ground
speed signal) and pin 7 (ground).
- Setpoints:with wheel frequency on: approx. 0,8 V (DC)
with wheel frequency off: approx. 8 V (DC)
• Set outputs > rear P.T.O.
With this test step a signal is transmitted from the output of the power take-off speed (plug X130 pin 6) to pin 3 of the sig-
nal socket.
- Indication: RPTO frequency on.
Now a voltage signal is existing at the 7-pole signal socket. Measuring is possible between pin 3 (power take-off speed
signal) and pin 7 (ground).
- Setpoints: with RPTO frequency on: approx. 0,8 V (DC)
with RPTO frequency off: approx. 8 V (DC)

• Set outputs > Reset outputs

All set outputs are reset and replaced by the original values.
Select “End output menu” and press the ENTER key to reset all outputs automatically and change into the test mode.

TEST MODE > F3 CHECK LCD

Upon pressing the key F3 the following window appears:

Fig. 58 - Check LCD displays

The last line “End LCD menu” is marked by a bar. Press the cursor keys to move the bar to the desired function and start
the function by pressing ENTER.

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

•Check LCD > 7 segment all segments off

All segments are cleared in the indication fields for operating-
hours, speed, etc.
• Check LCD > 7 segment horizontal segments
All horizontal segments appear in the indication fields.
• Check LCD > 7 segment vertical segments
All vertical segments appear in the indication fields.
• Check LCD > 7 segment all segments on
All segments appear in the indication fields.
• Check LCD > Checkctl – all dots off
All indications are deleted in the warning and maintenance display
(only for INFOCENTER 3).
• Check LCD > Checkctl – chess board pattern
In the warning and maintenance display every field is filled with a
weak grid (only for INFOCENTER 3).
• Check LCD > Checkctl – all dots on
In the warning and maintenance display every field is filled with a
slightly stronger grid than in the test step “chess board pattern”
(only for INFOCENTER 3).
• Check LCD > End LCD menu
Select this item to return to the test mode menu.

TEST MODE > F5 ANALOG INPUTS

Upon pressing the key F5 when the ignition is switched on the following window appears:

Fig. 59 - Check analog inputs

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

The values of charge control and terminal 15 reference will change when the engine is running:

Check analog inputs:

0 Tank 11,4% analog value
1 Tem perature 100% analog value
2 Charge control 100% analog value
3 Term inal15 reference 13,7 V olt term inal15 voltage

• Analog inputs > Tank

The signal of the tank transducer at plug X 131, pin 13 of the INFOCENTER is tested: The indicated % value corre-
sponds to the actual tank level. It is the percentage of the existing terminal 15 reference. When the plug is pulled off from
the tank transducer 100% will be indicated.

• Analog inputs > Temperature

The signal of the temperature sensor (engine coolant) at plug X 131, pin 15 of the INFO-CENTER is tested. The relation
between the input signal and the reference voltage terminal 15 is indicated in %.

• Analog inputs > Charge control

The signal of the charge control for the electric generator at plug X 131, pin 7 of the INFO-CENTER is tested. When the
engine is running a display of 100% indicates proper charging by the electric generator.

• Analog inputs > Terminal 15 reference

The power supply on terminal 15 at plug X 130, pin 2 of the INFOCENTER is tested. The indication 13,7 V is the actual
operating voltage.

Press the ENTER key to return to the TEST MODE.

TEST MODE > F6 POINTER

Upon pressing the key F6 the following window appears: The cursor is flashing behind “engine speed angle”. Engine speed
angle signifies Revolution Counter Angle.

Fig. 60 - Move pointer to position

• Pointer > Engine speed angle

Enter an angle, e.g. 180.
- Display: DZM angle 180 <<
After pressing the ENTER key the pointer of the engine speed indication will move from its 0 position by 180 (to about
1900 rpm).

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

• Pointer > Tank angle

After having performed the previous test step the following window appears:
- The cursor is flashing behind “Tank angle”.

Enter an angle, e.g. 45.

- Display: Tank angle 45 <<
Dopo aver premuto il tasto INVIO il puntatore del serbatoio si sposterà dalla posizione 0 di 45° verso il centro dello stru-
mento indicatore (il quale dispone di un angolo di indicazione generale di 90° ù
• Pointer > Temperature angle
After pressing the ENTER key the tank pointer will move from its 0 position by 45 towards the center of the indicating in-
strument. (The indicating instrument has an overall indication angle of 90.)

Enter an angle, e.g. 45.

- Display: Temp angle 45 <<
After pressing the ENTER key the temperature pointer will move from its 0 position by 45 o towards the center of the in-
dicating instrument. (The indicating instrument has an overall indication angle of 90 o .) Simultaneously the pointer win-
dow is quit and the main menue reappears.

4.1.5 END =QUIT THE INFOCENTER PROGRAM

Upon pressing the “End” key the following window appears:

In case of INFOCENTER 3 a gong is sounding now and all LEDs are lighting up. Subsequently, for about three seconds the
message “Read EProm from multipurpose instrument” appears.

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

The realized changes from the item “F1=change constant values” are saved. Changes like “Move pointer to position” etc.
are rejected and a self-test of the INFOCENTER will be performed.
Subsequently the EDS initial menu reappears (compare part A 1.3 “Launching and terminating of the EDS program”).

4.2 CONSTANT VALUES FOR INFOCENTER

Every INFOCENTER is programmed with 14 constant values in order to take into account the design features of the tractor,
which can be, e.g.
• Indication of the ground speed in km/h or mph
• Indication of the power take-off speed
• Radar sensor: existing or not existing
The central unit needs to be programmed with a specific progression of constant values which determines the type of trac-
tor and the design features. Every progression of constant values has a running number (K...) which is unique.
NOTE. Upon calibration (traveling the 100 m distance) the constant values 9 and 10 will be newly determined.

The constant values are displayed by the central unit upon the following conditions:
• Ignition OFF; dipped beam OFF
• Pull the main beam switch and hold it
• Switch ON the ignition
• After approx. 10 sec the constant values are flashing and can thus be read; Release the main beam switch
• Return to normal indication by means off ignition OFF-ON

The number of the constant value is indicated in the “speed” display and the value is indicated in the “Operating-hours” dis-
play.
• K1 - Theoretical ground speed above 15 km/h
• K2 - Rear power take-off
• K3 - not occupied
• K4 - Front power take-off 100 rpm
Upon later up-grading of the front power take-off K4 does not need to be programmed.
• K5 - Operating-hours
• K6 - (Gear ratio engine – electric generator) engine speed
• K7 - Constant value for the true ground speed (radar sensor) above 15 km/h
• K8 - Determination of km/h or mph, language, radar sensor existing/not existing
• K9 - Theoretical ground speed below 15 km/h. Determined by calibration (traveling the 100 m distance)
• K10 - True ground speed (radar sensor) below 15 km/h. Determined by calibration (traveling the 100 m distance)
• K11 - not occupied
• K12 - Rear power take-off
• K13 - not occupied
• K14 - not occupied

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

Table 1: Constant values K1 – K14

Agrotron

80-100 105 106 - 135 150

Constant 4.70 - 4095 6.01 6.00 - 6.30 6.45 160 - 200 230 - 260

K11) 3809 3675 2438 2826 1660/14402) 2220/20783)

K2 20 29/64) 70

K3 0

K4 210

K5 Operating hours

4800
1800
K6 (mechanical engine speed controller) (electronic engine
speed controller)

K7 1000

K8 see Table 2
K91) 3809 3675 2438 2826 1660/14402) 2220/20783)

K10 1000

K11 0

K12 6

K13 0

K14 0

NOTA
1) In case of the Agrotron tractors 80 – 150 the data of K1 and K9 refer to the 30 / 40 km/h version. For the 50 km/h version
these values need to be taken from table 3 and are to be entered accordingly.
2) Until month of construction 01/99: 1660, from month of construction 01/99 on: 1440
3) The constant values K1 and K9 for Agrotron 230/260 need to be chosen according to the tyre size (group 1; group 2)
as stated in table 4.
4) 29: with factory mounted sensor
6: with upgraded sensor (assembly set 04426723)

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

Table 2: Values of constant K8

Value of Radar sensor Flashing light -

Language Speed display
constant K8 existing? beep

75 danish km/h NO ON
107 danish km/h SI ON
11 danish km/h NO OFF
43 danish km/h SI OFF

65 german km/h NO ON
97 german km/h SI ON
1 german km/h NO OFF
33 german km/h SI OFF

66 english km/h NO ON
67 english km/h NO ON
98 english km/h YES ON
99 english km/h YES ON
2 english km/h NO OFF
3 english km/h NO OFF
34 english km/h YES OFF
35 english km/h YES OFF

69 french km/h NO ON
101 french km/h YES ON
5 french km/h NO OFF
37 french km/h YES OFF
77 italian km/h NO ON
109 italian km/h YES ON
13 italian km/h NO OFF
45 italian km/h YES OFF
79 dutch km/h NO ON
111 dutch km/h YES ON
15 dutch km/h NO OFF
47 dutch km/h YES OFF

73 portugese km/h NO ON
105 portugese km/h YES ON
10 portugese km/h NO OFF
41 portugese km/h YES OFF

71 spanish km/h NO ON
103 spanish km/h YES ON
7 spanish km/h NO OFF
39 spanish km/h YES OFF

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EDS (Electronic Diagnosis System) DIAGNOSIS OF THE INFOCENTER

Table 3: Constants K1; K9 for 30/40 km/h version, resp. 50 km/h version, and constant K6 depending on the engine con-
troller
K1 = K9 K1 = K9 Engine version, K6
Typ Vehicle ID no. EMR✽✽
30/40 50 km/h mech. controller
8001/8002 4.70 3809 – 1800 4400
8003/8004 4.80/80 3809 – 1800 4400
8005/8006 4.85/85 3809 – 1800 4400
8007/8008 4.90/90 3809 – 1800 4400
8009/8010 4.95/100 3809 – 1800 4400
8011 6.00/106 2438 – 1800 4800
8012 6.00/106 2438 2372 1800 4800
8013 6.05/110 2438 – 1800 4800
8014 6.05/110 2438 2372 1800 4800
8015 6.15 2438 – 1800 4800
8016 6.15 2438 2372 1800 4800
8017 6.20/120 2438 – 1800 4800
8018 6.20/120 2438 2267 1800 4800
8019 6.30/135 2438 2267 1800 4800
8020 6.45/150 2826 2411 1800 4800
8028 6.01/105 3675 – 1800 4400
8029 160 1660/1440✽ – – 4800
8030 175 1660/1440✽ – – 4800
8031 200 1660/1440✽ – – 4800
8058 230 – 2220 – 4800
8058 230 – 2078 – 4800
8059 260 – 2220 – 4800
8059 260 – 2078 – 4800
8063 115 2438 2372 1800 4800
8092/8093 120/135 – 2326 – 4800

✽ 1660: until month of construction 01/99, 1440 from month of construction 01/99
✽✽ EMR= electronic motor controller

Table 4: Constants K1; K9 for Agrotron 230 and 260 depending on the rear wheel tyres.
Group 1 Group 2
K1 = K9 =2220 K1 = K9 =2220
Designation Circumferential line (mm) Designation Circumferential line (mm)
20.8 R 42 5783 710 / 70 R 42 6180
650 / 65 R 42 5744 650 / 65 R 46 6060
620 / 70 R 42 5810 650 / 85 R 38 6084
710 / 75 R 34 5761 620 / 70 R 46 6120
710 / 70 R 38 5780 – –
580 / 70 R 42 5700 – –

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PAGE INTENTIONALLY
LEFT BLANK
ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT MAIN MENU

7. ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT

- - - R E A R L I F T - - - - PRESENTATION SCREEN
= = = = = = = = = = = = = = = =
E H D +

S o f t w a r e 0 . 0 0 A
➔ Software version.
1 8 - 0 5 - 1 9 9 8
➔ Release date.
H W - # #
K I N D O F T R A C T O R ➔
2 3 0 - 2 6 0 H P If the control unit has not been programmed or is damaged,
the following message is displayed:
C O N F . E R R O R

A S M i n s t a l l e d
➔ If ASM has not been installed, the following message is dis-
played:
= = = = = = = = = = = = = = = = A S M N o t I n s t a l l e d
[ E ] E x i t
Press E to continue.

M A I N M E N U MAIN MENU
= = = = = = = = = = = = = = = = 1- Monitor session:
used to display information processed by the vehicle
control units from input signals returned by sensors
1 - M o n i t o r (display of processed data).
2 - C o n f i g u r a t i o n 2- Configuration session:
3 - S e t t i n g s for configuration of the tractor.
4 - A l a r m L i s t 3- Calibration session:
indicates procedures for putting the tractor into service
(calibration of sensors, routine maintenance check) and
tractor configuration information (optional devices).
4- Alarms session:
list of active and passive alarms logged by the control
units.
Active alarm: error or fault detected and still present.
= = = = = = = = = = = = = = = = Passive alarm: error or fault detected but no longer ac-
[ E ] E x i t tive.
Press E to quit this menu.

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 1. MONITOR

1.MONITOR
M O N I T O R S
= = = = = = = = = = = = = = = = This menu is used to show the status of input signals for each
function.
Press E to quit this menu.
1 - L I F T
2 - C O N S O L L E
3 - A S M
4 - P O W E R S U P P L Y
5 - S E N S O R S

= = = = = = = = = = = = = = = =
[ E ] E x i t

1.1 LIFT
• Status....: Lift status
Possible values:
L I F T
LOCK lift locked
= = = = = = = = = = = = = = = =
STOPlift in 'stop' status
S t a t u s . . . X X X X X X
CTRLlift in control mode (e.g. when ploughing)
M i n P o s i t . M a x
TO UPlift being raised
X % X . X % X %
SAFE lift in safety condition
L t D r a f t R t
X . X X X . X % X . X X • Min Posit. Max: Lift position
Three columns are displayed
S l i p a g e
Min: setting selected with the minimum height
R e f : X X X X X X %
potentiometer (values from 0 to max setting).
R a d a r K m h X . X
Posit.: indicates current position of the lift (values from 0
W h e e l K m h X . X to 100).
M o d e -> X X X X X Max.: setting selected with the maximum height
E V u p X X X potentiometer (values from 0 to 100).
E V d w X X X • Lt Draft Rt: Draft monitor, left, right
P w m X X X X X X m A Three columns are displayed:
[ E ] E x i t Lt: signal (in volts) generated by the left side draft
sensor.
Draft: the value computed as a percentage of the draft
generated through the lift.
With the tractor stationary and no implement,
draft must be 50% approx.
Rt: signal (in volts) generated by the right side draft
sensor.

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 1. MONITOR

• Slipage: Wheelslip status

L I F T
Ref: setting selected with the wheelslip potentiometer
= = = = = = = = = = = = = = = =
(settings: ON = active - OFF = inactive)
S t a t u s . . . X X X X X X The value displayed after the setting indicates
M i n P o s i t . M a x actual wheelslip (0-100).
X % X . X % X % With the tractor stationary this must be 0%.
L t D r a f t R t Radar: Ground speed detected by the radar.
X . X X X . X % X . X X Values displayed:
S l i p a g e - - - - : radar not active
R e f : X X X X X X %
X X . X : speed (0-50 km/h)
R a d a r K m h X . X
W h e e l K m h X . X • Wheel: Wheel speed detected by sensor
Values displayed:
M o d e -> X X X X X
E V u p X X X X X . X : speed (0-50 km/h)
E V d w X X X • Mode ->: Lift control mode selected by way of “MIX”
P w m X X X X X X m A potentiometer.
[ E ] E x i t Values displayed:
DRAFT: lift in draft control mode
POS: lift in position control mode
MIX: draft and position control intermixed.
• EV up: Status of linkage Up solenoid valve
• EV dw: Status of linkage Down solenoid valve
NOTE
“Up SV” and “Dw SV" must not register “ON” status at the
same time.
• Pwm: Control signal sent to “Up” or “Down” solenoid
valve currently active.
Two columns are displayed:
0-1000 value of control signal
0-5000 mA current

Press E to quit this menu.

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 1. MONITOR

1.2 CONSOLE
C o n s o l l e
= = = = = = = = = = = = = = = = • CtrlLever: Output voltage of control lever
Possible values:
- transport position: 4,70÷6,69
C t r l L e v e r X . X X V
- stop position: 3,00÷4,32
S e t P o i n t X . X X V
- control position: 1,61÷2,59
M a x H e i g h t X . X X V
- float position: 0,72÷1,61
C t r l M o d e X . X X V
• SetPoint: output voltage from the control
D r o p S p e e d X . X X V
potentiometer (value 0 - 8V)
S l i p a g e X . X X V
• MaxHeight: output voltage from maximum height
B u t t o n U P
potentiometer (valu 0 - 8V)
B u t t o n D W
• CtrlMode: output voltage from operating mode
potentiometer (value 0 - 8V)
• DropSpeed: output voltage from rate-of-drop
potentiometer (value 0 - 8V)
• Slipage: output voltage from wheelslip switch
[ E ] E x i t (value 0 - 8V)
• ButtonUP: fender pushbutton - linkage Up
(Values: ON=depressed - OFF= released)
• ButtonDW: fender pushbutton - linkage Down
(Values: ON=depressed - OFF= released)

Press E to quit this menu.

1.3 ASM
A S M
= = = = = = = = = = = = = = = = • Mode: transmission operating mode
(values AUTO - MAN)
M o d e X X X X
W h e e l k m h X X . X • Wheel: Ground speed
S l i p a g e X X X . X % • Slipage: wheelslip percentage value
S t e e r • Steer: steering control is effected by way of two sensors
S 1 = X S 2 = X | - 0 0 - | relaying a sequence of signals from which it can be
determined whether the tractor is steering left, right or
straight ahead.
B r a k e s X The control sequence is indicated in the following table:
A U T O B u t t o n X
Steering angle S1 S2 Symbol
D I F F B u t t o n X
D I F F X X X X m A α≥30 0 1 \ - 30 - \
Steer
4 W D X X X X m A 25 ≤α < 30 1 1 \ - 25 - \
left
15 ≤α < 25 1 0 \ - 15 - \
Straight
ahead
0 ≤α < 15 0 0 | - 00 - |
[ E ] E x i t
15 ≤α < 25 0 1 / - 15 - /
Steer
25 ≤α < 30 1 1 / - 25 - /
right
α≥30 1 0 / - 30 - /

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 1. MONITOR

A S M • Brakes: when one of the brake pedals is depressed, the

letter P is displayed; when the pedal is released or both
= = = = = = = = = = = = = = = =
pedals are depressed, the letter R is displayed.
M o d e X X X X
• AUTO Button - DIFF Button: these pushbuttons are
W h e e l k m h X X . X used to control the ASM system as indicated by the
S l i p a g e X X X . X % following table:
S t e e r Console switches Status on test meter
S 1 = X S 2 = X | - 0 0 - | ASM DT DIFF Puls.AUTO Puls.DIFF
OFF OFF OFF R R
B r a k e s X OFF OFF ON R P
A U T O B u t t o n X OFF ON OFF R R
D I F F B u t t o n X OFF ON ON R P
D I F F X X X X m A ON OFF OFF R R
4 W D X X X X m A ON OFF ON P P
ON ON OFF P R
ON ON ON P P
[ E ] E x i t
• DIFF: current input to differential lock solenoid valve.
• 4WD: current input to 4WD solenoid valve.
Press E to quit this menu.

1.4 POWER
P O W E R S U P P L Y
This menu displays the input voltages of the ECU and com-
= = = = = = = = = = = = = = = = ponents connected to it.

Press E to quit this menu.

+ 5 V O U T V X X . X
+ 8 V O U T V X X . X
B a t t e r y V X X . X

[ E ] E x i t

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 2. CONFIGURATION

1.5 SENSORS
S E N S O R S
This menu displays the input voltages (V) to the position sen-
= = = = = = = = = = = = = = = = sors, the right and left draft sensors and the external sensor.
P O S I T I O N Also displayed are the lift position (%) and the signals from
X . X X V X X X . X % the draft sensors and the external sensor.
R I G H T D R A F T The values displayed are:
X . X X V X X X . X % POSITION: 0–5 V - 0–100%
L E F T D R A F T RIGHT DRAFT - LEFT DRAFT - EXTERNAL:
X . X X V X X X . X % 0–8 V - 0–100%
E X T E R N A L
NOTE
X . X X V X X X . X %
With no implement attached, the percentage values for the
left and right draft sensors should be approximately 50%.

Press E to quit this menu.

[ E ] E x i t

P A R A M E T E R M E N U 2. CONFIGURATION
= = = = = = = = = = = = = = = = 1 - Speed constant: using this menu, the technician can
configure radar and tyre parameters
2 - Options: this menu can be used to enable or disable
optional functions and devices on the tractor
Press E to quit this menu.
1 - S p e e d C o n s t a n t
2 - O p t i o n s

= = = = = = = = = = = = = = = =
[ E ] E x i t

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 2. OPTIONS

2.1 SPEED CONSTANTS

S P E E D C O N S T A N T
1 - Radar:
= = = = = = = = = = = = = = = =
• If the radar is installed, the value displayed will be
6500.
• If the radar is not installed, the value displayed will be 0.
2 - Wheel: the value is 3250 and must not be changed.
Press E to quit this menu.
1 - R A D A R 6 5 0 0
2 - W H E E L 3 2 5 0

= = = = = = = = = = = = = = = =
[ E ] E x i t

O P T I O N S 2.2 OPTIONS
= = = = = = = = = = = = = = = = The screen shows factory-set values for the various options.
NOTE
1 - A S M 1 The ART can only display the screen pages of this menu in
English.
2 - A U T O D R O P 0
3 - 4 W D - 3 0 D E G 0 1- ASM: selecting this option, the ASM can be enabled or
4 - R O T A T E A L A R M 1 disabled.
(1 - ON: enabled / 0 - OFF: disabled)
5 - E X T D A L A R M 0
2- AUTODROP: selecting this option, it becomes
6 - S E N S I T I V . 2 5 5
possible to enable or disable automatic lowering of the
implement at the selected rate of drop, down to the
7 - T R A C T O R 1 working position.
8 - E X T S E N S O R 1 (1 - ON: enabled / 0 - OFF: disabled)
9 - M I X M O D E 0 3- 4WD - 30 DEG: selecting this option, when ASM is
activated, 4WD is disengaged automatically when the
steering angle becomes equal to or greater than 30°.
= = = = = = = = = = = = = = = =
(1 - ON: enabled / 0 - OFF: disabled)
[ E ] E x i t
4- ROTATEALARM: if this option is enabled, active
alarms can be displayed in rotation via the diagnostic
LED. If the option is disabled, only the alarm with the
lowest code will be displayed.
(1 - ON: enabled / 0 - OFF: disabled)

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ALL ROUND TESTER FOR LIFT AND ASM CONTROL UNIT 3. CALIBRATIONS

O P T I O N S 5- EXTDALARM: enabling this option, alarm codes will be

displayed in the extended format, i.e. with a different
= = = = = = = = = = = = = = = =
code for each alarm type.
Disabling the option, different alarms may be grouped
1 - A S M 1 together under a single standard code.
2 - A U T O D R O P 0 (1 - ON: enabled / 0 - OFF: disabled)
3 - 4 W D - 3 0 D E G 0 6- SENSITIV.: this options allows the technician to
change the response of the draft and wheelslip control
4 - R O T A T E A L A R M 1
functions. Decreasing the value reduces the response
5 - E X T D A L A R M 1 speed, whereas if the value is set to 0, the response can
6 - S E N S I T I V . 2 5 5 be adjusted by way of the rate-of-drop potentiometer.
7- TRACTOR: this option is used to select the type of
7 - T R A C T O R 4 tractor.
8 - E X T S E N S O R 1 8- EXTSENSOR: this option tells the ECU whether the
signal from the external sensor is to be used in the
9 - M I X M O D E 0
control cycle or to limit the opening of the linkage Up
valve.
= = = = = = = = = = = = = = = = (1 - ON: enables Up valve limiter function /
[ E ] E x i t 0 - OFF: enables control by way of external sensor
9- MIX MODE: allows selection of the MIX potentiometer
operating mode. If the function is enabled, the MIX po-
tentiometer is used to set the draft/position or draft/po-
sition/wheelslip mix. (1 - ON: enabled / 0 - OFF: disabled)
Press E to quit this menu.

S E T T I N G M E N U 3.CALIBRATIONS
= = = = = = = = = =
= = = = = = This menu contains all the calibration operations that can be
1 - M i n H e i g t h
0 . 9 4 performed when the lift ECU or position sensor is replaced.
2 - M a x H e i g t h
4 . 0 2 1 - MinHeight: calibration of the minimum lift height.
3 - L o c k S p e d e 2 0 2 - MaxHeight: calibration of maximum lift height.
4 - S l i p a g e % 1 0 3 - LockSpeed: ground speed at which the lift lock is
applied
- - - M a i n L
e v e r - - -
4 - Slipage: percentage threshold used to control
5 - T r a n s p o
r t 5 . 3 6
wheelslip.
6 - S t o p 3 . 6 6
5 - Transport: output current from the lift control lever in
7 - C o n t r o l 1 . 9 2 TRANSPORT position.
8 - F l o a t 1 . 4 5 6 - Stop: output current from the lift control lever in STOP
position.
7 - Control: output current from the lift control lever in
CONTROL position.
= = = = = = = = = = = = = = = = 8 - Float: output current from the lift control lever in FLOAT
[ E ] E x i t position.
Press E to quit this menu.

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3.1 MINIMUM HEIGHT

M i n . H e i g h t
This menu can be used to set the minimum lift height.
= = = = = = = = = = = = = = = =
PROCEDURE
1- Start the engine and run on idle
2- Unlock the lift.
A c t u a l : # . # # 3- Lower the lift completely using the fender pushbuttons.
4- Press E to confirm the value.
N e w : # . # #
5- Press C to confirm again, or press A to clear.

[ A ] C a n c e l
[ C ] C o n f i r m

M a x . H e i g h t 3.2 MAXIMUM HEIGHT

= = = = = = = = = = = = = = = = This menu can be used to set the maximum lift height.
PROCEDURE
1- Start the engine and run on idle
2- Unlock the lift
A c t u a l : # . # #
3- Raise the lift completely using the fender pushbuttons.
CAUTION!
N e w : # . # #
Carry out these manoeuvres with the engine idling
to avoid mechanical damage to the lift.
4- When the lift has reached maximum height, lower it by
2-3 degrees (approx. 0.2 V).
5- Press E to confirm the value.

6- Press C to confirm again, or press A to clear.

[ A ] C a n c e l
[ C ] C o n f i r m

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3.3 LOCK SPEED

L O C K S P E E D
The value in this menu must not be changed.
= = = = = = = = = = = = = = = =

1 - A C T U A L 2 0
2 - N E W

[ A ] C a n c e l
[ C ] C o n f i r m

3.4 WHEELSLIP
S L I P A G E
The value in this menu must not be changed.
= = = = = = = = = = = = = = = =

1 - A C T U A L 1 0
2 - N E W

[ A ] C a n c e l
[ C ] C o n f i r m

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3.5 TRANSPORT
T R A N S P O R T
The voltage value relative to the TRANSPORT position of the
= = = = = = = = = = = = = = = = lift control lever is programmed and stored in the ECU mem-
ory.
The value can be changed by putting the lift lever in the
1 - A C T U A L # # # # TRANSPORT position and confirming the new value by
2 - N E W # # # # pressing C .
The permissible range is 4.70V to 6.69V.

[ A ] C a n c e l
[ C ] C o n f i r m

3.6 STOP
S T O P The voltage value relative to the STOP position of the lift con-
= = = = = = = = = = = = = = = = trol lever is programmed and stored in the ECU memory.
The value can be changed by putting the lift lever in the STOP
position and confirming the new value by pressing C .
1 - A C T U A L # # # # The permissible range is 3.00V to 4.32V.
2 - N E W # # # #

[ A ] C a n c e l
[ C ] C o n f i r m

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3.7 CONTROL
C O N T R O L
The voltage value relative to the CONTROL position of the lift
= = = = = = = = = = = = = = = = control lever is programmed and stored in the ECU memory.
The value can be changed by putting the lift lever in the CON-
TROL position and confirming the new value by pressing
1 - A C T U A L # # # # C .
2 - N E W # # # # The permissible range is 4.70V to 6.69V.

[ A ] C a n c e l
[ C ] C o n f i r m

3.8 FLOAT
F L O A T
The voltage value relative to the FLOAT position of the lift
= = = = = = = = = = = = = = = = control lever is programmed and stored in the ECU memory.
The value can be changed by putting the lift lever in the
FLOAT position and confirming the new value by pressing
1 - A C T U A L # # # # C .
2 - N E W # # # # The permissible range is 3.00V to 4.32V.

[ A ] C a n c e l
[ C ] C o n f i r m

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4.ALARMS LIST
A L A R M L I S T
= = = = = = = = = = = = = = = = ➔ Most recent alarm
This page displays the last 10 alarm signals to be generated.
All the active alarms are displayed on the last line against a
dark background.
Press D to cancel, or press E to quit.

[ D ] E R A S E L I S T
[ E ] E X I T

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ALL ROUND TESTER FOR AXLE SUSPENSION CONTROL MAIN MENU

8. ALL ROUND TESTER FOR AXLE SUSPENSION CONTROL

UNIT

F R O N T S U S P E N S I O N PRESENTATION SCREEN
= = = = = = = = = = = = = = = =

S o f t w a r e 0 . 0 0 A
➔ Software version..
g g - m m - a a a a
➔ Release date.

= = = = = = = = = = = = = = = =
[ E ] C o n t d . Press E to continue.

MAIN MENU
M A I N M E N U
= = = = = = = = = = = = = = = = 1- Monitor session:
used to display information processed by the sensors
and by the actuators connected to the control unit.

1 - M o n i t o r 2- Parameters session:
used to configure the speed for automatic system en-
2 - P a r a m e t e r
able and disable..
3 - L i s t o f a l a r m
3- Alarms list session:
4 - C o n f i g u r a t i o n
list of alarms logged by the control units.
4- Configuration session:
for configuration of the tractor.

= = = = = = = = = = = = = = = =
Press E to quit this menu.
[ E ] E x i t

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1.MONITOR
M O N I T O R M E N U
= = = = = = = = = = = = = = = = This menu is used to show the status of input signals for each
function.
Press E to quit this menu..
1 - S U S P E N S I O N
2 - P O W E R S U P P L Y

= = = = = = = = = = = = = = = =
[ E ] E x i t

S U S P E N S I O N 1.1 SUSPENSION
= = = = = = = = = = = = = = = = • Status....: status of the suspension position
S t a t u s . . . . x x x x x x Possible values:
CTRL automatic position control
M i n - - - P o s . - - - M a x LOCK suspension locked in lowered position
x x x V x x x V x x x V STOP control disabled, position lowered
• Min Pos. Max: position sensor reading in Volts
L S S V x x x x m A x x x Three columns are displayed:
U P S V x x x x m A x x x Min: minimum position.
D W S V x x x x m A x x x Pos.: current position.
Max.: maximum position.
B r a k e x x x • LSSV: LOAD SENSING solenoid valve
UPSV: UP solenoid valve
4 W h e e l D r i v e x x x
DWSV: DOWN solenoid valve
W h e e l s k m / h x x x x Data will indicate output current in mA and in (ON-OFF)
status.
[ E ] E x i t • Brake: indicates brake pedal status (ON depressed - OFF
released).
• 4Wheel Drive: indicates four wheel drive status (ON en-
gaged - OFF disengaged).
• Wheels: indicates ground speed (km/h) of the tractor
sensed by the wheels pickup.

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1.2 POWER
P O W E R S U P P L Y
This menu displays the input voltages of the ECU and com-
= = = = = = = = = = = = = = = = ponents connected to it.

➔ • Reading of input voltages to sensors (nominal value 8V).

+ 8 V O u t V x x x x
➔ • Reading of battery voltage
B a t t e r y V x x x x nominal value 12 V).

Press E to quit this menu.

[ E ] E x i t

P A R A M E T E R 2. PARAMETERS
= = = = = = = = = = = = = = = = 1 - Minimum speed for automatic control: used to
configure the minimum speed at which automatic
system enable and disable occurs.
Press 1 to continue

Press E to quit this menu.

1 - M i n i m u m s p e e d .
f o r a u t o m a t i c
c o n t r o l

= = = = = = = = = = = = = = = =
[ E ] E x i t

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1 - Speed: parameter determining the speed at which

P A R A M E T E R
position control is activated with the system in operation.
= = = = = = = = = = = = = = = =
2 - Speed1: parameter determining the speed at which po-
sition control is activated with the system not in opera-
tion (axle suspension locked).

Press 1 or 2 to change factory settings.

1 - S p e e d k m / h x
2 - S p e e d 1 k m / h x Press E to quit this menu.

= = = = = = = = = = = = = = = =
[ E ] E x i t

Example of how the “speed” parameter is changed

S p e e d 1- Enter the value to be set.
= = = = = = = = = = = = = = = = 2- Press E to confirm the value.
3- Press C to confirm again or press A to clear.

A c t u a l : x
N e w : x

[ D ] D e l e t e
[ E ] E x i t

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3. ALARMS LIST
L I S T O F A L A R M
= = = = = = = = = = = = = = = = This screen displays the last 10 alarm signals to be gener-
ated.
Press D to cancel, or press E to quit.

[ D ] D E L E T E
[ E ] E X I T

S E L E C T I O N S 4.CONFIGURATIONS
= = = = = = = = = = = = = = = =
The menu is used to enable the display of solenoid valve
alarms in extended format, using differentiated flashes.
1 - E x t e n d e d
s h o w o f Press 1 to change the type of selection:
A L A R M S x x x ON: indication of extended alarms active
OFF: indication of extended alarms not active

[ D ] D E L E T E
[ E ] E X I T

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SERDIA SETUP AND COMMUNICATIONS

9. SERDIA (LEVEL III)

1. SETUP AND COMMUNICATIONS

SERDIA is a software program. Together with the notebook and the interface, it constitutes a tool which serves as an aid
to communication with the engine ECUs.
SERDIA supports DEUTZ ECUs EMR, EMS and MVS. You can also communicate with three different ECUs using just one
software product.
Any changes you wish to make to the ECUs as far as settings, parametrizations, error deletion and calibra-tion are con-
cerned are only possible with SERDIA.
SERDIA runs under the MS Windows®3.11 and Windows95 (98) user surface.
You can choose English or German as the user language when carrying out program installation.
The user surface enables the user to call up the functions required simply by clicking on the appropriate buttons.
The menu points listed below are available:
• ECU selection
• Measured values
• Parameters
• Error memory
• Function test
• Extras

1.1 MINIMUM EQUIPMENT REQUIRED

To run SERDIA, the following minimum equipment configuration is required:

1.1.1 CONTROL UNITS

• EMR1, Electronic engine controller System description TN 0297 7432
• EMR2, electronic engine controller System description TN 0297 9885
• MVS, solenoid valve system System description TN 0297 7488
• EMS2, engine monitoring system System description TN 0297 7930

1.1.2 DIAGNOSTIC CONNECTOR

Serial diagnostic connector TN 0419 9615 as specified in ISO 9141 and SAE J1587

1.1.3 INTERFACE
Link from control module (engine) to PC
• Level adaptation for ISO 9141, SAE J1708 and RS 485
• Security system with dongle, copy protection
• 12-24 V voltage supply range
• Supply source: engine
• Safety switching for protection against overvoltage and incorrect pole connection
• Galvanic isolation

1.1.4 PC/ NOTEBOOK

Minimum equipment required:
• Notebook or PC with 1 RS 232 serial interface PC (IBM-AT compatible) (should not be otherwise occupied, for example,
mouse or IR interface).
• Parallel interface for printer
• Graphics card VGA/SVGA

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SERDIA SETUP AND COMMUNICATIONS

• Processor 80486 (or higher)

• Clock speed >= 100 MHz
• Installed memory >= 8 MB RAM
• Hard disk >= 15 MB (free disk space)
• Disk drive 3.5“ 1.44 MB
• Software: Operating system MS Windows 3.11, 95 or 98
Installation is also possible under Windows 3.1. However, because of a Windows problem, this can cause access conflicts
with the COM1 serial interface (see Chapter, "What to do if ...". For more details, please see the "Readme" file supplied with
SERDIA.).
With Windows 3.11, the standard (VGA) screen driver should be installed for correct display of SERDIA screens.

1.2 ORDERING
SERDIA can be ordered, like the DEUTZ special tools, through:

SAME-DEUTZ-FAHR ITALIA S.p.A.

Viale F. CASSANI, 15
24047 TREVIGLIO (BG) - ITALIA

1.2.1 FIRST-TIME USERS

For first-time users, we recommend the SERDIA package Re-order No. 5.9030.740.4/10.
Scope of supply:
• SERDIA software (1 x 3.5' installation diskette)
• Diagnostics interface with implemented user level
• Brief instructions on installation
• A list of tools and modifications usefui when troubleshooting, is included
• Carrying case

1.2.2 ORDERING SINGLE PARTS

Part Competence level Re-order No.
Installation diskette 5.9030.740.0
Adapter 5.9030.741.0
Interface level III Major overhaul 5.9030.740.2

1.2.3 ADAPTER
Some OEMs have different diagnostics plugs for certain versions. An adapter is therefore required for the interface from the
12 pole DE UTZ plug to the appropriate OEM plug.
The DEUTZ 12 pole counterpart is available as a genuine DEUTZ part.
A ready-made adapter is available, for diagnostics on engines in DE UTZ Fahr tractors (DEUTZ 12 pole -> DFA 14 pole):

DEUTZ Part No. 5.9030.741.0

1.2.4 SERDIA UPDATES

You will be informed of software updates by our service information department, as they occur.
There is no automatic exchange against older versions of the software.
When installing the update the target directory should contain the SERDIA version number.

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1.3 SWITCHING ON AND INSTALLING THE SOFTWARE

1.3.1 INSTALLING MS WINDOWS

If MS Windows is not already installed on your hard disk, it must first be installed following the installation instructions sup-
plied with MS Windows 3.1, 95, 98 o 2000.

1.3.2 INSTALLING SERDIA FROM DISKETTES

To run the SERDIA software, an interface with a connection to an engine control module is required. If this interface is not
present, SERDIA can still be installed, but will only run in Off-line mode. The software limitations imposed by off-line mode
are described in Chapter "Off-line mode".
Installation with Windows 3.1, 3.11:
• Start Windows.
• Insert SERDIA Installation diskette 1 in the disk drive (Drive A).
• Open "File Manager".
• Select disk drive A.
• Double-click on the "install.exe“ file to start installation.
• Follow the instructions appearing on the screen.
• When finished, remove Installation diskette 2 from the disk drive and store in a safe place together with diskette 1.
• After the computer is re-started, the SERDIA program group window opens.
• Double-click on the "Service diagnosis“ program group to start.
Installation bei Windows 95, 98:
• Start Windows.
• Insert SERDIA Installation diskette 1 in the disk drive (Drive A) einlegen.
• Open "Windows Explorer".
• Select disk drive A.
• Double-click on the "install.exe“ file to start installation.
• The Installation window opens:

•The name of the target directory should indicate the SERDIA Version number, for example "serdia35“.
• Follow the instructions appearing on the screen.
(If installing with Windows 98, select Windows 95 as the operating system)
• When finished, remove Installation diskette 2 from the disk drive and store in a safe place together with diskette 1.
• After the computer is re-started, the SERDIA program group window opens.
• Double-click on the "Service diagnosis“ program group to start.

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Special characteristic of Notebooks with Windows 98:

The ACPI entry (Advanced Configuration and Power Interface) may not appear under "Start\Settings\Control Panel\Sys-
tem\Device Manager\System components.
In this case, follow the instructions in the "Readme.txt" file ("Windows 98" section) included on the SERDIA
Installation disk.
Proceed as follows:
• Check whether ACPI is enabled.
• If there are ACPI entries, switch off ACPI using the "disacpi.reg“ file.
These files are in the SERDIA working directory.
(ACPI can be switched on again using the "enacpi.reg“ file).
• Run the new hardware recognition program:
Start\Settings\Control Panel\Add New Hardware\Next\ Search for new hardware.
(The Installation CD may be required for Windows 98).
• Re-start the computer.
Installation with Windows 2000:
To install under Windows 2000, the 32Bit Version of SERDIA is required. This should be available from May 2002, and will
be indicated in the service announcements.

1.3.3 INSTALLING SERDIA FROM THE SERPIC CD

• Start Windows.
• Insert the SERPIC CD in the CD drive.
• Open "Windows Explorer".
• Select the CD drive.
• Open the SERDIA directory.
• Open the "Disk1“ directory
• Double-click on the "install.exe“ file to start installation.

The Installation window opens:

The name of the target directory should indicate the SERDIA Version number, for example "serdia35“.
Follow the instructions appearing on the screen.
(If installing with Windows 98, select Windows 95 as the operating system)
• Remove the CD from the drive and store in a safe place.
• After the computer is re-started, the SERDIA program group window opens.
• Double-click on the "Service diagnosis“ program group to start.

1.3.4 USER LEVEL, ACCESS RIGHTS

DEUTZ Service has defined four different user levels for the SERDIA software (I, II, III, IIIa), which are pre-set in the interface.
The reason for the four different levels is to prevent unauthorised persons from accessing particular parameter settings (in
the same way as the seals at injector pumps).
The use of access rights means access is only allowed to those parameters and fields authorised for a particular user level.

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1.3.5 SETTING UP THE LINK BETWEEN CONTROL MODULE (ENGINE) AND NOTEBOOK
Communication characteristics:
• Serial communication
• BaudRate = 9600
• Serialport = COM1
The SERDIA interface (supplied) is used to connect the control module to a Notebook. Despite the numerous safety pre-
cautions in the interface and control module (such as protection against wrong pole connection and overvoltage, and gal-
vanic isolation), mistakes can still happen, and the following procedure should always be applied when connecting the
Notebook to the control module.
The connection is set up in the following order:
1) Switch off the engine, ignition switch (Circuit 15) is Off. Do not switch on the Notebook yet.
2) Connect the diagnostic connector to the vehicle / installation diagnostic socket.
The diagnostic connector must be provided by the customer, and can be supplied by DEUTZ on request.
3) Connect the other side (interface side) to the RS 232/COM1 serial interface. (9-pin connector on the back of your
Notebook).
Note: On PCs, the COM1 interface may already be occupied by the mouse. In this case, the interface must be connected
to the PC's serial interface (COM2). This must then be configured (see Chapter, "What to do if ...).
4) The ignition switch (Ct.15) and Notebook can now be switched on. The engine remains off at first.
5) The SERDIA can now be started as describe in Chapter 1.8, "Starting the Program".

1.3.6 STARTING THE PROGRAM

In the Windows environment, the SERDIA program is started by clicking twice on its icon.
Starting for the first time:
When the program is started forthe first time, the control module is interrogated. SERDIA does this to find out which control
modules are connected and can therefore be addressed. This process can last for about 30 seconds, as the program in-
terrogates all the possible control modules one after the other. While this is taking place, the message "Startup routine for
connected ECUs“ is displayed. The "ECU selection“ subscreen then appears, in which unidentified control units are
greyed out.

• Select the desired control unit and click OK.

• The message "Initialisation is active!“ appears (and remains for about 7 seconds). Communications are then set up with
the control unit.

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Starting the next time:

SERDIA registers the control units identified the last time the program was started (for example the EMR2).
If this control unit is connected the second time the program is started, SERDIA skips the interrogation stage and im-
mediately initialises the control unit. This substantially reduces the program startup time. The message "Initialisation is ac-
tive!“ appears (and remains for about 7 seconds). Communications are then set up with the control unit.
If another control unit is connected the next time the program is started, the interrogation process is performed again (and
lasts about 30 seconds).
In engines with two control units (for example an EMR with EMS2), the desired control unit can be selected through another
interrogation (see paragraph 2.1).

1.3.7 SETTING UP COMMUNICATIONS WITH THE CONTROL UNIT (ECU)

Communications possible:
After communications have been successfully set up, the main "Service diagnosis“ screen appears, with the fields "ECU“,
"ECU identification“ and "Measured values“ (see Chapter 2, "ECU selection").
This screen contains a menu, and a "Tasks“ switch (see Chapter 8 , " Tasks").
EMR1 EMR2

The communication status between the PC/Notebook and the control unit is indicated by plain text messages, and by a
colour code on the status bar:
Yellow (flashing): ISO block processing, i.e. useful data (for example measurements) are being exchanged between
SERDIA and the control unit.
Green (flashing): ISO connection OK, i.e. only data blocks needed for maintaining communications between SER-
DIA and the control unit are exchanged.
Red: Communications stopped.
Communications not possible:
It may not be possible to establish communications for the following reasons:
• No control unit connected.
• There is a communication error; see Chapter 9.1.1, "Communication errors". Setting up communications
In both cases an error message is displayed, and SERDIA offers to go into Off-line mode; see Chapter, Off-line mode.

1.3.8 OFF-LINE MODE

If no control unit/engine and/or interface is available, SERDIA can be run in password-protected mode or Demo mode for
training purposes.

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SERDIA SETUP AND COMMUNICATIONS

SERDIA always offers to go into password-protected mode or Demo mode when it has not been possible to establish com-
munications successfully.

Click on "Ignore". The desired mode can be selected in the "Confirm" box.

1.3.9 PASSWORD-PROTECTED MODE

If "Yes" is selected to confirm, and there is no control unit, authorised users can enter a password (check with head office)
and read and print configuration files, but not modify them.

1.3.10 DEMO MODE (TRAINING WITH NO CONTROL UNIT)

If "No" is selected in the Confirm box, the program goes into Demo mode.
1) In this mode, the user can practice working with SERDIA, without changing any values.
2) Graphic files can be read and printed. However, the graphic files must have been stored in digital form (filename ex-
tension *.egr).
Also, functional tests cannot be performed on the control units.

1.4 USING THE PROGRAM

Quick start:
1) In Windows, start the SERDIA program
2) In the main SERDIA screen, click on "ECU selection"
3) In the "ECU selection“ screen, select the desired control unit
4) In the main SERDIA screen, select the desired menu

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1.4.1 MAIN SCREEN, MENU SELECTION

Menu Control units Explanation
ECU selection
Selecting a control unit
ECU selection all
(only one can be selected at a time)

Print all Print measurements or control unit identification data on a printer or

to a file
Protocol all Interface configuration (Level IIIa only)
Restart all Interrogates control unit again
Program ECU EMR2 only Loads operating software into the EMR2 (Level IIIa only)
Engine off EMR2 only Remote engine switch-off
Reset ECU EMR2 only Resets control unit
Measured values
Shows current actual values (also with engine off, but with battery
actual measured values all voltage))
RAM-Values all EMR1: Level IIIa only, EMR2: Level III, IIIa only
Data logger EMS2 only Shows content of data logger
Input/output assignment all Control unit pin/signal assignments
CAN Status all Simple CAN Monitor
MVS Measured values MVS only cylinder-specific measurement display
Parameters
Configuration all To view or modify configuration data
Overall programming EMR1, EMR2, EMS2 Level III, IIIa only
Calibration Calibration of transducers, for example pedal travel sensors
MVS pump class MVS only pump class assignments
Error memory
Error memory all Reads, displays, and clears the error memory
Error memory 2 EMR2 only Reads, displays, and clears the error memory (Level III, IIIa only)
MVS error memory MVS only Cylinder-specific error display
Function test EMR1, EMR2 To use the actuator control (Level III, IIIa only)
Extras
Maximum speed EMR1, EMR2 Selection of three different maximum speeds
Logistic data al all
Load spectrum EMR2, EMS2
Maintenance interval EMS2 only
exceeded
Override memory EMS2 only
Maintenance data
Help all General help for main screen and screen buttons.
Tasks EMR1, EMR2 for certain service operations

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1.4.2 "ECU SELECTION“ MENU

DEUTZ engines may be equipped with one or more control units (for example, an MVS/ EMS2 combination). However,
SERDIA can only communicate with one control unit.
Exception: error lists and measured values can also be read from the MVS control unit through an EMS2.
The desired control unit must therefore be selected first in the "ECU selection“ menu.
For more details, see Chapter 2, "ECU selection".

1.4.3 MEASURED VALUES" ("ACTUAL MEASURED VALUES“) MENU

A number of measured values (including inputs/outputs) can be selected from a list of values and displayed.
Displayed values falling outside the maximum or minimum limit (if present) are shown on a coloured background.
Only measuring points that match the control unit are shown, with different display options:
• Read measured values
• Read measurement electronics
• Read logger data (special EMS2 menu)
arranged by
• designation
• value
• unit
Measured values are refreshed at a pre-set scan rate and can be displayed both with engine stopped and with engine run-
ning.
• For more details, see Chapter, "Measured values".

1.4.4 "PARAMETERS" MENU

The wide-ranging possibilities of DEUTZ control units require special programming to adapt them to their particular en-
vironment. Changes to parameters are necessary when access is required,
• due to customer request
• to adapt to local conditions
• to fit a replacement.
Parameters can only be changed through SERDIA!
This menu option can be used to replace the screwdriver setting (necessary with analog control units).
Some of the parameters (for example, dynamic control response) can be modified within certain pre-set limits.
Parameters are set through two screens, one for configuration and one for calibration. Access to the fields in the related
screens depends on user authorisation. Unauthorised fields are not shown.
For more details, see Chapter 4, "Parameters".

1.4.5 "ERROR MEMORY" MENU

This menu is used to read any error messages stored in the control units.
Error messages are related exclusively to electrical parts of the engine, such as cable harness and transducer.
For example, one error message could be "General fault or cable cut/short-circuit“.
Only passive error messages can be deleted; active messages are saved.
Active error messages become passive messages when they have been cleared.
Error messages are saved even when the battery/voltage supply is disconnected.
Error messages contain the following information:
• Fault location
• Fault type
• Environmental data at time of fault
• Total error count (per fault location)
• Frequency
• Emergency mode (yes / no)
For fault clearing, the user can refer to the SERDIA Help screens; it may also be helpful to refer to the "Measured values“ and
"Function test“ menus. For more details, see Chapter 5, "Error memory".

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1.4.6 "FUNCTION TEST" MENU

SERDIA supports wide-ranging function tests, differentiating between the control units installed (for example, testing the
actuator for the EMR1).
The function test option also provides valuable help, especially for troubleshooting and maintenance work.
Individual control unit outputs can be activated and checked separately. This is done by switching to Test mode.
The engine must be switched off first!
In the Function test, the control unit transmission program is bypassed and actuators are controlled by the test program.
Actuators are switched on and off by clicking on the little control box in the Actual Value column, beside the actuator's des-
ignation reference. "Actual Value" shows the response for the actuator status set by the control unit.
The actuator status test always takes place in the control unit, and can only be transferred to the SERDIA by the control unit
itself. This means that if the desired actual value does not appear, there may be a wiring fault. The "Error memory“ and
"Function test“ menu combination can be of help in determining the source of a fault.
Indirect indications about engine condition can also be obtained using the "Function test" menu in combination with the
MVS control unit.
For more details about the function test, see Chapter, "Function test".

1.4.7 "EXTRAS" MENU

SERDIA supports wide-ranging options specific to the control unit.
These are accessed through the related submenus, which have their own screens:
• Maximum speed
• Logistic data
• Load spectrum (EMR2 and EMS2)
• Maintenance interval exceeded
• Override memory
• Maintenance data
For more details, see Chapter, "Extras".

1.4.8 HELP
The SERDIA Help function can be used in conjunction with these user instructions. In Windows, the Help function is
opened by clicking on the "Help“ button.

1.5 CLOSING THE PROGRAM

Before disconnecting the cables between the Notebook and the engine control unit, go back to the main screen and click
on the "Close“ button.
If parameters have been changed, in many cases it is worthwhile checking the current parameter settings.
To do this, follow the steps below:
1. Close SERDIA
2. Switch off the engine supply voltage, then switch on again
3. Re-start SERDIA
4. Activate the control unit again
5. Open the "Parameters“ menu
6. In the configuration screen, click on the "ECU->PC“ button
7. Print out the configuration data by clicking on the "Print“ button
8. Keep the printed data with the engine documentation.

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2. ECU SELECTION
2.1 SELECTING TWO CONTROL UNITS
DEUTZ engines can be equipped with two control units (for example, MVS in combination with EMS2).
However, SERDIA can only communicate with one control unit. Exception: Error lists and measured values can also be
read from the MVS control unit through an EMS2.
SERDIA tries to set up a connection automatically to the last control unit identified. If another control unit is to be selected,
the control unit recognition process must be repeated by opening the "ECU selection/Restart“ menu (this takes about 30
seconds).

After they have been successfully recognised, the control unit selection screen is opened. Only identified control units are
presented for selection. Non-selectable control units are greyed out.

Possible control units are:

• EMR1, EMR2 (Electronic engine controller)
• MVS (Solenoid valve system)
• EMS2 (Engine Monitoring System)

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2.2 PRINTING
Like the data in other windows, the identification data for the selected control unit can be printed in two ways.

1) Printing to a printer.
In this case, the correct printer driver should be selected under Windows.
At the top of all printouts are the logistics data:
• Type of control unit
• Date
• Time (as set in the Notebook system clock)
• Interface serial number
These are followed by the control unit identification data and measurement data.

2) Control unit data can also be printed to a file.

This file can then be further processed with another program, such as Excel.
The following table provides a summary of the data from the different screens, which can be saved:
• as printable files for further processing in other programs such as Excel.
• as configuration files for reporting modifications.
• as graphics files (*.egr), for viewing in SERDIA Demo mode.

From screen Button Filename Comment

extension
Service diagnosis Print (file) *.ecu for further processing in other
actual measured values File *.msv programs, such as Excel.

for further processing in other programs, such

RAM Values File *.msv as Excel.
(EMR1: Level IIIa only, EMR2: Level III, IIIa only)
for further processing in other programs,
(AscII) *.agr
Graphics such as Excel.
(Binary) *.egr viewable in SERDIA Demo mode.
Input/Output assignment Print (file) *.ino for further processing in other programs,
Print (file) *.kfg such as Excel

Configuration *.hex Configuration file

Save in file
*.tds Partial data set, Level IIIa only

Overall programming ECU -> file *.hex Configuration file

(Complete data set, Level III and IIIa)
Error memory Print (file) *.err for further processing in other
Logistic data Print (file) *.dat programs, such as Excel.

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2.3 PROTOCOL
This menu is for DEUTZ only, and is used for configuring the interface.

2.4 IDENTIFICATION AND MEASUREMENT DATA

2.4.1 EMR1

IDENTIFICATION DATA MEASUREMENT DATA

Meaning of identification data:

• DEUTZ part number: Part number of selected control unit.
• Business partner number: Product number
• Type of control unit selected:
1 = EMR1
2 = MVS
3 = EMS2
• Hardware version number: Version number of the control unit.
• Software version number: Number of the EEPROM contained in the control unit. If the number before the point has
changed (for example, 2.1 to 3.1), the data set will no longer match the control unit. In this case, company head office
should be contacted.
• Day, Month, Year: Date at which the control unit parameters were last configured.
• Service ID: Serial number of interface used for previous access. The first digit indicates the authorised access level.
• OperHourCount:Engine[h]: numero delle ore di funzionamento del motore.
• Number of engine start
• Interface serial number: serial number of interface now being used.

Measured values:
The "Measured values“ field shows some of the measured values directly. This selection is not configurable.

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2.4.2 EMR2
IDENTIFICATION DATA MEASUREMENT DATA

Meaning of identification data:

• DEUTZ partNo: Part number of selected control unit.
• SupplierNo
• ProductNo:
Type of control unit selected:
1 = EMR1
2 = MVS
3 = EMS2
• Hardware Rev: Version number of the control unit.
• Software Rev: numero versione software
Number of EEPROM contained in the control unit. If the number before the point has changed (for example, 2.1 to 3.1),
the data set will no longer match the control unit. In this case, company head office should be contacted.
• Binary code checksum
• ISO Access control
• Identification data Measurement data
• Deutz SW-PN: Part number of EMR2 operating software
• ECU SerialNo Year ECU SerialNo Month
• ECU SerialNo
• Engine number
• Day, Month, Year of last change: Date at which the control unit parameters were last configured.
• Lats Service ID: Serial number of interface used for previous access. The first digit indicates authorised access level.
• Interface serial number: Serial number of interface now being used.

Measured values:
The "Measured values“ field shows some of the measured values directly. This selection is not configurable.

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3. MEASURED VALUES
3.1 ACTUAL MEASURED VALUES (GENERAL)
The measured values are read out cyclically and displayed on the "Actual measured values" screen.

Values outside the sensor's measuring range have coloured backgrounds:

• Yellow: Measuring range is exceeded,
• Blue: Below measuring range.

EXPLANATION OF THE FUNCTION BUTTONS:

• Meas. values: The "Measured value selection" window containing all the available measured values is displayed. The
measured values that are to be displayed can be selected from here. In general, the repeat rate of the display is in-
creased if there are not many measured values to be displayed. The number of available measured values varies, de-
pending on the type of control unit.
• Graphics: The button "Graphics" displays, in the form of a graphic, the progress over time of the selected measured
values (maximum of 5). If more than 5 measured values are selected, an error message will appear.
• Collect. time: The recording period is displayed in the Measurement duration field in seconds. The minimum value for
the recording period is one second. A few hours (expressed in seconds) can be entered for the upper measuring time.
The default setting is 10 s. The shortest scanning rate is 40 ms for RAM values and 60 ms for other values.
For a measuring period of 10s, therefore, the total number of measuring points for RAM values is: 10000 ms/40 ms = 250
and for other values: 10000 ms/60 ms = 166.
Since the program records an approximate maximum of 2000 measuring points, the scanning rate is automatically ad-
justed - accordingly before the beginning of the data recording phase.
The minimum possible scanning rate is determined by the duration of data transmission from the control unit to the PC.
The more measured values that are to be displayed simultaneously, the longer the data transmission period and there-
fore the lower the scanning rate will be.
• File: The current measured values can be stored in a file and reloaded at a later date, for example for further processing
in Excel.
• Print: The displayed measured values are printed out.
• Close: Return to the main window "Service diagnosis".

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3.1.1 MEASURED VALUE SELECTION

The list of available measured values is displayed.

The measured values to be displayed can be selected from this list. An individual measured value is selected by clicking on
the associated check box. If a graphical display is required, not more than 5 measured values can be selected (see 3.1.2
Graphics). The four buttons on the right of the list can be used to activate and de-activate a collection of measured values.
These have the following functions:
• Save: The displayed selection of measured values is saved to a file.
• Load: The selected measured values are loaded from a file.
• Delete selection: All measured values are de-activated for display.
• Select all: All measured values are activated for display.
• OK: Return to the display of the current measured values. The changes made to the selection of measured values are
saved.
• Cancel: Return to the display of the current measured values. The changes made to the selection of measured values
are cancelled.

The following tables give an overview of the measured values which can be displayed. For some parameters, a config-
uration operation is also required (see Chapter 4 Parameters); this enables specific measuring points to be assigned to the
inputs and outputs of the EMR1/EMR2 ("Configuration", "Page 11: assignment inputs/measured values“ and "Page 13:
assignment outputs/measured values"). The values required for parameter configuration are shown in the tables. The as-
signment can be subsequently checked in the "Measured values" menu, with the window "Display of inputs and outputs"
(see 3.4 Input/output assignment).

3.1.1.1 MEASUED VALUES EMR1

MEASURED VALUE SELECTION

Associated
Name of measuring point Description RAM value
Battery voltage Battery voltage –
Speed 1 (camshaft)
Engine speed 2000 2002
Speed 2 (crankshaft)
Control rod position Control rod position
(M9)Coolant temperature Coolant temperature 3551
Fuel injection quantity Fuel injection quantity

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Associated
Name of measuring point Description
RAM value
Fuel consumption Fuel consumption
(F24)Accelerator pedal=SWG1 Voltage of accelerator pedal potentiometer 3551
Rel.Accelerator pedal=SWG1 Pick-off point for accelerator pedal potentiometer 3551
(M24)Boost pressure Charge air pressure 3531
(M21)Oil pressure Oil pressure 3541
Torque 2701
Oil pressure warning signal 3011
Reserve
Speed 1 - Speed 2 2000 2002
(F20)Hand throttle=SWG2 Hand throttle 3521
Summary of outputs
Selector switch Gear selector switch
Vehicle speed Driving speed

3.1.1.2 MEASURED VALUES EMR2

MEASURED VALUE SELECTION

Corresponding
Name of measuring point Description
RAM value
Battery voltage
Speed 1 (camshaft) 2000
Speed 1 (camshaft)) 2031
Speed 2 (crankshaft) 2002
Control rod position 2300
Control rod position 2330
Coolant temperature 2904
Fuel temperature 2906
Charge air temperature 2905
Voltage of accelerator pedal potentiometer 2900
Pick-off point for accelerator pedal potentiometer
Hand throttle 2901
Charge air pressure 2902
Oil pressure Oil pressure 2903
Atmospheric pressura Atmospheric pressur 2930
Coolant level Coolant level 2820
Engine brake status Engine brake status 2826
Status of gear selector switch Status of gear selector switch 2827
Error lamp Status of error indicating lamp Error lamp Status of error indicating lamp 2868

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Associated
Name of measuring point Description
RAM value
SourceOfEngineStop
VehicleVelocity state
Vehicle-Velocity Driving speed
calc. FuelConsumption Fuel consumption 2360
Fuel injection quantity Fuel injection quantity 2350
FuelQtyLimitation Fuel quantity limitation 2701
ActFuelQtyLimitng Active fuel quantity limitation
ActualSetpoint
ActPowerReduction
ActTopCurve 3145
ActSpeedLimiting
Oil pressure warning signal (optional)
Torque (optional)
Outp:(F16)/Freq Speed 1 - Speed 2 2000 2001 2002
Outp:(F16) Digital 7 2857
Outp:(M2) Digital 3 2853
Inp:(F6)Digital 3 3 Input 2854
Inp:(F18) Dig/PWM 1 Input 2856
Inp:(F18)Digital/PWM 1 Input
Inp:(F19)Digital 4 Input
Inp:(F20)Digital/Analog 3 Input
Inp:(F21)Digital/PWM 2 Input
Input
Input
Charge air temperature 2905
Fuel temperature 2906
Input
Coolant temperature 2904
Oil pressure sensor input
Sensor input Charge air temperature

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3.1.2 GRAPHICS
If up to any 5 measured values have been selected, the "Graphic display" window can be opened by clicking on "Graph-
ics".

The measured values are displayed within the display range (minimum to maximum). The scaling divisions for the axes are
set in the column called "Delta".
It is possible to let the program carry out automatic scaling by activating the control field called "Auto".
Because the program does this scaling based on the minimum and maximum values of the respective measured values,
it is not possible to have automatic scaling for time-constant measured values.
A maximum of two axes, one on the left and one on the right side of the graph will be drawn. A measured value can be as-
signed to a left or right axis in the columns marked L (left) and R (right).

EXPLANATION OF THE FUNCTION BUTTONS:

• Start: The data recording operation is started using this function button.
• Update: This function button is used to update the information displayed. This is required if a change has been made
to the minimum, maximum or delta values. The update takes account of the new values.
• Print : Clicking on this button will commence output to a printer. The printer selection screen is displayed first, then the
user has the option of entering any comments before the graph is finally printed out.
• Save : The information displayed can be saved to a file in two different ways:
1) As an ASCII file (*.agr) for further processing, e.g. in Excel.
2) As a binary file (*.egr) for display of measurement graphics in offline mode, see 1.9 Offline mode.

• Apri: Load : The graphics information stored in a file is loaded and displayed.

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3.2 RAM-VALUES
RAM values are calculated from the measured values with the aid of the microprocessors in the control units and are made
available by SERDIA as additional data.

The following tables provide an overview of the possible RAM values which are used in the EMR2 control unit.

2000Speed 2130IMFuelSetp 2300ActPos

2001SpeedPickUp1 2131IMFuelSetpSelect 2330ActPosSetpoint
2002SpeedPickUp2 2132IMOrAllSpeedGov 2350FuelQuantity
2003SpeedPickUp1Value 2133IMGovAtMaxOrIdle 2353FuelQuantityCorr
2004SpeedPickUp2Value 2134IMFuelSetOrGovernor 2360FuelConsumption
2005ActivePickUp 2135IMSetpoint 2361FuelEconomy
2025SpeedGradient 2140TorqueSetpoint 2400Can:Online
2031SpeedSetp 2141TorqueReserveMax 2401Can:RxTelActive
2032SpeedSetpRamp 2142TorqueReserveCurve 2402Can:RxTelTimeOut
2033SpeedSetpSelect 2143TorqueLimitMax 2403Can:RxTelVoltTimOut
2041DigitalPotOffset 2144TorqueLimitCurve 2404Can:RxIRCount
2100P_CorrFactor 2145TorqueLimitCurveAct 2405Can:TxIRCount
2101I_CorrFactor 2150EngineBrakeActive 2406Can:BusOffCount
2102D_CorrFactor 2251LimitsDelay 2407Can:RxBufOverflow
2110FuelSpeedGovernor 2280GlowPlugActive 2408Can:Tx0BufOverflow
2111SpeedGov:P-Part 2281FlameGlowPlugActive 2409Can:Tx1BufOverflow
2112SpeedGov:I-Part 2282FlameValveActive 2410Can:FragBufOverflow
2113SpeedGov:D-Part 2283PreheatActive 2411Can:SetpointPhase
2115StaticCorrActive 2284PostheatActive 2412Can:SetpointError
2120DroopPresent 2285StartReadActive 2533FuelTempFuelCorr

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2600EngineNo:Low 2730SetpLimitCan 2852DigitalOut2

2601EngineNo:High 2731SetpLimitVelocity 2853DigitalOut3
2602FunctionSetNo:Low 2740Setp1Source:Analog 2854DigitalOut4
2603FunctionSetNo:High 2741Setp1Source:PWM 2855DigitalOut5
2604CanSetNo:Low 2742Setp1Source:Subst 2856DigitalOut6
2605CanSetNo:High 2743Setp1Source:Can 2857DigitalOut7
2606ASAP2SetNo 2750CurrSetp:Setpoint1 2861DigitalOut1State
2607SerdiaID:Low 2751CurrSetp:Setpoint2 2862DigitalOut2State
2608SerdiaID:High 2752CurrSetp:SpeedFix1 2863DigitalOut3State
2609SerdiaDate:Day 2753CurrSetp:SpeedFix2 2864DigitalOut4State
2610SerdiaDate:Month 2754CurrSetp:Freeze 2865DigitalOut5State
2611SerdiaDate:Year 2755CurrSetp:FreezeSetp 2866DigitalOut6State
2612EOLDate:Day 2756CurrSetp:HoldButton 2867DigitalOut7State
2613EOLDate:Month 2757CurrSetp:MinButton 2868StatusErrorLamp
2614EOLDate:Year 2758CurrSetp:MaxButton 2900Setpoint1Extern
2701FuelLimitMax 2759CurrSetp:CalIdle 2901Setpoint2Extern
2702FuelLimitStart 2761CurrSetp:VeloIdle 2902BoostPressure
2703FuelLimitSpeed 2810SwitchDroop2 2903OilPressure
2704FuelLimitBoost 2811SwitchDroopCurve 2904CoolantTemp
2705FuelLimitSimBoost 2812SwitchSpeedFix1 2905CharAirTemp
2706FuelLimitVelocity 2813SwitchSpeedFix2 2906FuelTemp
2707FuelLimitCan 2814SwitchSpeedLimit2 2920BoostPressureCorr
2710FuelLimitMinActive 2815SwitchSpeedLimit3 2921FuelTempCorr
2711FuelLimitMaxActive 2816SwitchGovernIMOrAll 2930AmbientPressure
2712StartLimitActive 2817SwitchFreezeSpeed 2931AmbientPressActive
2713SpeedLimitActive 2818SwitchFreezeSetp 3000ConfigurationError
2714BoostLimitActive 2819SwitchOilLevel 3001ErrPickUp1
2715SimBoostLimitActive 2820SwitchCoolantLevel 3002ErrPickUp2
2716VelocityLimitActive 2821SwitchSpeedInc 3003ErrVelocity
2717CanLimitActive 2822SwitchSpeedDec 3004ErrOverSpeed
2720SpeedLimit1Active 2823SwitchMinButton 3005ErrSetp1Extern
2721SpeedLimit2Active 2824SwitchMaxButton 3006ErrSetp2Extern
2722SpeedLimit3Active 2825SwitchHoldButton 3007ErrBoostPressure
2723ReduceCan 2826SwitchBrake 3008ErrOilPressure
2724ReduceOilPressure 2827SwitchNeutral 3009ErrCoolantTemp
2725ReduceCharAirTemp 2828SwitchGlowPlug 3010ErrCharAirTemp
2726ReduceCoolantTemp 2829SwitchEngineStop 3011ErrFuelTemp
2727ReduceAmbientPress 2851DigitalOut1 3030ErrOilPressWarn

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3031ErrCoolantTempWarn 3099EEPROMErrorCode 3178S1ErrRAMTest

3032ErrCharAirTempWarn 3101S1ErrPickUp1 3180S1ErrPowerCurrent
3033ErrOilLevelWarn 3102S1ErrPickUp2 3183S1ErrRef1
3034ErrCoolantLevelWarn 3103S1ErrVelocity 3184S1ErrRef2
3035ErrWarnSpeed 3104S1ErrOverSpeed 3185S1ErrRef4
3036ErrFuelTempWarn 3105S1ErrSetp1Extern 3186S1ErrIntTemp
3040ErrOilPressEcy 3106S1ErrSetp2Extern 3187S1ErrAmbPressure
3041ErrCoolantTempEcy 3107S1ErrBoostPressure 3190S1ErrData
3042ErrChargeAirTempEcy 3108S1ErrOilPressure 3193S1ErrStack
3043ErrOilLevel 3109S1ErrCoolantTemp 3194S1ErrIntern
3044ErrCoolantLevel 3110S1ErrChargeAirTemp 3201S2ErrPickUp1
3050ErrFeedback 3111S1ErrFuelTemp 3202S2ErrPickUp2
3052ErrRefFeedback 3130S1ErrOilPressWarn 3203S2ErrVelocity
3053ErrActuatorDiff 3131S1ErrCoolTempWarn 3204S2ErrOverSpeed
3059ErrFeedbackAdjust 3132S1ErrChAirTempWarn 3205S2ErrSetp1Extern
3060ErrDigitalOutput3 3133S1ErrOilLevelWarn 3206S2ErrSetp2Extern
3062ErrDigitalOutput7 3134S1ErrCoolLevelWarn 3207S2ErrBoostPressure
3063ErrOverCurrentOD3 3135S1ErrWarnSpeed 3208S2ErrOilPressure
3067ErrHardwSetp1 3136S1ErrFuelTempWarn 3209S2ErrCoolantTemp
3068ErrCanSetp1 3140S1ErrOilPressEcy 3210S2ErrChargeAirTemp
3070ErrCanBus 3141S1ErrCoolantTempEcy 3211S2ErrFuelTemp
3071ErrCanComm 3142S1ErrCharAirTempEcy 3230S2ErrOilPressWarn
3076ErrParamStore 3143S1ErrOilLevel 3231S2ErrCoolTempWarn
3077ErrProgramTest 3144S1ErrCoolantLevel 3232S2ErrChAirTempWarn
3078ErrRAMTest 3150S1ErrFeedback 3233S2ErrOilLevelWarn
3080ErrPowerCurrent 3152S1ErrRefFeedback 3234S2ErrCoolLevelWarn
3083ErrRef1 3153S1ErrActuatorDiff 3235S2ErrWarnSpeed
3084ErrRef2 3159S1ErrFeedbackAdjust 3236S2ErrFuelTempWarn
3085ErrRef4 3160S1ErrDigitalOut3 3240S2ErrOilPressEcy
3086ErrIntTemp 3162S1ErrDigitalOut6 3241S2ErrCoolantTempEcy
3087ErrAmbPressure 3163S1ErrOverCurrentOD3 3242S2ErrCharAirTempEcy
3090ErrData 3167S1ErrHardwSetp1 3243S2ErrOilLevel
3093ErrStack 3168S1ErrCanSetp1 3244S2ErrCoolantLevel
3094ExceptionNumber 3170S1ErrCanBus 3250S2ErrFeedback
3095ExceptionAddrLow 3171S1ErrCanComm 3252S2ErrRefFeedback
3096ExceptionAddrHigh 3174S1ErrCanPassive 3253S2ErrActuatorDiff
3097ExceptionFlag 3176S1ErrParamStore 3259S2ErrFeedbackAdjust
3098ErrorActive 3177S1ErrProgramTest 3260S2ErrDigitalOut3

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3262S2ErrDigitalOut6 3541AnalogIn4_Value 3844SerialDate

3263S2ErrOverCurrentOD3 3550TempIn1 3845SerialNumber
3267S2ErrHardwSetp1 3551TempIn1_Value 3847BootDevelopmVersion
3268S2ErrCanSetp1 3560TempIn2 3850Identifier
3270S2ErrCanBus 3561TempIn2_Value 3851LastIdentifier
3271S2ErrCanComm 3570TempIn3 3865CalculationTime
3274S2ErrCanPassive 3571TempIn3_Value 3870Timer
3276S2ErrParamStore 3600ServoCurrrent 3895RAMTestAddr
3277S2ErrProgramTest 3601PowerSupply 3896RAMTestPattern
3278S2ErrRAMTest 3603Reference1+5V 3897CStackTestFreeBytes
3280S2ErrPowerCurrent 3604Reference2+5V 3898IStackTestFreeBytes
3283S2ErrRef1 3605Reference4+5V 3905ServoPIDCorr
3284S2ErrRef2 3606IntTemp 3906ServoStateStatic
3285S2ErrRef4 3700StartCounter 3916ServoCurrentSetp
3286S2ErrIntTemp 3701WorkingHours 3917ServoCurrentCorr
3287S2ErrAmbPressure 3702WorkingSeconds 3944EMR1ActuatorActive
3290S2ErrData 3720LoadWorkMap:h 3950Feedback
3293S2ErrStack 3730LoadWorkMap:s 3955FeedbackReference
3294S2ErrIntern 3740ElectronicTemp:T 3960FeedbackCorrection
3300Velocity 3745ElectronicTemp:h
3350EGRValveActive 3750ElectronicTemp:s
3351EGRFuelFilter 3800EmergencyAlarm
3352EGRBoostLimitActive 3801CommonAlarm
3353EGRFuelActive 3802EngineStop
3354EGRCoolantActive 3803EngineStopped
3355EGRAmbientActive 3804EngineStarting
3356EGRMapActive 3805EngineRunning
3500PWMIn1 3806EngineReleased
3501FrequencyIn1 3810ButtonActive
3502PWMIn2 3821EEPROMAccess:ISO
3503FrequencyIn2 3823EEPROMAccess:Button
3510AnalogIn1 3827EEPROMAccess:Memory
3511AnalogIn1_Value 3828EEPROMAccess:Work
3520AnalogIn2 3830Phase
3521AnalogIn2_Value 3840HardwareVersion
3530AnalogIn3 3841AddHardwareVersion
3531AnalogIn3_Value 3842SoftwareVersion
3540AnalogIn4 3843BootSoftwareVersion

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3.3 DATA LOGGER (ONLY EMS2)

The screen for this menu item can only be selected if an EMS2 has been selected as the control unit.

3.4 INPUT/OUTPUT ASSIGNMENT

The inputs and outputs can be configured. This menu item displays the current input and output assignment.
Limitation:
EMR1 and EMS2 control units only.

3.5 CAN STATUS

This window displays the CAN bus activities of the EMR1 or EMR2.

EMR1 EMR2

• Sent: Contains the information Can:TxCounter (0 to 65535, word). The value is increased with every CAN send mes-
sage and displays the sending activity of the EMR1.
• Received: Contains the information Can:RxIrCounter (0 to 65535, word). The value is increased with every CAN send
message and displays the sending activity of the EMR1.
• Bus off: Counter indicating how often the EMR1 has disconnected from the CAN bus because of continuous errors
(CanBusOffCounter 0 to 255, bytes).
• Status: CanOnline indicates whether the EMR1 is active on the CAN bus. A value 1, for online and a value 0, for offline,
is sent via the ISO 9141 interface. The SERDIA program displays the text "online" (for value 1) or "offline" (for value 0).

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SERDIA MEASURED VALUES

• Phase: The variable CanSetPointPhase (0 to 255, bytes) is sent via the ISO 9141 interface. This variable displays the
time sequence of the setpoint value specification:
Code Text
0 0:Engine standstill, initialization
1 1:Engine standstill, phase 1, no CAN error
2 2:Engine standstill, phase 2, no CAN timeout error
3 3:Engibe start, ... until idling speed is recognized
4 4:Engine runs, wait for CAN setpoint
5 5:Engine runs, setpoint preset via CAN is allright
6 6:Engine runs, emergency op., setpoint preset via CAN failed
7 7:This phase doesn't exist

ERROR INFORMATION/EVENT COUNTER:

The EMR1 sends an error number CanErrorNumber (0 to 255, bytes) via the ISO 9141 interface specially for CAN bus errors.
In SERDIA, these numbers are assigned a text, which is displayed in the window of the -CAN interface.
Cod. Testo
0 0: No fault existing
1 1: Message request not received at controller object 15
2 2: Invalid controller object
3 3:Engine start, ... until idling speed is recognized
4 4: CAN active, but no message activated
5 5: Diagnosis object not activated
6 6: Scan rate 0 in diagnosis message
7 7: Scan rate 0 in measure value telegram
8 8: preset engine speed config.6 does not match TSC2 activation
9 9: TSC1 activated, but ´Setpoint eng. speed´ not set to ´6´
10 10: ´GovernConf=6´,neither TSC1 nor function shift is activated
11 11: ´GovernConf=6 & Setp.eng.speed=6´, but TSC1 is not activated
12 12: TSC1 activated, but ´Governor config!=6´
13 13:TSC1NotAct&FunctShiftAct&´GovernConf.!=6´=>´ShiftMGovernMode!=0´
14 14:TSC1Act&FunctShiftAct&´GovernConf.=6´=>´ShiftMaskGovernMode!=0´
100 100 Receipt message failed
101 101 Setpoint telegram failed w.eng.idle (repl. value)
102 102 Setpoint telegram missing w.eng.idle due to low battery voltage
103 103 Setpoint telegram missing after eng.start due to low battery
104 104 Setpoint telegram missing after eng.start, repl.value used
105 105 Setpoint telegram missing during eng.oper., repl.value used

TimeOut errors for receipt messages require special treatment. They are all reported with an error number of 100.
To identify which message is causing a time-out error, SERDIA proceeds as follows:
• CanRxObjActive displays, in bit mode, the active messages, i.e. the messages that have actually been received.
• CanConf_bits contains the configured receipt messages, in bit mode.

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SERDIA MEASURED VALUES

SERDIA rejects CabRxObjActive in bit mode (inactive message) and then carries out a bit-mode AND logic operation with
CanConf_bits. The receipt messages which are configured and inactive (CanRxTimeOutBits) are received in bit mode as
a result.
A text is assigned to each bit of CanRxTimeOutBits; this text contains the name of the respective receipt messages. Be-
cause not all bits have to be used, entering "dc", for "don't care" into the text specifies that the text output for this bit is sup-
pressed.
If the text "100 receipt message failed" appears, a list of the missing receipt messages will also be output.

Example of displayed error information:

100 Receipt message failed
Engine Temperature
Engine Fluid Level /Pressure
Function shift
Inlet / Exhaust Conditions
VanRxTimeOutBit Text
0 Engine Temperature
1 Inlet / Exhaust Conditions
2 Engine Fluid Level /Pressure
3 TSC1
4 Engine protection
5 Function shift

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SERDIA PARAMETERS

4. PARAMETERS
4.1 CONFIGURATION (GENERAL)
IMPORTANT:
1 - For safety reasons, the original data set should be saved before making any changes.
2 - Engine running tests are allowed for PID parts only, and should only be carried out by suitably qualified personnel.
3 - Incorrect settings may cause damage to the engine!

CONFIGURATION PROCEDURE
Select the "Parameters" menu on the menu bar to go into the "Configuration" screen. A configuration is carried out in the
following steps:
• On the top line, click on the tab for the desired page or
• Using the "Next" and "Previous" buttons, browse to the page that contains the parameter to be set (For example: ’Ac-
cPedal (SWG1)up. ref’ on page 10: Setpoint gen. calibration values).
• Click in the "New value" field, and enter the required value. This should be between the indicated minimum and max-
imum values.
• Click on the "PC->ECU" button. All configuration data are transferred to the control unit. The data are now in the control
unit and can be used for testing the engine setting. When the supply voltage is switched off, this data is lost.
Next step
• using the "Save in ECU" button, save the data set in the control unit (the old data are overwritten).
• For checking, the data can be read and displayed by clicking the "ECU->PC" button.
• When the engine is running satisfactorily, click on the "Save in file" button to save the data on hard disk or diskette.

DESCRIPTION OF SCREEN BUTTON:

• CENTR.->PC: Configuration data are read from the control unit and displayed.
• PC->CENTR.: Modified configuration data are transferred into the control unit. In the case of the EMR1, the "Save in
ECU" button must be used to store the data permanently.
• Open file: Configuration data are read from a file (*.hex) and displayed.
• Save in file:
All configuration data are stored in a file (*.hex). When saving, the engine number is prompted as the file name - this is
only a suggestion.
Any other name can be entered. Finally, click OK to confirm.
The file (i.e. the engine data set) is then saved under the name <Engine number>.hex.

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SERDIA PARAMETERS

• Save in ECU (EMR1 only): The configuration data are stored in the control unit.
ATTENTION!
• All modifications must be reported back!
• The reporting procedure is described in Service Announcement 0199-99-9287.
• Previous: The data on the previous screen are displayed.
• Next: The data on the next screen are displayed.
• Print: Print the displayed configuration data on the printer. The configuration window can be printed page by page, or
in sets (from Page ... to Page ...), or in full.

4.2 OVERALL PROGRAMMING

Saving data from the control unit:
• By clicking "ECU->file“ menu, read the data from the control unit. The "Save as" window opens.
• Save the data under any name, in the form <Filename>.hex.
The default name <Engine number>.hex is suggested; this can be replaced by any other name.
Confirm by clicking OK. The file (i.e. engine data set) is saved under the selected filename.

Overall control unit programming.

• Click on the "Programming" button; the "Open" window appears.
• Select the desired file and open it.
• Click on the "Save in ECU" button.

Of the configuration data, only the operating data read from the control unit (Column 2) or file (Column 3) are displayed. Be-
fore the configuration data are transferred to the control unit, the operating data can be edited in Column 4. This data is also
transferred to the control unit along with the configuration data.
Overall programming is not allowed at user Level I or II.
EMR1 EMR2

DESCRIPTION OF SCREEN BUTTON:

• ECU->file: Configuration data are read from the control unit, displayed, and saved as a HEX file.

PROGRAMMING:
The modified configuration data, or the configuration data HEX file, is transferred to the control unit. In the case of the
EMR1, the "Save in ECU" button must be used to store the data permanently.
• Save in ECU: Configuration data are permanently stored in the control unit.

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SERDIA PARAMETERS

4.2 CALIBRATION
System components can only be calibrated through the diagnostic interface. The SERDIA diagnosis software is required
for the calibration. Along with the EMR1, the accelerator pedal and hand throttle potentiometer (if present) must also be cal-
ibrated (does not apply to large assemblies).
Important conditions:
• Engine off
• Supply voltage (Ignition/Circuit 15) on
• Integrated accelerator pedal

EXPLANATION OF CONCEPTS (EXAMPLES):

• Acceler(SWG1) = Acc. pedal sensor (position sensor 1), Input 24 FS
• Hand throttle(SWG2) = Hand throttle pot. (position sensor 2), Input 20 FS

GENERAL CALIBRATION PROCEDURE:

• Select calibration value in the upper window.
• Place accelerator pedal/Manual throttle potentiometer in the desired position.
• "Get value“ button enabled: Click the button. The calibration value assigned to the position appears in the Edit field.
• "Get value“ button disabled: Enter the calibration value in the Edit field.
• By clicking "PC->ECU", transfer the calibration value to the control unit.
• By clicking "Save in ECU", save the calibration value in the control unit.
• Switch the ignition on and off.

SCREEN BUTTON DESCRIPTION:

• Get value: If the "Get value" button is enabled, it can be used to read the calibration value for a pedal position.
• PC->ECU: The displayed calibration value is transferred to the control unit.
• Save in ECU: The calibration data are permanently stored in the control unit.

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SERDIA ERROR MEMORY

5. ERROR MEMORY
5.1 GENERAL
The error memory lists the diagnosable errors that have occurred since the last deletion. The current contents of the error
memory can be displayed by selecting the menu item "Error memory".

If errors have been eliminated, the corresponding error messages can be deleted from the "Error memory" window :
• Display the error memory's error messages by clicking on the button "Read EM".
• In the "Error location" window, mark the displayed error location with the mouse.
(Example: "8112:(M17)Rack travel sensor"). The background of the error location text becomes blue.
• Click on "Clear EM". The error location will be deleted, the message will disappear.
• Exit the "Error memory" by clicking on "Close".

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SERDIA ERROR MEMORY

DESCRIPTION OF THE FIELDS:

• Error location: List of error locations from which an individual error location can be selected for detailed information.
Because there can be several causes of error for some components, this list may list some error locations several times.
For example, oil pressure monitoring: Power rating and switch-off limit.
• Type of error: All the information contained in this field refers to the error location selected in the top field.
• Environment data: Additional details (e.g. measured values) which contain more information on the selected error lo-
cation.
• Total no. of errors: Sum of all recorded error locations.
• Frequency: Frequency at which the selected error location occurs.
• Error status: Selected error active or passive.

EXPLANATION OF THE FUNCTION BUTTONS:

• Read EM: This function button is used to read out the error memory again from the control unit and the display is up-
dated.
• Clear EM: This function button sends a request to the control unit to delete the error memory

5.2 ERROR TABLE

5.2.1 EMR1 ERROR TABLE
8002:(F18)Signal monitoring PWM-Inp1
8012:(F21)Signal monitoring PWM-Inp2
8020:ECU (positioner actuation)
8030:shutoff magnet
8112:(M17)Rack travel sensor
8120:(F24)AccelerPedal(SWG1)
8130:(F20)HandThrottle(SWG2)
8140:(M9)CoolantTempSensor
8150:(M24)BoostPressureSensor
8160:(M21)OilPressureSensor
8170:(M13)Speed 1, camshaft
8180:(M11)Speed 2, terminal W
8190:(intern)ElectronicsTemperature
81A0:(M11)Engine speed sensor
8210:Data loss EEPROM
8220:Data loss coil data
8230:EDC calibration error
8305:Speed monitoring
8343:Coolant temp. monitoring
8345:Eng.OFF->CoolantTempMonit
8363:Oil pressure monitoring
8365:Eng.OFF->OilPressMonit
8405:Actuator (positioner, travel meter, fuel rack)
8500:ISO-Bus-Error
8600:CAN-Bus-Error
The possible types of error are:
(0) Broken cable or short-circuit
(1) Broken cable or short-circuit
(2) Measuring point defective
(3) Power reduced
(4) Limit exceeded, power reduction activated
(5) Shutoff limit exceeded/ fallen below

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SERDIA ERROR MEMORY

The following table can be used to assist in the elimination of possible causes of errors which have occurred. When doing
this, the status of the fault indicator must be noted:
• Permanent light: Error statuses permitting limited engine operation. The error must be eliminated as quickly as possible
to avoid further damage.
• Flashing light: Error statuses resulting in the engine being shut off or preventing the engine from being started. The error
must be eliminated so that the engine can be put back into operation.

ERROR MESSAGES, CAUSES AND REMEDIES

Error messages (only readable with Serdia) Possible causes Remedy
Error pilot lamp Type n.
of Error location
error O.K.
Plug-in connection inter-
8120:(F24)AccelerPedal(SWG1)1 rupted Restore plug-in connection

8130:(F20)HandThrottle(SWG2)2 OK
Plug-in contacts contam- Clean connector and replace
8140:(M9)CoolantTempSensor3 inated or corroded if necessary
8150:(M24)BoostPressureSensor OK
(0)
8160:(M21)OilPressureSensor Sensor defective Replace sensor
8170:(M13)Speed 1, camshaft4 OK
Check cable harness and re-
8180:(M11)Speed 2, terminal W Cable harness defective place if necessary
8190:
Permanent light (intern)ElectronicsTemperature
(Engine opera- 8002: PWM signal cannot be
tion restricted) Check signal
(F18)Signal monitoring PWMInp1 evaluated
(2)
8012:
(F21)Signal monitoring PWMInp2

Temperature warning limit

exceeded too long. Fallen Check coolant
below oil pres-sure alarm Check oil level
(3)5 8343:Coolant temp. monitoring limit for too long.
8363:Oil pressure monitoring
Check data in SERDIA menu
Faulty configuration. Check ”configuration” and
change if necessary

(5)6 8305:Speed monitoring Overrun cond. activated.

Plug-in connection Restore plug-in connection

interrupted
OK
Plug-in contacts Clean connector and replace
contaminated or corroded if necessary
Flashing 8170:(M13)Speed 1, camshaft7
(Engine off) (0) OK
Sensor defective Replace sensor
OK

Cable harness defective Check cable harness and

replace if necessary

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SERDIA ERROR MEMORY

Plug-in connection
interrupted Restore plug-in connection

OK
Plug-in contacts Clean connector and replace
contaminated or corroded if necessary
(2) 8112:(M17)Rack travel sensor OK
Actuator defective Replace actuator
OK
Check cable harness and
Cable harness defective replace if necessary
Flashing
(Engine off) 8305:Speed monitoring Overspeed reached

Temperature alarm limit

8345: exceeded for too long. Check coolant
Eng.OFF->CoolantTempMonit. Fallen below oil pres-sure Check oil level
alarm limit for too long.
(5) 8365:
Eng.OFF->OilPressMonit Check data in SERDIA menu
Faulty configuration ”Configuration” and change
(e.g. overrun cond. OFF). if necessary
8405:Actuator (positioner, travel Actuator defective Replace actuator
meter, fuel rack)
(Engine start not 8210:Data loss EEPROM Check battery
possible) Battery or cable harness
(0) 8220:Data loss coil data
defective, ECU failure
Check cable harness
8020:ECU (positioner actuation) Replace ECU

Error in central electron-

a) Flashing ics, pro-gram in EMR was Replace ECU
not executed

b) Flashing or Plug-in connection inter-

Permanent light rupted Restore plug-in connection

c)Off OK
Plug-in contacts Clean connector
(0) 8170:(M13)Speed 1, camshaft7 contaminated or corroded and replace if necessary
OK
Actuator defective Replace actuator
OK
Check cable harness and re-
Cable harness defective place if necessary

8405: Actuator (positioner, travel Actuator defective

(5) meter, fuel rack)
Replace actuator

1 Switch to SWG 2 (if SWG 2 available). Fixed speed with 2% speed droop is set.
2
Switch to SWG 1 (if SWG 1 available). Fixed speed with 2% speed droop is set..
3
Electronics temperature is evaluated.
4 Continued running with reduced rated speed, if speed sensor 2 is available.
5
Injected fuel limitation (if activated).
6
The measured value exceeds maximum speed.
7 Speed sensor 2 not available or defective.

It is recommended to use a multimeter as measurement aid.

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PAGE INTENTIONALLY
LEFT BLANK
 5.1.2 EMR2 ERROR TABLE
Ricon. Blink codee
Fault no.
Fault locality/ EMR SERDIA
Fault group (in Cause Remarks Help
SERDIA) Fault description short long horts
0,4 s 0,8 s 0,4 s
Zero error - No faults 2 - - No active faults present
display
Governor in emergency operation Check distance.
(if sensor 2 available). Check cable connection.
01 Speed sensor 1 2 1 1
Emergency switchoff (if sensor 2 Check sensor and replace if re-
Sensor failure. quired.
Distance from gear too far. not available or failed).
Additional fault impulses. Governor in emergency operation
Cable joint interrupted.
(with sensor 1)
Speed sensor 2 2 1 2
Emergency switchoff (if sensor 1
not available or failed).
Tacho failed. Check cable connection
Revolutions 03 Speed sensor 2 1 3 Additional fault impulses. Governor in emergency operation. and tacho.
/ speed Cable connection interrupted. (see Chapter 4.15). Replace if required.
acquisition
Check parameter (21).
Check speed settings.
Check PID setting.
Check rods.
Check actuator and replace if
04 Excess speed switch 2 1 4 Speed was/is in excess of limit. e. Engine stop. (see Chapter 4.3.3) required.
Check cable to actuator (
impulse on incorrect speed).
Check no. of teeth.
For vehicles check for possible
thrust mode.
Set point sensor 1
05 accelerator pedal) 2 2 1

Set point sensor 2

06 (hand throttle) 2 2 2
See Chapter 4.15 influencing fault Check sensor cable.
07 Charge air pressure 2 2 3 Fault at corresponding reaction. Check sensor and replace if
Sensors 08 Oil pressure 2 2 4 sensor entry With failure of the sensor, the required.
(e.g. short circuit or cable break). associated monitoring function is Check fault limits for sensor.
09 Coolant temperature 2 2 5 de-activated.
Charge air
10 temperature 2 2 6

11 Fuel temperature 2 2 7

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EMR2 ERROR TABLE
 After a delay time - fill limitation.
Oil pressure below Fault message (disappears Check engine (oil level, oil pump).
30 Oil pressure warning 2 3 1 speed-dependent when oil pressure is again Check oil pressure sensor

SERDIA
warning line characteristic above recovery limit). and cable.

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Check oil pressure warning line
characteristic.
Fault message (disappears when Check coolant.
Functional 31 Coolant temperature 2 3 2 Coolant temperature has coolant temperature again drops Check coolant
fault warning exceeded warning level. below recovery level). temperature sensor
warning After a delay time - fill limitation. and cable.

Charge air Fault message (disappears when Check charge air.

32 temperature 2 3 3 Charge air temperature charge air temperature again drops Check charge air temperature
warning has exceeded warning level. below recovery level). After a delay sensor and cable.
time - fill limitation.

Switch input “Low coolant level” is Check coolant level.

34 Coolant level warning 2 3 5 active. Fault message. Check coolant level sensor and
cable.
Check parameters.
Check speed settings (21).
Check PID setting.
Check rods.
Speed warning (with Revolution was/is above (top) Check actuator and replace if
35 thrust mode 2 3 6 revolution speed limit. See Chapter 4.3.3 required.
operation). “Thrust mode” function is active. Excess speed protection. Check cable to actuator.
Check speed sensor (impulses
on incorrect speed).
Check no. of teeth.
For vehicles check for possible
thrust mode.
Guasti
funzionali,
avvertenza

Fault message (disappears when Check fuel.

36 Fuel temperature 2 3 7 Fuel temperature has exceeded fuel temperature again drops Check fuel temperature
warning warning level. below recovery level). sensor and cable.
EMR2 ERROR TABLE
 Emergency stop
Check engine (oil level, oil pump).
Oil pressure switch Check oil pressure sensor
40 off 2 3 1 Oil pressure below switch-off limit and cable. SERDIA
Check oil pressure switch-off
limit.
Check coolant level.
Coolant temperature Coolant temperature has Emergency stop. Check coolant level sensor and
Functional 41 2 3 2
fault, switch-off exceeded switch-off limit. cable.
switch-off Check switch-off limit.
Check charge air.
Charge air tempera- Charge air temperature has Check charge airtemperature
42 ture switch-off 2 3 3 exceeded switch-off limit. sensor and cable.
Check switch-off limit.
Check coolant level.
44 Coolant level 2 3 5 Switch input “Low coolant level Emergency stop. Check coolant level sensor and
switch off is active. Start lock. cable.
Check actuator, replace if
required.
50 Feedback Check cable, check
Actuator not connected. Emergency switchoff. “Confirmation”.
Fault in actuator confirmation. Actuator cannot be operated. Check actuator, replace if
required.
52 Reference feedback 2 5 1 Check cable, check fault limits
for “Rifeness confirmation”.
Injection pump/actuator jammed Check actuator/
or not connected. actuator rods /
53 Control travel Difference between nominal/actual Fault message (disappears when injection pump,
difference control travel is > 10 % of the overall difference is < 10 %). replace if required
Actuator control path. Check actuator cable.
Check actuator and replaced
if required.
Check feedback cable.
Check voltage supply/cables.
Check fault limits and reference
Auto calibration No automatic actuator equalization Engine stop / start lock. values of the feedback.
59 BOSCH-EDC pumps 2 5 2 possible. Governor cannot be taken into use. Program the fault limits for
faulty operation Incorrect input of the actuator EDC actuator calibration required feedback, save values.
reference values. (see Chapter 8.4). Switch ignition off and on again.
Check again.«If faulty, inform
DEUTZ-Service and carry out
automatic equalization again.
Set fault limits again.

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EMR2 ERROR TABLE
 Digital output 3
60 (Switch-off solenoid, 2 6 1 Driver level is switched off.
pin M 2) Fault (short circuit /cable break) Check cable of digital output

SERDIA
at digital output. (cable break or short circuit).

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62 Digital output 6, 2 6 2 Fault message.
pin M 7
Hardware
inputs/outputs Excess voltage
63 2 6 1
switch-off solenoid

67 Error Hand Setp 1 2 6 2

68 Error CAN Setp 1 2 6 2

CAN-controller for CAN-bus
is faulty.
70 CAN-Bus controller 2 7 1 Check CAN connection,
Fault removal despite reinitialising
Communication continuously not possible Applicationdependent. terminating resistor
(see Chapter 12.4).
Overflow nel buffer di ricezione Check control unit.
CAN interface
71 SAE J 1939 oppure non è possibile un invio
tramite bus.
Parameter Fault in parameter programming in
76 programming the governor fixed value memory.
(write EEPROM) Switch ignition off and on again.
Check again. If faulty inform
Constant monitoring of program DEUTZ Service
77 Cyclic program test 2 8 1 memory shows error Emergency switchoff. engine
Memory (socalled “Flash-test”). cannot be started.
Note values of parameters
Constant monitoring of working (3895 and 3896).
78 Cyclic RAM test memory shows error. Switch ignition off and on again.
Check again.
If faulty inform DEUTZ Service.
Switch ignition off and on again.
80 Power supply 2 9 1 Power supply for actuator not Fault message (disappears when Check again. If faulty inform
(Actuator) in the permissible range. power again in the normal range). DEUTZ Service.

83 Reference voltage 1
Fault message (disappears when Check voltage supply.
84 Reference voltage 2 2 8 2 Reference voltage for actuator not power again in the normal range). Switch ignition off and on again.
in the permissible range. Auxiliary value 5 V Check again.
Control unit 85 Reference voltage 4 If faulty inform DEUTZ Service
hardware
Internal temperature for control unit Fault message (disappears when
86 Internal temperature not in permissible range. power again in the normal range).
Switch ignition off and on again.
Fault message (disappears when Check again. If faulty inform
Atmospheric Atmospheric pressure not in power again in normal range). DEUTZ Service.
87 pressure 2 9 2 permissible range. Atmospheric pressure monitoring
function de-activated.
EMR2 ERROR TABLE
 Check data for correct settings.
Parameter fault
No data found or checksum of data
Save parameters. SERDIA
is faulty (note: fault only occurs dur-
90 (EEPROM retrieval or 2 10 1 ing setting of parameter / saving or Engine cannot be started. Switch ignition off and on again.
checksum faulty). reset.). Check again. If faulty inform
DEUTZ Service.

Program logic

Note parameters (389 7 an d

Internal calculation fault (so-called Emergency switchoff. 3898).
93 Stack overflow 2 10 1 “Stack overflow” fault). Engine cannot be started. Switch ignition off and on again.
Check again. If faulty inform
DEUTZ Service.

94 Internal fault

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EMR2 ERROR TABLE
SERDIA EMR2 ERROR TABLE

5.1.3 ERROR MEMORY 2

This error memory has the same functions as the error memory described previously, however errors can only be read out,
displayed and deleted here with EMR2 and the interface for Level IIIa.

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SERDIA EXTRA

6. EXTRAS

6.1 MAXIMUM SPEED

This screen can be used to select from three different maximum vehicle speeds (30, 40, 50 km/h) (not implemented yet in
EMR2)..

6.2 LOGISTIC DATA

The screen is used to read and print the logistic data stored in the control unit.
EMR1/EMR2:
• Engine Serial Number
• Part number, EMR function data set
• Part number, ASAP2 data set
• Date, month and year of manufacture
• EMR2 only:
• Part number, CAN function data set
• Hours of operation
• Number of engine starts

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SERDIA EXTRA

Data can only be written and protected in the control unit by DEUTZ AG..

EMR2

6.3 LOAD SPECTRUM

This screen provides an overview of the engine speed and load ranges over which the engine has been operating.
Users with the higher authorisation levels may delete entries in the control unit.
Limitation: EMR2, EMS2 only

6.4 MAINTENANCE INTERVAL EXCEEDED

This screen shows maintenance intervals that have been exceeded. Users with higher authorisation levels can delete the
exceeded maintenance intervals.
Limitation: EMS2 only

6.5 OVERRIDE MEMORY

This screen shows, for certain measured quantities, any periods during which the engine was running in the alarm or shut-
off range. Users with higher authorisation levels can delete the entries in the control unit.
Limitation: EMS2 only

6.6 MAINTENANCE DATA

Limitation: EMS2 only

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SERDIA TASKS

7. TASKS
7.1 EMR1
During service operations, this button on the SERDIA main screen is used to show the screens for the individual con-
figuration tasks:
Diagnosis and Testing
• Meas. governor performance
• Meas. start manoev.
• Meas. monitoring functions
• Meas. boost pressure
• Meas. sensors
• Meas. veh. speed
• Meas. setpoint value input
• Meas. dig. inputs/outputs
Adjusting
• Set max. veh. speed
• Set idle speed
• Governor setting
• Set droop
• Define inputs and outputs
• Monitoring
Error memory
• Read/delete error memory

7.1.1 EXAMPLE GOVERNOR SETTING

Proceed as follows:
• Click on the "Tasks" button.
• Click on the "Adjusting:Governor setting" menu option. The "Governor setting" menu opens.

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SERDIA TASKS

Screen button functions:

• ECU->PC: Configuration data are read from the control unit and displayed.
• PC->ECU: Modified configuration data are transferred into the control unit. To store the data permanently, use the
"Save in ECU" button.
• Save in ECU: Configuration data are permanently stored in the control unit.

All modifications must be reported back!

The reporting procedure is described in Service Announcement 0199-99-9287.

• Graphics: The "Graphics" button can be used to see a graphical representation of the selected measurement quan-
tities over time (5 maximum). If more than 5 quantities are selected, an error message is displayed.
• Collect. time: The measurement collecting time is indicated in the "Collect. time" box, in seconds. The smallest unit of
collecting time is one second. The highest time may be several hours (specified in seconds). The basic setting is 10 s.
The shortest scan rate is
40 ms for RAM values
60 ms for other values.
A measurement time of 10 s gives
10000 ms/40 ms = 250 measurement points for RAM values
10000 ms/60 ms = 166 measurement points for other values.
Since the program takes around 2000 measurement points maximum, the scan rate is adapted automatically before
data collection begins.
The lowest possible scan is determined by the duration of data transfer from the control unit to the PC. The higher the
number of measured quantities to be displayed at the same time, the longer the data transfer time, and the narrower the
scan frequency.
• Print: Prints the measured values appearing on the screen.
• Close: Return to the "Tasks" menu.

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SERDIA TASKS

7.1.2 EXAMPLE SPEED DROOP SETTING

Proceed as follows:
• Click on the "Tasks" button.
• Click on the "Adjusting: Set droop" menu option. The "Droop setting" menu opens.

Screen button functions:

• ECU->PC: Configuration data are read from the control unit and displayed.
• PC->ECU: Modified configuration data are transferred into the control unit. To store the data permanently, use the
"Save in ECU" button.
• Save in ECU: Configuration data are permanently stored in the control unit.

All modifications must be reported back!

The reporting procedure is described in Service Announcement 0199-99-9287.

• Print: Prints the measured values appearing on the screen.

• Close: Return to the "Tasks" menu.

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7.1.3 DEFINE INPUTS AND OUTPUTS

Using the "Tasks" button, the possible assignments

1. are displayed with the right mouse button
2. allocated with the left mouse button
This screen also shows functions that can be inverted, and the measured values for all inputs and outputs (to view these,
click on the "Measurement" button).
This configuration feature is only present with Access Level III.

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8. WHAT TO DO IF...?

8.1 SERDIA GENERAL

8.1.1 ERROR WHILESETTING UP COMMUNICATIONS
If communications cannot be set up although the interface and control unit have been connected, an error message is dis-
played:

Possible reasons for the error message:

• No supply voltage to the control unit or interface.
• Voltage supply was cut when the engine was switched off.
• Incorrect assignment of serial interface on PC (see 9.1.2).
• Wrong pole connection on voltage supply from engine to interface.
• Not all of the 4 wires (+, -, k, l) are connected.
• Wrong control unit, or control unit faulty.
Remedy, quick checks:
• Yellow interface LED should light up when SERDIA is started.
• Measure the diagnostic connector supply voltage (the interface requires 8 - 28 V DC).
• In Windows, check the assignment of the serial interface (usually COM1).
• Connect another control unit.
Further information on operating voltages for control units, interface and PC:
• EMR control units require an operating voltage from 10 V to 30 V (typically 12-24 V).
Power consumption: 5 A at 12 V, 7 A at 24 V
• The MVS control unit takes a voltage of 24 V only.
• The interface is supplied by the engine and takes a voltage from 12 V to 24 V.
• The control units and interface are protected against wrong pole connection and overvoltage. However, an accidental
incorrect connection, to a 230 V source for example, can still cause damage.
• Using an interface with an integrated optical link, the PC (Notebook, and printer) can be connected to the vehicle battery
and ground with no risk for the control unit and interface, and no risk of loss of data.

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8.1.2 INTERFACE CONFIGURATION WITH ISETUP

On PCs, the COM1 interface may already be occupied by the mouse. In this case, the interface must be connected to the
other serial interface (COM2). This port can then be configured with ISETUP to allow it to communicate with the interface.
Proceed as follows:
• Start the ISETUP.EXE program.
• Select the other COM port and click OK.
The initialisation file ISODRV.INI is modified automatically.
• Re-start Windows.
Note: On many PCs, the second serial interface is the 25-pin type. In this case, a hardware adapter (25-pin to 9-
pin) must be inserted to allow connection of the 9-pin diagnostic interface.

8.1.3 ACCESS CONFLICTS IN WINDOWS 3.1

The ISODRV.386 interface driver can only be loaded statically. In the Windows SYSTEM.INI file, the ISODRV.386 driver is
entered in the [386Enh] section (with the working directory path). This may cause problems with other programs that ac-
cess the same serial interface.
Remedy:
• Start the ISETUP.EXE program.
• Delete the driver entry from the SYSTEM.INI file.
• Re-start Windows 3.11.

8.1.4 ERROR MESSAGE IN WINDOWS 3.11 WHEN STARTING SERDIA

When starting SERDIA in Windows 3.11, the following error message may appear:

This is because the VXDLDR.386 driver is not activated.

Remedy:
• Start the ISETUP.EXE program.
• Check the "Device VXDLDR.386 enabled“ checkbox and click OK to confirm.The appropriate driver entry is made au-
tomatically in the SYSTEM.INI file.
• Re-start Windows 3.11.

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8.2 EMR1

8.2.1 ENGINE SURGES

Fault finding:
Troubleshooting with the EMR1 is done in the same way as for engines with mechanical regulators, i.e. the engine com-
ponents and functions such as pump, control rod movement, fuel supply, etc, are examined. In most cases, especially if
the engine was running correctly before engine surges begin to occur, the fault does not lie in the EMR1.
Controller setting:
Controller setting is performed mainly for new operation modes, and should be thoroughly tested and documented with
the system (engine and installation) in all operating conditions.
If the new application is connected and enabled, the user-specific controller parameters must be confirmed with company
headquarters. Follower engines with the same operation mode do not usually require any additional adjustments.
Opening the menus:
SERDIA main menu -> Tasks menu -> Governor setting -> Execute

General rules for setting correction:

• Setting correction is carried out with the engine running.
• Raising the P/I/D parts increases the control tolerance range.
• Enter the value to be corrected in the "new value“ field. One way of doing this is
•select the old value with the mouse, then simply type in the new value (the old value is deleted automatically).
• Click on the "PC->ECU" button to send the new value to the control unit. The governor applies the new setting, and the
result will be detectable in the engine behaviour.
• After setting correction has been carried out successfully and before disconnecting the voltage supply (circuit 15), the
new parameters must be stored in the EMR1.
To do this, click on the "Save in ECU" button.

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Governor basic setting:

The control unit is programmed at the end of the band with the following standard values.

Standard value
Parameter (Variable) Comment
Assembly Vehicle
SpeedGvnr: P part 18-20 4,0 Basic setting gain factors for P/I/D parts.
These parameters are independent of engine
SpeedGvnr: I part 10,0 10,0
status (speed, load still active) and show the main
SpeedGvnr: D part 5-12 2,5 instruments for governor setting.

Lowering the governor parameter for the static

SpeedGvnr: damping 90,0 65,0 range.
Speed band around nominal value. Within this
SpeedGvnr: damping 15,0 80,0 speed band, the engine runs smoothly and with
range precision, and does not respond strongly to speed
variations.
PosGvnr: P part 10,0 10,0
PosGvnr: I part 10-15 5,0
PosGvnr: D part 5-10 5,0 Setting corrections should only be made after con-
PosGvnr: DT2 part 8,0 8,0 firming

SpeedGvnr: damping 160-180 180,0

SpeedGvnr: damping 0,25 0,25

Standard values may vary according to engine model and application

Standard values, speed and load dependent parameters:

3 performance maps for the P, I, and D part = fkt (speed, quantity injected)..

Parameter (Variable) Standard value Comment

X: Engine speed position values (r.p.m.) 60…2500 7 speed values
Y: Quantity position values (cmm/str) 0, 20 …100 4 injection quantity values
Total 3 x 28 entries. A 100 % entry causes the speed gov-
Map (%) 100 ernor PID parts to be accepted (Page 4). Corrections must
be made at the related measurement point. EMR1

Making a setting correction:

Before modifying any parameters, we recommend saving the current configuration using the "Save in file" menu option,
and/or printing configuration pages 4, 5 and 17.
The setting procedure consists of 3 stages:
1. PID governor basic parameters For the most part, the correction is made with the basic parameters.
• If a new governor basic setting is required, set all performance maps (Page 17) to 100%.
• The P part is the most important parameter and must be set first. Raise the parameter value for "SpeedGvnr: P part" by
10 % to begin with, until the engine accelerates under the the sudden load variation and vibration dips to f > 1 Hz. Then
reduce the P part again by 25 %.
Example: P part with vibration dip (unstable) = 12. 12-25 % of 12 = 9 (new setting value).
The setting depends heavily on weight moment of inertia (engine + generator). For weight moments of inertia up to
8kgm2 the value range for the P part is between 10 and 45 %.
At higher moments of inertia, the P part can be raised by up to 90 %.
Note regarding major engine assemblies:The optimum governor values are determined at operating speed with dif-
ferent loads. Note the P part determined for each, and enter the average in "SpeedGvnr: P part".
For double-frequency installations, the second frequency must be included in the average value calculation.
Note regarding vehicle engines:The optimum governor values are determined at several engine speed and load points.

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Note the P part determined for each, and enter the average in "SpeedGvnr: P part".
The different P parts given by the various load and speed points must be corrected in the PID performance map.
• The D and I parts (Page 4) are now set applying the same procedure, i.e. raising the values by 5 % first till unstable, then
reduce again by 25 %.
2. Parameters for static and dynamic operation.
Setting the "SpeedGvnr: damping“ and "SpeedGvnr: damping range“ parameters (Page 4).
The "SpeedGvnr: damping range“ parameter determines the speed band in which speed is in the static range. For ex-
ample, entering a value of 15 r.p.m. sets a +/-15 r.p.m. band around the nominal speed .
The "SpeedGvnr: damping" parameter determines the lowering of the governor parameter (PID parts) for the static
range, i.e. if the speed is within the speed band around nominal value, the governor parameter (PID parts) falls to the
value for the damping factor.
For example, SpeedGvr: P part =10 %
SpeedGvr: damping =65 %
This has the effect that, in the static engine condition of nominal speed range +/- damping range, the P part falls to 6.5
%. The aim of this step is that the engine will run smoothly and precisely within the speed band, without responding
strongly to slight speed changes. If the engine runs outside of the speed band due to a fault, the set governor pa-
rameters become effectively 100 % again and the governor will quickly correct the speed error as far as possible.
Standard settings - see "Governor basic setting". Setting corrections can only be made through the engine running
test.
3. Speed and load dependent parameters.
For the P, I, D basic parameters there are corresponding performance maps that depend on speed and injected
quantity (load) (Page 17). The effective parameters are determined by multiplying the basic parameter by the content
of the performance map.
For example, SpeedGvr: P part =10 %
Map P part =200 % at 2000 r.p.m. and 50 cmm/stroke
Result: For the given operating point, the P part becomes effectively 20 %.

8.2.2 ACCELERATOR PEDAL CALIBRATION

An accelerator pedal is usually designed as a foot pedal, operated by the driver of a vehicle. However, the input provided
for the accelerator pedal (vehicle connector Pin 24) can also be used as a remote input, like those used in locomotives and
ships. In all cases, calibration is required.
Calibration must be carried out both at initial startup (either by the customer or by service engineers), and whenever a re-
placement is made.
The accelerator pedal is not always supplied by DEUTZ AG. However, we recommend the pedal value sensor (DEUTZ Part
No. 0419 9457. Other accelerator pedals can also be installed by the customer, subject to confirmation with company head
office.
The following are then required:
• Connection as in EMR1 System overview:
Signal input (Pin 24/vehice connector) to GND (Pin 23/vehicle connector)
• Analog signal:
> 0.5 V (accelerator pedal in 'parked' position), for example 1 V
< 4.5 V (accelerator pedal at 'full throttle'), for example 4V
• The EMR1 provides a reference voltage at the vehicle connector (Pin 25, +5 V).
This reference voltage is also intended for the manual throttle potentiometer.
Therefore the total load current should not go over 25 mA if the pedal value sensor and manual throttle potentiometer
are arranged in parallel, (i.e. total resistance > 200 Ω .)
Calibrazione acceleratore per mezzo del menu "Calibrazione":
Accelerator pedal calibration using the "Calibration" menu:
Calibration is menu-driven. Both end stops "parked position" and "full throttle" are calibrated as limit values. See "General
procedure for calibration", Chapter ,"Calibration".
Accelerator pedal calibration using the "Measured values" and "Configuration" menus:
The aim of calibration is to inform the control unit of the limit values for the two end stops: "parked position" as the lower
and "full throttle" as the upper reference point. Also, the "upper fault value" (+5 % from upper reference point) and "lower
fault value" (-5 % from upper reference point) must be entered, relative to the two reference points.

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Parameter designations
Configuration screen Calibration screen Value

AccPedal(SWG1)up. err val. Acceler(SWG1)upper fault limit max. setpoint x 1.05+

[full throttle...5V]
Acceler(SWG1)full throttle
AccPedal(SWG1)up. ref max. setpoint
[pressed down, upper limit]
Acceler(SWG1)parked position
AccPedal(SWG1)lo. ref [lower limit] Pedal at rest = Idle

AccPedal(SWG1)lo. err val. Acceler(SWG1)lower fault limit Pedal at rest - 0.05 x max. setpoint
[0V...parked pos.]

Measuring the limit values:

• Open the "Measured values" menu, "Actual measured values".
• Measured value "(F24)Accelerator pedal=SWG1“: with pedal in parked position (lower reference) and pedal pressed
(lower reference), "Get value", transfer to the control unit and save.
Configuration:
• Open the "Parameters“ menu, "Configuration" option.
• Enter values, referring to the following example table ("Acc. pedal input configuration", see below).
Conversion: 5 V=1023 digits.

Example: Acc. pedal input configuration

Actual value/
Factory setting Calibration Configuration
Parameter measured value
mV digits mV mV digits
1
AccPedal(SWG1)up.err val. 4750 973 4357 893
AccPedal(SWG1)up. ref 4500 921 4150 4150 850
AccPedal(SWG1)lo. ref 500 102 670 670 137
2
AccPedal(SWG1)lo. err val. 250 51 463 95

1) Measured value "upper reference point" + 5 % (v. upper reference point)

2) Measured value "lower reference point" -5 % (v.lower reference point)

8.2.3 MANUAL THROTTLE CALIBRATION

The manual throttle (Pin 20 FS) is intended for vehicles such as agricultural machines. When ploughing, for example, a driv-
er can make the appropriate engine speed setting and then take his/her foot off the accelerator pedal. As with the me-
chanical adjusting levers, the manual throttle position must be set to zero (lowest engine speed) before starting the engine.
The manual throttle positioning is combined with the accelerator pedal and determines minimum speed. In proportion to
the preset nominal value, engine speed can be set between lower idle speed (for example 650 r.p.m.) and nominal engine
speed (for example 2300 r.p.m.). Depending on the manual throttle setting, the engine responds in the same way as to an
accelerator pedal. For example, if the speed is set with the hand throttle to 1500 r.p.m., accelerator pedal operation only
becomes effective at higher speeds than this.
Manual throttle positioning is not supplied by DEUTZ, but it still has to be programmed at the factory.
A potentiometer can be used as the adjusting link, and installed by the customer.
Requirements for manual throttle nominal value setting (potentiometer) when installed by customer:
• Input Pin 20 vehicle connector
• Potentiometer supply as pedal value sensor, 5V reference voltage Pin 25, and GND Pin 23.
• Loading reference voltage together with pedal value sensor < 25 mA.
• Protection system IP65
• End stops adjusted to between 10 % and 90 % of the potentiometer value.
For example, if potentiometer resistance = 1 k., the setting range between mechanical stops must then be between 100 Ω
and 900 Ω . This setting range can be achieved by
a) Narrowing the turning angle

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b) Series resistors in the supply lines.

Manual throttle calibration:

The two potentiometer end stops must be calibrated.
The aim of calibration is to inform the control unit of the limit values for the two end stops: "Potentiometer stop LI speed"
as the lower and "Potentiometer rated speed" as the upper reference point. Also, the "upper fault value" (+5 % from upper
reference point) and "lower fault value" (-5 % from upper reference point) must be entered relative to the two reference
points.

Parameter designations
Configuration screen Calibration screen Value
Hand throttle(SWG2)
Hand thr.(SWG2)up. err val. upper fault limit(upper limit...5V) Rated engine speed x 1.05+

Hand thr.(SWG2)up. ref Hand throttle(SWG2) Rated engine speed

max.eng. speed (upper limit)
Hand throttle(SWG2)
Hand thr.(SWG2)lo. ref Low idling engine speed
min. eng.speed (lower limit)
Hand throttle(SWG2)
Hand thr.(SWG2)lo. err val. lower fault limit (0V...lower limit) LI engine speed - 0.05 x rated eng. speed

8.2.4 EXAMPLE OF FAULT FINDING

Fault finding:
Connection broken? not OK Restore the connection.
OK
Plug contacts dirty
or corroded? not OK Clean plug, replace if necessary.
OK
Sensor faulty? not OK Replace sensor.
OK
Cable harness faulty? not OK Check the harness, replace if necessary.

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8.2.5 ENGINE DOES NOT START

Indication Possible cause Remedy

Check using multimeter:

Starter speed > 160 r.p.m. terminal voltage at starter Replace battery.
not reached. Clean earth wire connections.
< 7V (12V system).

Starter speed ok, fuel rack tra-vels Faulty fuel supply. Restore fuel supply.
to start position.

Remove vehicle connector and check

for correct connections:
No power supply, connected to Pin 14F=+Ubatt
wrong pins or incorrect polarity.
Pin 1F=-Ubatt
Pin 2F=-Ubatt
Shutoff solenoid defective or not
connected.
Locate site causing stiffness and remedy as
Starter speed ok, fuel rack stays at Fuel rack stiff. appropriate.
zero position.
Speed sensor faulty. Replace sensor, check plug connection and
line.

Starting fuel charge limitation is set U s i n g SE R D I A c h ec k m ea s u re d va l u e

too low or coolant temperature is “(M9)coolant temperature” in the menu
too high for the EMR. “current measured values”.

There is a serious fault in the EMR

Flashing pilot light. system. You should remedy the Locate error using SERDIA.
fault before attempting any further
starts.

Identification of fuel rack travel

SERDIA error message: deviation, measured value in Replace actuator, see service example,
”8405: Actuator (positioner, travel shutdown range. actuator replacement.
meter, fuel rack)”. Shutoff solenoid defective or not Additional setting is not necessary.
connected.

Short circuit or interruption on the Replace sensor, check plug connection for
SERDIA error message:
”8170:(M13)Speed 1, camshaft”. speed sensor (camshaft sensor) or contamination or corrosion, check lines be-
supply line or plug connection. tween vehicle plug and sensor for damage.

SERDIA error message:

”8210:Data loss EEPROM” Memory error in the EMR Replace ECU. Transfer data from old ECU to
Memory error in the EMR
”8220:Data loss coil data” ECU Failure the new one “1:1”.
”8020:ECU (positioner actuation)”
Oil pressure measured value (M21) Replace sensor, check plug connection for
SERDIA error message:
”8160:(M21)OilPressure Sensor” lies outside permitted range, also contamination or corrosion, check lines be-
with engine switched off. tween vehicle plug and sensor for damage.
Coolant temperature measured
SERDIA error message: value (M9) lies outside the
”8140:(M9)CoolantTemp Sensor” permitted range, also with Replace sensor, plug and line control
engine switched off.
SERDIA error message: Accelerator pedal sensor Check calibration values in the menu
”8120:(F24)Acceler Pedal(SWG1)” incorrectly calibrated. “Calibration” and change if necessary.

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8.2.6 ENGINE STOPS FOR NO KNOWN REASON

Indication Possible cause Remedy

Shutdown not initiated by error

message in the EMR.
Other possibilities:
Following shutdown:
(Key switch not yet actuated, Fuel supply ! Restore fuel system.
off/on) Check whether additional speed monitoring
Error pilot light off ! Speed monitoring independent of
EMR. (e.g. solenoid) is available and make relevant
system check.
Check EMR vehicle connector, fuse, key
Interruption of supply voltage.
switch etc. for loose contact.

Trace error location and error Carry out systematic check depending on er-
environment with SERDIA.
Error message: ror message:
Following shutdown:
(Key switch not yet actuated, Overspeed (is reached for instance Guide value: rated speed+15% to be correct-
off/on) upon sudden load change) ed if necessary.
Error pilot light Permanent light
Check connector on oil pressure sensor for
!e.g. ”Oil pressure” additonal
remark: “inactive”. loose contact and replace sensor if neces-
sary.
Take action according to the indicated error
Following shutdown:
(Key switch not yet actuated, There is a serious error in the EMR location. This may involve replacing the ECU,
system. Prior to engine start, trace actuator or sensor. The additional remark “in-
off/on) error location with SERDIA. active” indicates a loose contact at the indi-
Error pilot light flashing
cated error location.

8.2.7 REPLACING THE EMR1 ACTUATOR

The actuator is a purely mechanical component of the EMR1, fixed to the engine. It contains a solenoid controlled by the
EMR1, which positions the control rod and thus regulates the fuel feed to the engine. A fuel rack position sensor fitted into
the actuator indicates the control rod position to the EMR1.
The following error messages may make it necessary to replace the actuator:
• 8113:(M17)Rack travel sensor
• 8405:Actuator (positioner, travel meter, fuel rack)

Replacement instruction:
• Switch off the voltage supply to the EMR1 and detach the connection cable from the actuator.
For safety reasons, the positive terminal of the battery must be disconnected.
• Remove the actuator and clean the mounting surface on the engine.
IMPORTANT: With the actuator removed, the control rod is at maximum filling position, i.e. the engine must not be
started in any circumstances!

• Attach the new actuator with sealant (DEUTZ Part No. 0101 6102) to the engine.
When fitting a new actuator, check that it is compatible with the control unit.
At the moment, there are 3 possible combinations for replacement:

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Actuator/control unit compatibility

Software Related
Control unit, Version actuator, Part Procedure for replacing the actuator
Part no.
No. EMR1 No.

This combination must be completely replaced by combi-

0211 1846 0211 1841 nation 0211 1911 / 0211 1910.
Confirmation from company head office is required.
0211 1910 0211 1911
0211 2017 1.08 0211 1926
0211 2017 1.11 0211 1926 The actuator content is the same as 0211 1911.
Only the attachment method for the housing is different.
0211 2686
1.10 0211 1926
0211 2690

EDC actuator and pump are associated with each other.

0211 6178 EDC actuator replacement: additional settings required.
1.31 Bosch EDC
0419 9995 1) Self-calibration (Level 4)
2) Transfer EDC Data to the control unit (Level 3)

IMPORTANT: Special feature of the 1015. Note the pump with EDC actuator.
• Restore the connection to the control unit and start the engine.
• In SERDIA, select the "Parameters" menu ->"Configuration" and, with the "PC->ECU" button, transfer the parameters
to the EMR1, and start the engine.
• When the engine is running satisfactorily, save the parameters in the control unit.
• When the tests with SERDIA are completed, clear the error memory.
• On the SERDIA main menu, print the control unit identification list, and in the "Extras" menu, print the logistics data for
the documentation record.
• The document must be sent along with the old actuator to company head office.

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8.2.8 CONTROL UNIT REPLACEMENT

The control unit can be replaced in two ways:
1. When the control unit is damaged, but the data are still readable (communications with SERDIA are possible).
2. A new control unit is installed with engine data set programmed at the factory.

General overview of EMR1 control units

1012/1013/2013 1015 1012/1013 for Deutz-Fahr only
- With MN label - Without MN label - With MN label - Without MN label - With MN label - Without MN label
- Programmed - Not programmed - Programmed - Not programmed - Programmed - Not programmed
-Part No. on control -Part No. on control -Part No. on control
-SERPIC Part No. unit -SERPIC Part No. unit -SERPIC Part No. unit
0211 2016 0211 2017 0211 2016 0211 2017 0211 2451 0211 2088
See also:
SM 130-99-9305
Replaced by Replaced by Replaced by Replaced by Replaced by Replaced by
0211 2581 0211 2570 0422 6179 0422 6178 0211 2580 0211 2571
See also: See also:
SM 130-27-9308 SM 130-27-9308
Replaced by Replaced by Replaced by Replaced by Replaced by Replaced by
0211 26911 1) 0211 2686 1) 0419 4043 1) 0419 9995 1) 0211 2692 1) 0211 2690 1)

1) Current Part No., supplied if ordered.

General overview of EM2 control units

All model series

- With MN label - Without MN label
- Programmed - Not programmed
- SERPIC Part No - Part No.on control unit
0211 2704 0211 2850

Notes on the entries above:

The completed control unit.

To be able to operate with the engine, each control unit must be programmed with the specific
- With MN label
- Programmed data set for the engine (it has a label with the engine number attached). In this way, the engine
and control unit together form an integrated unit.
- SERPIC Part No.
Therefore, when ordering a new control unit, the engine number (MN) is indicated along with
the engine model. Control units are completed by DEUTZ.
Unprogrammed control unit.
The engine cannot be started with this control unit.
For reconditioning operations, this control unit can be completed by transferring the specific
- Without MN label engine data set from the 'old' control unit, using SERDIA Level III. See also SERDIA Manual
- Not programmed "Complete programming".
- Part No.on control unit For reconditioning purposes, this means that unprogrammed control units can also be or-
dered from DEUTZ Service partners (Competence Class II). They are then completed (with the
MN label) by the service partner.
If the data set cannot be read from the 'old' control unit, this can be requested by Email in the
same way, as described in SM 0199-99-9287 ‚ "Confirming modifications to EMR data".

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METHOD 1.
1. Step: Read engine data set from old control unit:
• Switch on ignition/supply voltage.
• Open the SERDIA program.
• In SERDIA, select the "Parameters“ menu ->"Overall programming".
• Click on the "ECU -> file" button. The configuration data files are read. The "Save as " window then opens.
• Give the file a name, and save.

When saving, the engine number is prompted as the file name - this is only a suggestion. Any other name can be entered.
Finally, click OK to confirm. The file (i.e. the engine data set) is then saved under the name <Engine number>.hex.
The data transferred from the old control unit includes, among other things, indications of the number of operating hours
and number of engine starts.
• Close the program. Switch off the ignition/supply voltage.

2. Step: Replacing the control unit:

Control unit compatibility must be considered, and checked against the above table (Part Numbers should be the same.).
Compatibility of the control unit with the actuator must also be checked and verified.
• Switch on ignition/supply voltage.
• Open the SERDIA program.
• In SERDIA, select the "Parameters“ menu ->"Overall programming".
• Click on the "Programming" button. The "Open" window is displayed.
• Select the saved engine data set (<Engine number>.hex) by double-clicking on it.
• Transfer the engine data set to the EMR1 by clicking on the "OK" button.
• Save the data set in the control unit by clicking on the "Save in ECU" button.

3. Step: Start the engine and check that it runs satisfactorily.

• In the "Error memory" menu clear the error memory.

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METHOD 2.:
Every EMR1 has a specific engine data set, which is kept in a central computer at DEUTZ AG when the engine is delivered.
Any modifications to EMR1 configuration settings must be reported back to DEUTZ AG. When a new control unit is or-
dered, it is programmed with a data set available to DEUTZ AG under the corresponding engine number.
Therefore, if setting corrections to the engine are not reported back to DEUTZ AG, these may not be taken into account
when programming a new control unit.
• Switch off the ignition/supply voltage.
• Remove both connectors from the old control unit.
• Connect the control unit with the engine and vehicle connectors (both 25-pin).
• Switch on ignition/supply voltage.
• Open the SERDIA program.
• In the "Error memory" menu, clear the error memory.
• Start the engine and check that it runs satisfactorily.

8.2.9 ERROR READING THE CONFIGURATION DATA

This error message appears if SERDIA is unable to read the Hex file. The file possibly contains Umlauts (ä, ö, ü), or other
special characters not understood by SERDIA

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SECTION 30

CONTENTS

METHOD FOR REMOVAL AND REFITTING OF AIR BRAKING SYSTEM VALVES............................... 31

RIGID PIPES AND WIRING.......................................... 1 Removal.................................................................... 31
TOP VIEW OF WIRING AND PIPES............................. 2 Installation ................................................................ 33

VIEW OF UPPER WIRING AND PIPES........................ 3 TRAILER AIR BRAKES COUPLING HEADS ............. 34
Removal.................................................................... 34
PIPES ON RIGHT-HAND SIDE .................................... 4 Installation ................................................................ 34
TOP VIEW OF REAR PIPES ......................................... 5 HYDRAULIC TRAILER BRAKING VALVES ............... 35
DETAIL OF AIR TRAILER BRAKING SYSTEM ........... 6 Removal.................................................................... 35
ENGINE HOOD AND LAMP ASSEMBLIES ................. 7 Installation ................................................................ 36
Removal...................................................................... 7 AIR CONDITIONING SYSTEM ................................... 37
Installation ................................................................ 10 Description ............................................................... 37
BATTERY .................................................................... 11 Technical specifications ........................................... 37
Removal.................................................................... 11 Operation .................................................................. 38
Installation ................................................................ 12 Maintenance ............................................................. 39
Tension of the compressor drivebelt ........................ 39
CAB ACCESS STEPS................................................. 13 Discharging, flushing and recharging ....................... 40
Removal.................................................................... 13
Installation ................................................................ 13 AIR CONDITIONING COMPRESSOR........................ 41
Removal.................................................................... 41
BATTERY SUPPORT.................................................. 14 Installation ................................................................ 42
Removal.................................................................... 14
Installation ................................................................ 14 RECEIVER-DRIER ...................................................... 43
Removal.................................................................... 43
STARTER MOTOR ..................................................... 15 Installation ................................................................ 43
Removal.................................................................... 15
Installation ................................................................ 15 CONDENSER ASSEMBLY ......................................... 44
Removal.................................................................... 44
COMPRESSOR DRIVEBELT...................................... 16 Installation ................................................................ 44
Renewal.................................................................... 16
Tensioning ................................................................ 16 GEARBOX OIL/FUEL COOLERS ............................... 45
Removal.................................................................... 45
AIR COMPRESSOR.................................................... 18 Installation ................................................................ 46
Removal.................................................................... 18
Installation ................................................................ 20 RADIATOR .................................................................. 47
Removal.................................................................... 47
FAN DRIVE BELT ....................................................... 21 Installation ................................................................ 48
Renewal.................................................................... 21
EXPANSION TANK ..................................................... 49
FAN.............................................................................. 23 Removal.................................................................... 49
Removal.................................................................... 23 Installation ................................................................ 49
Renewal.................................................................... 24
Installation ................................................................ 25 INTERCOOLER........................................................... 50
Removal.................................................................... 50
ALTERNATOR DRIVEBELT ....................................... 26 Installation ................................................................ 51
Renewal and tensioning ........................................... 26
COMPLETE RADIATOR/COOLERS ASSEMBLY ..... 52
ALTERNATOR ............................................................ 29 Removal.................................................................... 52
Removal.................................................................... 29 Installation ................................................................ 54
Installation ................................................................ 29
FLEXIBLE COUPLING OF THE FRONT PTO ............ 55
REMOVAL OF THE AIR RESERVOIRS...................... 30 Renewal .................................................................... 55
Removal.................................................................... 30 Installation ................................................................ 58
Installation ................................................................ 30

30-i
 CONTENTS

TURBOCHARGER.......................................................59 FRONT PTO ASSEMBLY ......................................... 105

Removal ....................................................................59 Removal ................................................................. 105
Installation .................................................................60 Installation .............................................................. 105
AIR INLET PIPE ...........................................................61 FRONT SUSPENSION CYLINDERS ........................ 106
Removal ....................................................................61 Removal ................................................................. 106
Installation .................................................................61 Installation .............................................................. 108
AIR CLEANER .............................................................62 Disassembly ........................................................... 109
Removal ....................................................................62 Assembly ................................................................ 110
Installation .................................................................63 FRONT AXLE AND SWINGING SUPPORT ............. 111
EXHAUST PIPE ...........................................................64 Removal ................................................................. 111
Removal ....................................................................64 Installation .............................................................. 113
Installation .................................................................64 FRONT SUSPENSION VALVES ............................... 114
SILENCER ...................................................................65 Removal ................................................................. 114
Removal ....................................................................65 Installation .............................................................. 114
Installation .................................................................65 FRONT SUSPENSION POSITION SENSOR ........... 115
4WD PROPELLER SHAFT ..........................................66 Removal ................................................................. 115
Removal ....................................................................66 Positioning.............................................................. 115
Installation .................................................................67 Testing.................................................................... 116

4WD PROPELLER SHAFT ..........................................68 REINFORCING SIDE MEMBERS ............................ 117

Removal ....................................................................68 Removal ................................................................. 117
Installation .................................................................71 Installation .............................................................. 117

BRAKE MASTER CYLINDERS ...................................72 FRONT CARRIER ..................................................... 118

Removal ....................................................................72 Removal ................................................................. 118
Installation .................................................................73 Installation .............................................................. 118
BRAKING SYSTEM .....................................................74 ACCELERATOR POTENTIOMETER ....................... 119
Bleeding ....................................................................74 Renewal.................................................................. 119
Installation .............................................................. 119
BRAKE LIGHT SWITCHES .........................................76
Adjustment ................................................................76 FUEL TANK............................................................... 120
Removal ................................................................. 120
POWER STEERING UNIT ...........................................77 Installation .............................................................. 120
Testing.......................................................................77
Adjustment ................................................................77 GEARBOX GEAR PUMP .......................................... 121
Removal ....................................................................78 Removal ................................................................. 121
Installation .................................................................78 Installation .............................................................. 122
Dismantling ...............................................................79 POWER STEERING - LIFT
Assembly...................................................................86 AND HYDRAULIC SERVICES PUMPS.................... 125
FRONT WHEELS .........................................................96 Removal ................................................................. 125
Removal ....................................................................96 Installation .............................................................. 128
Installation .................................................................96 REMOTE CONTROL VALVES.................................. 129
FRONT FENDERS .......................................................97 Removal ................................................................. 129
Removal ....................................................................97 Installation .............................................................. 133
Installation .................................................................97 Disassembly ........................................................... 134
Assembly ................................................................ 136
REAR WHEELS ...........................................................98
Removal ....................................................................98 REMOTE CONTROL VALVES ASSEMBLY............. 137
Installation .................................................................98 Removal ................................................................. 137
Installation .............................................................. 140
LIFT VALVE BLOCK ....................................................99
Removal ....................................................................99 LIFT CYLINDERS ..................................................... 141
Installation .................................................................99 Removal ................................................................. 141
Installation .............................................................. 142
FRONT LIFT CYLINDERS.........................................100 Disassembly ........................................................... 143
Removal ..................................................................100 Assembly ................................................................ 143
Installation ...............................................................101
LIFT POSITION SENSOR......................................... 144
FRONT LIFT ASSEMBLY..........................................102 Testing.................................................................... 144
Removal ..................................................................102 Renewal.................................................................. 145
Installation ...............................................................104 Installation .............................................................. 145
Adjusting ................................................................ 146

30-ii
 CONTENTS

LIFT DRAFT SENSOR .............................................. 148 PARKING BRAKE SWITCH...................................... 183

Removal.................................................................. 148 Adjustment ............................................................. 183
Installation .............................................................. 148 CLIMATE CONTROL PANEL ................................... 184
DRIVER'S SEAT........................................................ 149 Removal.................................................................. 184
Removal.................................................................. 149 Installation .............................................................. 184
Installation .............................................................. 149 HEATER VALVE ........................................................ 185
STEERING WHEEL, STEERING COLUMN SWITCH Removal.................................................................. 185
UNIT AND Installation .............................................................. 185
INSTRUMENT PANEL.............................................. 150 HEATER MATRIX ..................................................... 187
Removal.................................................................. 150 Removal.................................................................. 187
Installation .............................................................. 151 Installation .............................................................. 189
STEERING COLUMN SWITCH UNIT AIR CONDITIONING EVAPORATOR ....................... 190
AND THE SHUTTLE CONTROL LEVER.................. 152 Removal.................................................................. 190
Removal.................................................................. 152 Installation .............................................................. 191
Installation .............................................................. 153
RIGHT-HAND AIR CONDITIONING FAN ................ 192
CENTRE CONSOLE AND SHROUD........................ 154 Removal.................................................................. 192
Removal.................................................................. 154 Installation .............................................................. 192
Installation .............................................................. 157
LEFT-HAND AIR CONDITIONING FAN ................... 193
RIGHT-HAND CONSOLE ......................................... 158 Removal.................................................................. 193
Removal e opening................................................. 158 Installation .............................................................. 193
Installation .............................................................. 164
PARKING BRAKES................................................... 194
LEFT-HAND CONSOLE ........................................... 165 Adjustment ............................................................. 194
Removal.................................................................. 165
Installation .............................................................. 166 CAB DOOR CABLE .................................................. 195
Renewal .................................................................. 195
LIFT, FRONT SUSPENSION AND TRANSMISSION
ELECTRONIC CONTROL UNITS............................. 167 TRAILER BRAKING AIR PRESSURE GAUGE ........ 197
Removal.................................................................. 167 Removal.................................................................. 197
Installation .............................................................. 168 Installation .............................................................. 197
FUSE AND RELAY BOARD...................................... 169 TRANSMISSION STATUS DISPLAY........................ 198
Removal.................................................................. 169 Removal.................................................................. 198
Installation .............................................................. 170 Installation .............................................................. 198

ENGINE ECU ............................................................ 171 CAB ........................................................................... 199

Removal.................................................................. 171 Removal.................................................................. 199
Installation .............................................................. 171 Installation .............................................................. 206
CLUTCH PEDAL AND RELATED DEVICES............ 172 ENGINE -TRANSMISSION ....................................... 207
Removal of the potentiometer................................ 172 Separation .............................................................. 207
Refitting the potentiometer..................................... 172 Reconnection.......................................................... 209
Adjustment of the clutch pedal position and travel 173
Renewal of the proximity sensor ............................ 173
CONTROL PANELS AND LEVERS OF THE
AUXILIARY SERVICE VALVES AND THE PTO....... 174
Removal.................................................................. 174
Installation .............................................................. 177
PTO ENGAGEMENT AND SELECTION CONTROL
CABLES .................................................................... 178
Removal.................................................................. 178
Installation .............................................................. 179
AUXILIARY SERVICE VALVE CONTROL CABLES 181
Removal.................................................................. 181
Installation .............................................................. 182

30-iii
 METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING

METHOD FOR REMOVAL AND REFITTING OF RIGID PIPES AND WIRING

1 - The rigid pipes of the various systems can all be re- IMPORTANT
moved individually , i.e. without having to remove
1 - After removing pipes, immediately plug the ends
any pipes belonging to other systems.
of the pipes and the open fittings on the compo-
2 - For particularly complex removal operations, num- nents from which they were disconnected in or-
ber the pipes in the order in which they are removed, der to prevent the entry of contaminants.
label any intermediate connections and the posi-
2 - After disconnecting electrical connectors, pro-
tions of the intermediate retaining clamps. Refit the
tect them against oil, dust and other contami-
pipes in reverse order to removal.
nants by c over ing them in ba gs ma de of
3 - After having repositioned the pipes in their original waterproof material and attach the bags to the
locations, tighten the fittings by hand and locate the wiring with insulating tape.
retaining clamps and intermediate fixings.
3 - Should any oil, coolant, moisture or water come
4 - First tighten the fittings using also a holding wrench into contact with the connectors, clean them with
to the torques specified in the tables in Section 00, compressed air at low pressure (max. 2 bar) and
and then tighten the pipe clamps. clean the wires and contacts with isopropyl al-
cohol or a specific water-repellent product.
5 - To help the operator trace the routes of the rigid pi-
pes and cables on the tractor frame, the following 4 - Check wiring fixings carefully; these must not im-
photos show the relative positions of pipes and ca- pinge on the connectors and must be positioned
bles for the version with air trailer braking. at regular intervals of about 30 cm to prevent vi-
bration that could cause an interruption in cur-
rent flow or signal loss.

30-1
 TOP VIEW OF WIRING AND PIPES

TOP VIEW OF WIRING AND PIPES

30-2
 VIEW OF UPPER WIRING AND PIPES

VIEW OF UPPER WIRING AND PIPES

30-3
 PIPES ON RIGHT-HAND SIDE

PIPES ON RIGHT-HAND SIDE

30-4
 TOP VIEW OF REAR PIPES

TOP VIEW OF REAR PIPES

30-5
 DETAIL OF AIR TRAILER BRAKING SYSTEM

DETAIL OF AIR TRAILER BRAKING SYSTEM

30-6
 ENGINE HOOD AND LAMP ASSEMBLIES

ENGINE HOOD AND LAMP ASSEMBLIES

Removal
4
1. Removal of the hood
1 - Raise the hood (1) fully.
3
2 - Disconnect the screen washer pipe (2).
3 - While keeping the hood in the raised position, remove 1 2
the cotter pins (3) and the washers (4).

F0043710

4 - Detach the gas springs (5) from the frame and remove
the complete hood assembly (1).

5 5

F0043720

1.1 Adjustment of the hood latch

11
★ Before adjusting the hood latch, make sure that the
10
hood release buttton is fitted and that the gas springs
are disconnected. 9
1 - Check that the spring (6) is engaged with the plate (7)
of the release button (8) and check that when the hood
6
gasket (9) comes to rest on the frame, the spring (6) en-
gages the groove on the striker (10). 8
If necessary, adjust the depth of the striker by way of
self-locking nut (11). 7

D0003920

2. Removal of the side panels

1 - Lift and remove the grilles (12).

12

F0043730

30-7
ENGINE HOOD AND LAMP ASSEMBLIES

2 - Unscrew and remove the front bolts (13).

13

13
F0017020

3 - Unscrew and remove the rear nut (14) and remove the
washer (15).

14

15

F0043740

3. Removal of the lamp assemblies and hood re-

lease button
16
1 - Remove the lateral retaining screws (16).

F0017040

2 - Remove the central retaining screws (17).

17

F0017050

30-8
 ENGINE HOOD AND LAMP ASSEMBLIES

3 - Unplug the lamp connectors (19) from the lamp as-

semblies (18).
18

19

F0017060

4 - Remove the lamp assemblies (18) by rotating them to

the rear and moving them sideways to disengage the
release button (8).
18

F0017070

5 - If necessary, press the plate (7) of the release button

(8) to help disengage the spring (6).
1 7

F0017080

4. Removal of the lower guard

19
1 - Loosen and remove the bolts (19) of the rear mount-
ings.

19

F0077790

30-9
ENGINE HOOD AND LAMP ASSEMBLIES

2 - Loosen and remove the bolts (20) and (21) of the in-
termediate and front mountings.
20
21

F0077800

3 - Remove the lower guard (22), withdrawing it to-

wards the front of the tractor.

22

F0077810

Refitting
• Refitting is the reverse of removal

1
★ While engaging the release button with the spring
(6), take care not to break the latch plate (7) by ap-
plying excessive force.

30-10
 BATTERY

BATTERY

Removal
1 - Unscrew and remove the nut (1) securing the toolbox
(2).
Remove the toolbox (2) by sliding it towards the front 2
of the tractor.

F0043760

2 - Remove the bolts (3) with their washers (4) and remove
the battery cover (5).
3 4

3 4

F0017130

3 - Remove the terminal covers (6) and disconnect the

leads (7) and (8).. 1
Always disconnect the negative lead (–) before
the positive lead (+). 8
6

7
F0017140

4 - Loosen off the nuts (9) sufficiently to tilt and remove

the battery (12) securing clamp (10) and rods (11).

10

11 12

F0017150

30-11
BATTERY

5 - Remove the battery (12) using the handles provided.

If the battery is not to be used for several days,
store it in a dry, well-ventilated place at a tem-
perature above +5°.

12
F0043770

Refitting
• Refitting is the reverse of removal.

1
Always re-connect the positive lead (+) before the
negative lead (–).

30-12
 CAB ACCESS STEPS

CAB ACCESS STEPS

Removal
1 - Unscrew and remove the bolts (1) securing the lower
fender (2).

F0017170

2 - Loosen the bolts (3) and (4) securing the steps (5).
★ For safety reasons, do not remove the bolts yet.
3
5

4 4

F0017180

3 - Attach a hoist to the steps (5).

Steps: 17 kg (37.5 lb.)
4 - Remove the central bolt (3), disengage the steps (5)
from the two remaining bolts (4) and remove the steps.

F0043750

Refitting
• Refitting is the reverse of removal.

30-13
BATTERY SUPPORT

BATTERY SUPPORT

Removal
1 - Remove the battery.
(For details see "BATTERY").
2 - Unscrew and remove the lateral fixing bolt (1).

F0077820

3 - Loosen the central fixing bolts (2).

4 - While supporting the battery support (3), remove the
bolts (2); remove the support.
2
★ Recover the four spacers (4) from between the
gearbox and the support (3). 4
NOTA On tractors equipped with a front lift, spacers
are only fitted to the two upper bolts.

F0077830

Refitting
• Refitting is the reverse of removal.

30-14
 STARTER MOTOR

STARTER MOTOR

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the left hood side panel (1) and the hood.

F0077840

2 - Remove the terminal protector (2) and the nut (3) se-
curing leads (4) and (5).
2 3
4

F0077850

3 - Remove the terminal cover (6) and disconnect the lead

(7).
8
4 - Remove the starter motor (8). 6
For details, see the engine manual.

F0077860

Refitting
• Refitting is the reverse of removal.

30-15
COMPRESSOR DRIVEBELT

COMPRESSOR DRIVEBELT

Renewal
Remove the key from the ignition and apply the park- 1
ing brake.
1 - Loosen the pivot and fixing bolts (1), (2) of the bracket 2
(3) supporting the belt tensioner pulley (4).
3

F0077870

• For models with front PTO only

2 - Loosen and fully unscrew the six bolts (5) (n°6) secur-
ing the flange of the cardan shaft (6). 8
5
3 - Detach the flange (7) from the flexible coupling (8).

6 7

F0078012

• For all versions

4 - Remove the old drivebelt (9) and fit the new one.
5 - Tension the drivebelt.

F0077880

Tensioning
★ Before adjusting the tension, carefully examine the
drivebelt for signs of wear.
The belt must be renewed immediately at the first
sign of cracking, fraying or separation of the plies.
If a new belt is fitted, re-adjust the tension after ap-
prox. 15 operating hours.
1 - Remove the right-hand guard (1).
1

F0077891

30-16
 COMPRESSOR DRIVEBELT

2 - Loosen the pivot and fixing bolts (2), (3) of the bracket
(4) as for the belt renewal procedure.
3 - Tension the drivebelt using a “T” bar and 3/4” exten- 3
sion inserted in the hole in the bracket (4).
4
4 - To tension the drivebelt, turn the bar clockwise and
then tighten the bolts (2), (3).
2
5 - Check the tension adjustment using the tool and
method described in the engine manual.
★ Static deflection immediately after fitting:
550±50 N
★ Static deflection after 15 minutes: 400±50 N F0077903

The check should be carried out with the engine

cold.

30-17
AIR COMPRESSOR

AIR COMPRESSOR

Removal
1
• For 4-cylinder heroes
1 - Partially drain the engine cooling system.

Coolant: approx. 5 ᐉ
(1.32 US.gall.)
2 - Remove the expansion tank (1).
(For details, see "EXPANSION TANK").

F0077910

• For all versions

3 - Label and disconnect the transmission oil pressure
and return pipes (2) and (3). 2
★ Immediately plug the ends of the pipes to pre-
vent impurities from entering the system.

F0077920

4 - Disconnect the air suction pipe (5) from the com-

pressor (4). 4
★ Always renew the copper gaskets.

F0077930

5 - Disconnect the pressure pipe (6) and lube oil pipe

(7) from the compressor (4). 4
★ Always renew the seals of the lube oil pipe.

F0077940

30-18
 AIR COMPRESSOR

6 - Loosen the strap (8) and disconnect the lube oil re-
covery pipe(9).
8
9

F0077950

7 - Loosen and remove the bolts (10) securing the

compressor.

10

F0077960

8 - Remove the compressor (4), withdrawing it up-

wards.
4

F0077970

30-19
AIR COMPRESSOR

Refitting
• Refitting is the reverse of removal.
If the oil has been drained from the compressor crank-
case, add engine oil before re-connecting the lube
pipe.

Quantity of oil: approx. 100 g (0.220 lb.)

1
★ Tension the drivebelt to obtain a static deflec-
tion “A”:
immediately after fitting of = 550±50 N F0077980

after 15 minutes of operation: 400 N.

★ For details see "COMPRESSOR DRIVEBELT -
Tensioning"
This check should be carried out with the engine
cold

• For 4-cylinder models

1 - Refit the expansion tank and top up the coolant.

Coolant: approx. 5 ᐉ
(1.32 US.gall.)

30-20
 FAN DRIVE BELT

FAN DRIVE BELT

Renewal
Remove the key from the ignition and apply the
parking brake.
1 - Remove the drivebelt of the air compressor.
(For details, see "COMPRESSOR DRIVEBELT").
2 - Drain the engine cooling system.
Coolant: max. 17.5 ᐉ
(4.62 US.gall.)

3 - Remove the expansion tank (1).

(For details, see "EXPANSION TANK"). 1

F0077910

4 - Recover the refrigerant from the air conditioning

system..
(For details, see "AIR CONDITIONING SYSTEM -
Maintenance").

F0077990

5 - Remove the complete radiator/coolers assembly

(2).
(For details see "COMPLETE RADIATOR/COOLERS
ASSEMBLY"). 2

F0044421

30-21
FAN DRIVE BELT

6 - Remove the fan (3).

(For details see "FAN"). 3

F0078000

• For models with front PTO

7 - Loosen and fully unscrew the six bolts (4) securing
the flange of the cardan shaft (5). 7
4
8 - Detach the flange (6) from the flexible coupling (7).

5 6

F0078010

• For all versions

9 - Loosen the tensioner (8) and remove the old drive-
belt. 8
10 - Tension the drivebelt.
(For details, see "AIR CONDITIONING SYSTEM -
Tension of the compressor drivebelt").

F0078020

30-22
 FAN

FAN

Removal
Remove the battery cover and disconnect the neg-
ative battery lead (–).
1 - Remove the side panels, the lamp assemblies and
lower grille.
(For details, see "ENGINE HOOD AND LAMP AS-
SEMBLIES").
2 - Drain off the engine coolant.

Coolant:
max. 17.5 ᐉ (4.62 US. gall.)
3 - Remove the expansion tank.
(For details, see "EXPANSION TANK").
4 - Recover the refrigerant from the air conditioning
system
(For details, see "AIR CONDITIONING SYSTEM -
Maintenance").

F0077990

5 - Remove the radiator/coolers assembly (1).

(For details see "COMPLETE RADIATOR/COOLERS
ASSEMBLY").
1

F0044422

6 - Loosen the bolts (2) and (3) securing the air condi-
tioning compressor (4) and the tensioner block (5). 5
7 - Turn the screw (6) anti-clockwise in order to slacken
6
and release the fanbelt (7).
1

3
7

F0078083

30-23
FAN

8 - Using a hex socket wrench, loosen and remove the

central screw (8) securing the fan (9) and its pulley.

F0078040

9 - Remove the complete fan assembly (9).

9

F0078001

Renewal
10 - With the fan assembly (9) on a bench, loosen and 9
remove the four retaining bolts (10) and remove the
old fan.

10

F0078050

11 - Position the new fan taking care to align the two lo-
cating marks.
12 - Tighten down the bolts (10) of the fan-pulley as-
sembly.

F0078060

30-24
 FAN

Refitting
• Refitting is the reverse of removal 6

1
★ Turn the tensioner screw (6) clockwise to tension
the compressor and fan drivebelt.
(For details, see "AIR CONDITIONING SYSTEM -
Tension of the compressor drivebelt").
1 - Fill the engine cooling system.

Coolant:
max. 17.5 ᐉ (4.62 US. gall.) F0078021

2 - Flush and recharge the air conditioning system.

(For details, see "AIR CONDITIONING SYSTEM - Dis-
charging, flushing and recharging").
3 - Start the engine and run for a few minutes to allow
the coolant to circulate.
4 - Stop the engine; check the level of the coolant in the
expansion tank and top up if necessary.

30-25
ALTERNATOR DRIVEBELT

ALTERNATOR DRIVEBELT

Renewal and tensioning

★ The drivebelt must be renewed at the first sign of wear.
Check for fraying, cracks and separation of the belt
plies.
★ Some of the operations described below refer only to
models equipped with front PTO and cab air condi-
tioning.
For machines not equipped with these items, these
operations should be ignored.
Remove the battery cover and disconnect the nega-
tive battery lead (--).

1 - Remove the side panels (1).

1 1

F0078070

2 - Remove the radiator/coolers assembly (2).

(For details see "COMPLETE RADIATOR/COOLERS
ASSEMBLY").
2

F0044421

3 - Remove the complete fan assembly (3).

(For details see "FAN"). 3

F0078000

30-26
 ALTERNATOR DRIVEBELT

4 - Slacken the air compressor drivebelt (4).

(For details, see "COMPRESSOR DRIVEBELT").

F0077871

• For models with front PTO

5 - Loosen and fully unscrew the six bolts (5) securing
the flange of the cardan shaft (6). 8
5
6 - Detach the flange (7) from the flexible coupling (8).

6 7

F0078012

• For all versions

7 - Loosen the bolts (9), (10) and (11) to slacken the fan
and compressor drivebelt. 11
Remove the drivebelt (12).

9
12

10

F0078082

8 - Loosen the bolts (13) and (14) securing the fuel lift
pump, disengage the alternator drivebelt (15) and 13
remove it by passing it between the crankshaft pul-
ley and the front support. 14

15

F0078092

30-27
ALTERNATOR DRIVEBELT

9 - Using the same method, fit the new drivebelt (15)

for the alternator (16) and tension using a “T” bar 13
and a 3/4” extension, or a 3/4 angle bar” inserted in 17
15
the seat machined in the fuel lift pump support (17).
10 - Tension the drivebelt by turning the bar clockwise
and then tighten down bolts (13) and (14).

14 16

F0078103

11 - To check that the tension is correct, use the tool and

procedure indicated in the engine manual.
★ Static deflection ”A” immediately after fitting:
13 mm belt: 450±50 N
★ Static deflection”A” after 15 minutes:
13 mm belt: 300±50 N A
The check should be carried out with the en-
gine cold.

F0077882

12 - Fit and tension the fan drivebelt.

(For details, see "FAN").
13 - Fit and tension the air compressor drivebelt (4).
(For details, see "COMPRESSOR DRIVEBELT"). 4

14 - Complete the refitting procedure by following the

first steps of the removal procedure in reverse or-
der.

F0077902

30-28
 ALTERNATOR

ALTERNATOR

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the left and right side panels (1).
2 - Remove the air compressor.
(For details see "AIR COMPRESSOR").

1 1

F0078070

3 - Remove the terminal protector (2), remove the nut (3)

and disconnect the lead (4).
4 - Remove the nut (5) and disconnect the lead (6). 5

6
2 3

4
F0078110

5 - Loosen the bolts (7) and (8) of the fuel pump bracket (9)
in order to slacken off the drivebelt (10). 7

6 - Remove the alternator (11).

For details, see the engine manual. 8

10
9

F0078091

Refitting
• Refit the alternator following the removal steps in re-
verse order and adjust the drivebelt tension.
(For details, see "ALTERNATOR DRIVEBELT"). 11

1 - Start the engine and check the compressor pipe fit-

tings for leaks.

F0078104

30-29
AIR RESERVOIRS

AIR RESERVOIRS
(for version with air trailer braking only)

Removal
Vent residual pressure from the reservoir by removing
the cap (1) and pressing the button (2) on the pressure 1
regulator valve (3).
3
2

F0043800

1 - Disconnect the inlet and outlet pipes (5) from the right-
hand reservoir (4). 1
5
★ On the left-hand reservoir, disconnect the pipe to
the pressure regulator valve. 5

2 - While supporting the reservoir (4), unscrew and re- 4

move the nut (6) and the spacer (7) of the retaining
strap (8).
3 - Remove the reservoir (4). 8

6
7
F0043810

Refitting
• Refitting is the reverse of removal.

1
★ Before tightening down the reservoir, tighten
the fittings of the inlet and outlet pipes.

30-30
 AIR BRAKING SYSTEM VALVES

AIR BRAKING SYSTEM VALVES

Removal
Switch off the engine and remove the key from the ig-
nition.
Eliminate all residual pressure from the trailer air brak-
ing circuit. 3

1. Pressure regulator valve 1

1 - Loosen the fittings (1), disconnect the pipe (2) and re- 1
move the valve (3).

2
F0043801

2. Parking brakes valve

1- Disconnect the hydraulic brakes pipes (2) and pipe (3)
for the pressure switch (4) from the valve (1).
3

2
F0043960

2 - Disconnect supply pipe (5) from the inner side of the

valve (1).
1

F0043970

3 - Disconnect the tie-rod (7) from the valve control lever

(6). 1
6

F0043980

30-31
AIR BRAKING SYSTEM VALVES

4 - Remove the lower nuts (8) and two bolts (9); remove
the valve (1).

1
9

8
F0043990

3. Service brakes (EXPORT F version)

1 - Disconnect the supply pipes (2) and the two brake
control pipes (3) from the valve (1).
3
2 - Unscrew the bolts (4) and remove the valve.

1
2
4
3
F0044000

4. Pressure transducer
1 - Unplug the connector (1). 2
2 - Loosen the fitting (2) and remove the transducer (3). 3

F0043982

30-32
 AIR BRAKING SYSTEM VALVES

Refitting
• Refitting is the reverse of removal.
1 - Start the engine and allow the pressure to build in the
air braking circuit.
2 - Check the seal at all removed fittings using a soapy
solution.
3 - Bleed the brake circuit of air.
(For details, see "BRAKING SYSTEM").
4 - Check that the parking brake valve control lever op-
erates at the correct point and, if necessary, adjust the
length of the tie-rod.

Adjusting the length of the tie-rod

1
1 - Check that the parking brakes are perfectly adjusted
and that they are released.
2 - Raise the parking brake lever to the first notch; you
should distinctly hear the parking brake valve operate
in correspondence with the first notch position.
3 - If the valve operation is too ADVANCED, lengthen the
control rod.
If the valve operation is too RETARDED, shorten the
control rod.
4 - Operate the parking brake a few times, checking that
the tractor and trailer brakes are applied simultane-
ously.

30-33
TRAILER AIR BRAKES COUPLING HEADS

TRAILER AIR BRAKES COUPLING HEADS

Removal
2 2
Vent residual pressure from the reservoir by pressing
2
the button on the regulator valve.
Remove the key from the ignition and apply the park-
ing brake.
1 1
1 - Label the three pipes (1) and disconnect them from the 1
valves (2).

F0044010

2 - Loosen the retaining nut (3) and remove the coupling

head (4) that is to be replaced.

F0044020

3 - Disconnect the pipe (5) from the free drain quick cou-
pler.

F0044030

4 - Unscrew and remove the bolts (6) and remove the as-
sembly (7).

Refitting 7
• Refitting is the reverse of removal.
6

F0044040

30-34
 HYDRAULIC TRAILER BRAKING VALVES

HYDRAULIC TRAILER BRAKING VALVES

Removal
Remove the key from the ignition.

1. EXPORT Version
1 - Remove the right rear wheel.
(For details, see "REAR WHEELS").
Thoroughly clean the area before commencing re-
moval.

F0044050

2 - Disconnect pipes (2), (3) and (4) from the valve (1).
★ Plug the pipelines and ports to prevent impuri- 2
ties getting in.
1
3 - Disconnect the supply pipes (5), (6) to the service
brakes. 6
1
4 - Unscrew and remove the bolts (7) with their nuts. 3
Remove the valve (1).
7
5 4
F0044060

2. Italy version
1 - Remove the right rear wheel.
(For details, see "REAR WHEELS").
Clean the area thoroughly before starting the removal
procedure.

F0044050

2 - Unplug the connector (2) from the pressure switch (1).

4 5
3 - Disconnect, in the order given, pipes (4), (5), (6), (7) and
(8) from the valve (3). 3
★ Plug the pipelines and ports to prevent impuri-
ties getting in. 1 6
9
4 - Unscrew and remove the bolts (9) with their nuts.
Remove the valve (3).
2

1 7
8 F0044070

30-35
HYDRAULIC TRAILER BRAKING VALVES

Refitting
• Refitting is the reverse of removal.

1
★ Bleed the braking system.
(For details, see "BRAKING SYSTEM").

30-36
 AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM

2
Low pressure gas
14÷17 bar
(203÷246,5 psi)
High pressure gas
3 bar 28 bar
(43,5 psi) (406 psi)
High pressure liquid

1a

3 1

9
CAB INTERIOR
D0013150

Description Technical specifications

1- Compressor with electromagnetic clutch • Minimum and maximum safety pressure:
2- Condenser 2.4 – 28.5 bar (34.8 – 413.3 psi)
3- Receiver-drier • Refrigerant type: R134a
4- Bistable pressure switch for compressor clutch en- • Refrigerant quantity: 1600 g (56.4 oz.)
gagement/disengagement • Total quantity of moisture-free oil added at 1st charg-
5- Expansion valve ing:
6- Evaporator 210 cm³ (12.81 Cu.in.)
7- Evaporator temperature sensor
8- Cab air blowers
9- Condenser cooling fan

30-37
AIR CONDITIONING SYSTEM

Operation

The compressor (1) is driven from the crankshaft via a The temperature of the air flow over the evaporator (6)
drivebelt and pulley with an electromagnetic clutch (1a), generated by the centrifugal blowers (8) is significantly
which is operated from a switch on the control panel. higher than -- 8°C (17.6°F), and therefore it gives up its
The system is protected by a safety pressure switch, heat to the refrigerant, causing it to boil and evaporate.
which performs the following functions: On leaving the evaporator (6), the refrigerant returns to the
1 - To inhibit engagement of the electromagnetic compressor (1) to repeat the cycle.
clutch (1a) when the system pressure falls below 2.4 The removal of heat from the ambient air flowing over the
bar (34.8 psi) as a result of incomplete charging or evaporator causes the moisture in the air to condense,
refrigerant loss. and the air is thus dehumidified; the moisture condenses
2 - To disengage the clutch (1a) and thereby stop the on the fins of the evaporator, where, if it is not maintained
compressor when the pressure exceeds the per- at temperature above 0°C (32°F), it will freeze and com-
mitted maximum of 28.5 bar (413.3 psi) (generally as prise the efficiency of the evaporator.
a result of over-heating). The task of maintaining the evaporator at a temperature
The refrigerant (in vapour state) is drawn in by the com- above 0°C (32°F) (and within the optimum temperature for
pressor where it is compressed, causing the temperature efficient heat exchange), is performed by an electronic
of the vapour to rise; the refrigerant flows to the condens- temperatures sensor (7); this sensor disengages the com-
er (2), where its heat is radiated to the air flow and it is thus pressor clutch (1a) when the temperature falls to the lower
cooled to the point where it condenses to high-pressure limit and engages the clutch (1a) when the evaporator
liquid. temperature reaches an upper limit.
On leaving the condenser, the liquefied refrigerant flows The condensate that forms on the evaporator fins con-
to the receiver-drier (3) which performs three main func- tains dust, pollen and other particles suspended in the air;
tions: to filter out any impurities, to absorb any water in the continuous condensation thus has the effect of purifying
circuit, and finally, to act as a storage reservoir. the air, and the drips of condensate are conveyed out of
On leaving the receiver-drier, the clean, dry liquid passes the vehicle via two ducts.
to the evaporator (6) through an expansion valve (5), A fixed quantity of moisture-free oil is added to the circuit
which meters the flow of refrigerant into the evaporator to in order to lubricate all the mechanical components of the
ensure optimum evaporation. system; a certain percentage of this oil continuously cir-
In the evaporator, the refrigerant is heated and expands to culates in the form of an oil mist, thereby lubricating the
the point of evaporation with an ambient temperature of compressor (pistons and bearings) and the expansion
around -- 8°C (17.6°F). valve.

30-38
 AIR CONDITIONING SYSTEM

Maintenance
The checks and servicing operations required for the air
4 - Inspection and renewal of the electromagnetic
conditioning system are as follows:
clutch pulley (to be carried out at a specialised serv-
1 - Checking the tension and condition of the compres- ice centre).
sor drivebelt. 5 - Removal and renewal of the receiver-drier.
2 - Discharging, flushing and recharging of the system
6 - Removal and renewal of the condenser.
using a specific servicing machine and R134 refrig-
erant. 7 - Removal of the evaporator and the electronic tem-
perature sensor.
3 - Removal and renewal of the compressor.
(For these operations see "AIR CONDITIONING
EVAPORATOR").
Tension of the compressor drivebelt
★ Before adjusting the tension, carefully examine the
drivebelt for signs of wear.
The belt must be renewed immediately at the first sign
of cracking, fraying or separation of the plies.
If a new belt is fitted, re-adjust the tension after ap-
prox. 15 operating hours.
1 - Remove the right-hand grille (1).

F0077891

2 - Loosen the bolts (2) and (3) securing the air condi-
tioning compressor (4) and the tensioner block (5).
3 - Turn the tensioner screw (6) clockwise to tension 4
drivebelt (7) as indicated below: 2
★ Static deflection ”A” immediately after fitting:
550±50 N 3
★ Static deflection ”A” after 15 minutes:
400±50 N 5
The check should be carried out with the en-
gine cold.
4 - Tighten bolts (2) & (3). 6
F0078120

7
F0078130

30-39
AIR CONDITIONING SYSTEM

Discharging, flushing and recharging

1 - Before discharging, flushing and recharging the d - Separation of the moisture-free oil from the
air conditioning system, inspect the system for liquid refrigerant and determination of its
leaks using a suitable leak detector. quantity by weight.
2 - In order to carry out the system servicing oper- e - Recharging the system with exactly the same
ations you will require a dedicated servicing ma- amounts of refrigerant and oil as those recov-
chine capable of performing the following tasks: ered.
a - Aspiration of the refrigerant fluid. f - Measuring the system delivery side pressure
b - Creation of a high vacuum to purge the sys- and return pressure (low pressure).
tem of contaminants.
c - Filtration of the recovered refrigerant.

1. Discharging the system

1 - Connect the service machine to the high pressure
service valve (1) and follow the specific instructions for
the service machine to discharge the system.
2 - Disconnect the system component to be renewed or
overhauled immediately after the service machine
stops; plug the open ends of the system pipes as
1
quickly as possible.

2. Flushing and recharging the system

Before each recharging, the system must be purged of all
air, moisture and contaminants (oxides, deposits). F0044080

This entails creating a high vacuum within the system to

evaporate any moisture present. The vapour, when extract-
ed, draws with it any contaminants present in the system.
★ For the flushing and recharging operations, the ser-
vice machine must be connected to the high (1) and
low (2) pressure service valves.
Maximum vacuum” must be maintained for at least
10 minutes. 1

After flushing, the moisture-free oil recovered during the

discharging operation must be re-introduced into the sys-
tem, followed by the refrigerant.
F0044090

Quantity of refrigerant (R134a): 1600 g (56.4 oz.)

Quantity of oil: the quantity recovered.
If the system has to be discharged and flushed in or-
der to renew a system component, the quantity of oil
in the replaced component must be measured and
the same amount of new oil must added to that re- 2
covered with the refrigerant.
For details of the oil and refrigerant recharging pro-
cedure, refer to the instructions supplied with the
service machine.

F0078140

30-40
 AIR CONDITIONING COMPRESSOR

AIR CONDITIONING COMPRESSOR

Removal
1 - Discharge the liquid refrigerant from the system.
(For details, see "AIR CONDITIONING SYSTEM -
Maintenance").
2 - Remove the right-hand side panel (1).

F0077840

3 - Disconnect the inlet (3) and delivery (4) lines from the
compressor (2).
★ Immediately plug the open fittings to prevent the
entry of moisture. 1
4 - Disconnect the electromagnetic clucth control con- 3
nector (5).

2
4
5
F0078150

5 - Loosen the bolts (6) and (7) securing the tensioner

block (8) and acting as pivot for the support (9) of 9
the compressor (10).
6
10

F0078121

6 - Turn the tensioner screw (11) to slacken the fan and

compressor drivebelt.
★ Loosen the drivebelt sufficiently to be able to 11
slip it off the compressor pulley.

F0078084

30-41
AIR CONDITIONING COMPRESSOR

7 - Loosen and remove the self-locking nuts (12) and

bolts (13); remove the compressor (10).
13 13

12

10

F0078160

Refitting
• Refitting is the reverse of removal

1
★ Remove the plugs and connect the pipes immediate-
ly, fully tightening the fittings, to prevent the entry of
moisture.
★ Check the condition of the O-ring seals and renew
them if damaged.
1 - Adjust the tension of the compressor/fan drivebelt.
(For details see "COMPRESSOR DRIVEBELT" - "FAN
DRIVE BELT").
2 - Flush and recharge the system.
(For details see "AIR CONDITIONING SYSTEM - Dis-
charging, flushing and recharging").

30-42
 RECEIVER-DRIER

RECEIVER-DRIER

Removal 2
1
1 - Recover the refrigerant from the system.
(For details, see "AIR CONDITIONING SYSTEM -
Maintenance").
2 - Disconnect the connector (1) of the pressure switch (2).

F0044150

3 - Disconnect the inlet (4) and outlet (5) pipes from the re-
ceiver-drier (3).
★ Plug the ends of the pipes immediately to prevent 3
moisture getting into the system. 4
1
5
4 - Unscrew and remove the bolts(6) securing the bracket
(7) and remove the assembly.
If a new receiver-drier is to be installed, measure the
quantity of oil contained in the old unit in order to de-
termine the quantity of oil to be added to the system.
7
6
F0044160

Refitting
• Refitting is the reverse of removal.

1
★ Remove the plugs and connect the pipes immediate-
ly, fully tightening the fittings, to prevent the entry of
moisture.
★ Check the condition of the O-rings and replace them if
damaged.
1 - Flush and recharge the system.
(For details see "AIR CONDITIONING SYSTEM - Dis-
charging, flushing and recharging").

30-43
CONDENSER ASSEMBLY

CONDENSER ASSEMBLY
(The figures depict models with 6-cylinder engines)
Removal
1 5
Remove the key from the ignition and engage the
4
parking brakes.
1 - Remove the side panels.
2 - Recover the refrigerant from the system. (For details
2
see "AIR CONDITIONING SYSTEM - Discharging,
flushing and recharging").
3 - Disconnect the pipes (2) and (3) from the condenser
(1). 3
1
F0078170
★ Immediately plug the open ends of the pipes to
prevent moisture from getting into the system.
4 - Unscrew the knobs (4) and remove the cowling (5).
1
5 - Remove the bolts (6) (n°4).
6 - Remove the condenser assembly (1).
★ Take care not to damage the fins. 6

Refitting
• Refitting is the reverse of removal.

1 6
★ Remove the plugs and connect the pipes imme-
diately, fully tightening the fittings, to prevent F0078180

moisture getting into the system.

★ Check the condition of the O-ring seals and renew
them if damaged.
1 - Flush and recharge the system.
(For details see "AIR CONDITIONING SYSTEM - Dis-
charging, flushing and recharging").

30-44
 GEARBOX OIL/FUEL COOLERS

GEARBOX OIL/FUEL COOLERS

Removal
1 - Remove the side panels.
2- Disconnect the inlet and outlet pipes (2) and (3) from
the fuel cooler (1). 2 3
★ Label the pipes and fittings to avoid confusion on
reconnection.

F0017460

3 - Disconnect the inlet and outlet pipes (5) and (6) from
the oil cooler (4).
★ Label the pipes and fittings to avoid confusion on 6 5
reconnection.
★ Plug the open ends of the pipes to prevent mois-
ture getting into the system.

F0078190

4 - Loosen the knobs (7) securing the upper cowling (8)

of the heat exchangers assembly (9); remove the 8 9
cowling.

F0078200

5 - Remove the two bolts (10) supporting the coolers (9).

10

F0078210

30-45
GEARBOX OIL/FUEL COOLERS

6 - Remove the cooler assembly (9), by pulling the handle

(11) upwards. 11
Keep the coolers vertical to prevent spillage of 9
oil/fuel.

F0078220

7 - Only if the assembly is to be renewed:

a - Draw off the fuel and oil from the coolers.
11
b - Recover the pivot bolts (12), the brackets (13) and
the handle (11) and fit to the new assembly.
13
1

12

F0017500

Refitting
• Refitting is the reverse of removal.

1
Bracket retaining bolts: Loctite 222
1 - Start the engine and allow the gearbox oil and fuel to
circulate for about 5 minutes to fill the coolers; check
the seals and fittings for leaks.
2 - Stop the engine and check the gearbox oil level; top
up, if necessary.
This operation is essential if new coolers have
been fitted.

30-46
 RADIATOR

RADIATOR

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the side panels (1) and lower cover (2).
2 - Drain off the engine coolant.

Coolant:

Mod. 80 90 100 105

1 1
ᐉ 15.5 15.5 15.5 17.5
2 2
US.gall. 4.10 4.10 4.10 4.62 F0078071

3 - Remove the gearbox oil/ fuel coolers.

(For details, see "GEARBOX OIL/FUEL COOLERS").
4 - Remove the expansion tank.
(For details, see "EXPANSION TANK").
• On some 4-cylinder models only
5 - Remove the intercooler
(For details "INTERCOOLER").

• For all versions

6 - Disconnect the hose (3) of the engine connection
pipe (4) and remove the fitting (5).
5
★ Loosen the two clips (6) and slide the hose (3)
over the pipe (4).
3

6 4

F0017511

7 - Remove the three retaining bolts (7) and (8) on the

left side of the radiator. 7

8
7
7

F0078230

30-47
RADIATOR

8 - Loosen the clip (9) and disconnect the hose (10).

9 - Remove the three retaining bolts (7) and (8) on the
right side of the radiator. 7

10 8
9
F0078240

11 - Remove the radiator (13).

11

F0044281

Refitting
• Refitting is the reverse of removal.
1 - Fill the engine cooling system

Coolant:

Mod. 80 90 100 105

ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

2 - Start the engine and run for a few minutes to allow the
coolant to circulate; check the system for leaks.
3 - Stop the engine, check the coolant level in the expan-
sion tank and top up if necessary.

30-48
 EXPANSION TANK

EXPANSION TANK

Removal
3
1 - Partially drain the engine cooling system.
3
Coolant: 5
approx. 10 ᐉ (2.64 US. gall.)
• For 4-cylinder models
2 - Disconnect the pipe (1) and remove the retaining nut
(2) of the tank (3). 2
1
• For 6-cylinder models
Disconnect the pipe (4) on the left-hand side and re- 4
move the pin (5) securing the tank (3). F0044290

3 - Disconnect the pipes (6) and (7) on the right-hand side.

4 - Unscrew and remove the nut (8) and washer (9).
8 9

F0078250

5 - Loosen and remove the bolt (10) and the washer

(11). 3
6 - Remove the expansion tank (3).

10 11

F0078260

Refitting
• Refitting is the reverse of removal.
1 - Fill the engine cooling system.
Coolant:
approx 10 ᐉ (2.64 US. gall.)
2 - Start the engine and run for a few minutes to allow the
coolant to circulate.
3 - Stop the engine, check the level in the expansion tank
and top up if necessary.

30-49
INTERCOOLER

INTERCOOLER

Removal
Remove the key from the ignition and apply the park- 1
ing brake.
1 - Remove the side panels.
2 - Unscrew the knobs (1) and remove the cowling (2). 2

F0078201

3 - Raise the gearbox oil/fuel cooler assembly (3).

★ Support the assembly above the radiator.

F0078270

4 - Loosen the hose clamps (4) securing the air inlet (5)
and outlet (6) pipes to the intercooler. 6

7
F0078181

5 - Unscrew and remove the fixing bolts (7) of the con-

denser (8).
7
6 - Raise the condenser (8) and move it towards the front
of the tractor, past the receiver-drier assembly.

7 8

F0078283

30-50
 INTERCOOLER

7 - Remove the bolts (9) and the rear nuts (10) and re-
move the intercooler (11), moving it forwards so as 9 10
to detach it from the pipes. 1

11

9 10

F0078182

Refitting
• Refitting is the reverse of removal.

1
★ Carefully check the condition of the O-rings on
the fittings of the air inlet and outlet pipes.

30-51
COMPLETE RADIATOR/COOLERS ASSEMBLY

COMPLETE RADIATOR/COOLERS ASSEMBLY

Removal
3
1 - Remove all the side panels, lamp assemblies and
lower guards.
1
2 - Recover the refrigerant from the system.
(For details see "AIR CONDITIONING SYSTEM -
Maintenance").
3 - Disconnect pipes (1) and (2) from the condenser and
the receiver-drier and the wiring harness (3).
1
★ Immediately plug the ends of the pipes and the 2
open fittings on the condenser and receiver-drier
to prevent moisture from getting into the system. F0044161

4 - Drain the coolant from the engine cooling system.

Coolant:

Mod. 80 90 100 105

ᐉ 15.5 15.5 15.5 17.5 4
5
US.gall. 4.10 4.10 4.10 4.62

5 - Remove the bolts and remove the right-hand pipe

guide (4), the intercooler pipe (where present) and the
retaining straps (5) of the front wiring loom.

F0044370

6 - For models with intercooler, remove also the left-hand

guide (6) for the air pipe.
6

F0044380

7 - Release the pipes (7), (8) and the wiring from the re-
taining straps
7
8 - Label and disconnect the pipes from oil cooler (9) and
fuel cooler (10).
★ Immediately plug the ends of the pipes and the
10
open fittings on the coolers to prevent the entry of
contaminants.
9 - Remove the expansion tank.
(For details, see "EXPANSION TANK"). 9

8
F0044390

30-52
 COMPLETE RADIATOR/COOLERS ASSEMBLY

10 - Disconnect the hoses (11), (12) from the radiator; re-

cover the bulkhead fitting (13).
13 11

12

F0044400

11 - Remove the bulkhead (14) and direct the oil and fuel
cooler pipes (15) and (16) towards the rear of the
tractor.
16

14

15

F0078290

• For versions with intercooler

12 - Loosen the clips (17) and slide the hose (18) over the 17
outlet pipe (19). 20
13 - Remove the collar (20). 22
14 - Loosen the clips (21) and slide the hose (22) over the 19
suction pipe (23).
18

21 23

F0078300

15 - Loosen the clips (24) and remove the pipe (25) to the
intercooler. 2

25
24

F0078241

30-53
COMPLETE RADIATOR/COOLERS ASSEMBLY

• For all versions

16 - Attach a hoist (26) to the complete assembly.

Assembly: 28 kg (61.7 lb.)

26

F0044423

17 - Remove the front retaining bolts (27), (28) and remove

the complete assembly (26).

27

Refitting 28
• Refitting is the reverse of removal. F0078281

1
★ Remove the plugs and immediately connect the
pipes, fully tightening the fittings, to prevent mois-
ture from getting into the system.
★ Check the condition of the seals and renew them if
damaged.
2
★ Carefully check the condition of the O-ring seals
on the pipes; if in the least doubt about the con-
dition of these parts, fit new ones.
1 - Flush and recharge the air conditioning system. (For
details, see "AIR CONDITIONING SYSTEM - Dis-
charging, flushing and recharging").
2 - Fill the engine cooling system with coolant.

Coolant:
Mod. 80 90 100 105
ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

3 - Start the engine and run for a few minutes to allow the
coolant to circulate.
4 - Stop the engine, check the coolant level in the expan-
sion tank and top up if necessary.

30-54
 FLEXIBLE COUPLING OF THE FRONT PTO

FLEXIBLE COUPLING OF THE FRONT PTO

Renewal
1 - Remove the side grilles (1), and the lower cover (2).

1 1
2 2
F0078071

2 - Remove the front (3) and rear (4) retaining bolts of the
radiator support (5).

4
5

3
F0078282

3 - Release from its clips and disconnect the wiring (5)

of the air conditioning pressure switch (6). 5 6

4 - Drain the coolant from the engine cooling system.

Coolant:
max. 17.5 ᐉ (4.62 US. gall.)

F0044151

5 - Recover the refrigerant from the air conditioning

system.
(For details, see "AIR CONDITIONING SYSTEM -
Maintenance").

F0077990

30-55
FLEXIBLE COUPLING OF THE FRONT PTO

6 - Disconnect the inlet and outlet pipes (7) and (8) from
the evaporator.

F0078183

7 - Disconnect the connection pipe (9) to the expan-

sion tank (10).
8 - Remove the nut (11) and the washer (12). 11 12

10
9

F0078251

9 - Disconnect the pipe (13) from the left side of the ex-
4 CYLINDERS 6 CYLINDERS
pansion tank; remove the expansion tank.

13

13

F0044451

10 - Loosen the clips (14) and slide the hoses (15) and
(16) on the to the pipes (17) and (18). 14 17

15

16 18

14
F0078301

30-56
 FLEXIBLE COUPLING OF THE FRONT PTO

• For models with intercooler

11 - Also remove the guides (19) for the inlet and outlet
pipes.
19

19

F0044342

12 - Disconnect and remove the inlet pipe (20).

(For details see "COMPLETE RADIATOR/COOLERS
ASSEMBLY").

20

F0078310

• For all versions

13 - Move the radiator/coolers assembly (21) toward
the front of the machine. 21

F0044481

14 - Loosen and fully unscrew the six bolts (22) securing

the flange of the cardan shaft (23).
15 - Detach the flange (24) from the flexible coupling 22 25
(25).

23 24

F0078014

30-57
FLEXIBLE COUPLING OF THE FRONT PTO

16 - Loosen and remove the bolts (26) securing the cou-

pling (25) and remove the coupling. 1
25

26

F0018675

Refitting
• Refitting is the reverse of removal.

1
Bolts: Loctite 243
Bolts: 139±10% Nm (102.4±10% lb.ft.)
1 - Fill the engine cooling system with coolant.

Coolant:
max. 17.5 ᐉ (4.62 US. gall.)

30-58
 TURBOCHARGER

TURBOCHARGER

Removal
1 - Loosen the bolts (1) and move the connecting strap
(2) down.

2 1

F0044570

2 - Loosen the clips (3), (4) and (5) and remove the air
suction pipe (6) of the trailer braking compressor.
3

6 5

F0078322

3 - Disconnect the oil vapour suction pipe (7).

F0078330

4 - Unplug the connectors (8) of the filter clogged sen-

sor (9).
8

F0078340

30-59
TURBOCHARGER

5 - Loosen the clips (10) securing the hose (11).

6 - Remove the hose (11).

10

11

10

F0078350

7 - Loosen the clips (12) and push the hose (13) on to

the pipe (14). 12 14
8 - Loosen the clip (15) and remove the pipe (14) sup-
plying air to the intercooler.
9 - Remove the turbocharger (16) following the instruc- 14
tions in the “ENGINE WORKSHOP MANUAL”.
13 15
12
16

F0078361

10 - Loosen and remove the retaining nuts (17) and de-

tach the silencer (18) from the studs of the turbo- 17 18
charger (16).
★ Recover the bracket (19).
19

16

16
F0078371

11 - Remove the metal gasket (20).

★ Note which way round the gasket is fitted.
12 - Remove the turbocharger (16) following the proce-
dure described in the engine workshop manual.
20
Refitting
• Refitting is the reverse of removal.

16
F0078381

30-60
 AIR INLET PIPE

AIR INLET PIPE

Removal
1 - Loosen the hose clamp (1) and disconnect the hose (3)
from the pipe (2).
2 - Unscrew and remove the bolts (4).

3
1
2

4
F0044520

3 - Remove the nut cover (5) and, while supporting the

pipe (2), remove the upper retaining nut (6) and washer
(7).
2

5 6 7

F0017670

Refitting
• Refitting is the reverse of removal.

30-61
AIR CLEANER

AIR CLEANER

Removal
1 - Remove the screw (1) to release the clip (2). 2
2 - Loosen the clips (3) and (4) and remove the inlet
pipe (5) of the trailer braking air compressor.

5 4
1
3

F0078321

3 - Unplug the connectors (6) of the filter clogging sen-

sor.
6
4 - Loosen the clip and disconnect the oil vapour suc-
tion pipe (7).

F0078390

5 - Loosen the clips (8) and remove the suction hose

(10) from the air cleaner (9). 9

8 8 10

10

F0078400

6 - Loosen the clip (11) of the suction hose (12) and dis-
connect the hose from the air cleaner (9).

11
9

12

F0078411

30-62
 AIR CLEANER

7 - Loosen the screw (13) of the clip (14) securing the

air cleaner (9). 14

13

9 F0044551

8 - Remove the complete air cleaner assembly (9).

9

F0044561

Refitting
• Refitting is the reverse of removal.
★ Check that all the hose clamps are fully tightened.

30-63
EXHAUST PIPE

EXHAUST PIPE

Removal 6 CYLINDERS
Remove the key from the ignition and apply the park-
ing brake.
1 - Unscrew the bolts (1) and move the clamp (2) joining
the exhaust and the silencer. 1
2

F0044570

4 CYLINDERS

F0044580

2 - Attach a hoist to the exhaust pipe (3) and put the lifting
sling under slight tension.
Exhaust pipe: approx. 23 kg (50.7 lb.)
3 - Remove the bolts (4) and the nuts (5).
4 - Remove the exhaust pipe (3).

Refitting
• Refitting is the reverse of removal.

5 4
F0044590

30-64
 SILENCER

SILENCER

Removal
Remove the key from the ignition and apply the park-
ing brake.
1 - Loosen the bolts (1) and move the clamp (2) joining the
exhaust pipe to the silencer. 1
2
2 - Position the spacers “A” between the cylinder head
and silencer.

F0044572

3 - Loosen the clips (3), (4) and (5) and remove the air
compressor suction pipe (6).
3

6 5

F0078322

4 - Remove the nuts (7) securing the silencer to the tur-

bocharger (8) and remove the silencer (9). 7
★ Recover the part (10) for fixing the clip securing 8
the air compressor suction pipe.

9
10

F0078420

5 - Remove the gasket (11).

★ Note which way round it is fitted.
11
Refitting 11
• Refitting is the reverse of removal.

F0078430

30-65
4WD PROPELLER SHAFT

4WD PROPELLER SHAFT

Version without front suspension
Removal
Remove the key from the ignition and apply the park-
ing brake.
1 - Using suitable lifting equipment, raise the front of the
tractor by about 10-12 cm (4-5 in.).
2 - Position a jack “A “capable of supporting the tractor's
weight under the front carrier.

F0044630

3 - Remove the bolts (1) and remove the locating and

retaining washers (2) of the tank (3). B
★ Mark the washers so as to avoid error when re-
fitting the tank. 2
★ Note the position of the hole “B” as the tank is
levelled by rotating the front washer.

3
F0018636

4 - Label and disconnect the fuel suction pipe (4) and

return pipe (5) and the level indicator connector (6).
★ The fuel suction and return pipes are marked on 4
the side of the connection fittings.

6
5

F0078440

5 - Move the fuel tank 8–10 cm towards the outside.

Loosen and remove the bolt (7) securing the spacer
(8) and the lower guard.

F0078450

30-66
 4WD PROPELLER SHAFT

6 - Support the lower guard (9) and remove the bolt

(10).
7 - Remove the front bolts and remove the guard (9).

9
10

F0078460

8 - Position a jack “C” under the shaft (11) and remove

the bolts and self-locking nuts (12).
1
★ To enable removal of the upper bolts, turn the 12
wheels by hand.

11

F0078470

9 - Disconnect the flanges, lower the jack and with-

draw the shaft (11) towards the front of the tractor.
2

C
11

F0078482

Refitting
• Refitting is the reverse of removal.

1
Nuts: 43.5±10% Nm (32±10% lb.ft.)
★ Tighten the nuts in a cross-wise sequence.

2
Rear coupling: Grease

30-67
4WD PROPELLER SHAFT

4WD PROPELLER SHAFT

Version with front suspension
Removal
Before switching off the engine, disengage the front
suspension by pressing the button in the cab for at
least 20 seconds.
Remove the key from the ignition and apply the park- 1
ing brake. A
1 - Using suitable lifting equipment, lift the front of the
tractor so that the wheels are raised by about 10-12
cm (4-5 in.).
2 - Position a jack “A “capable of supporting the tractor's
weight under the front carrier (1). F0044660

3 - Position under the swinging suspension support (2) a

stand “B “that can be lowered through 10-12 cm (4-5
in.).

F0044670

4 - Discharge the residual pressure from the suspension

system by unscrewing the valve (3) two full turns.

3 3

F0078490

5 - Remove the bolts (4) and remove the locating and

retaining washers (5) of the tank (6). C
★ Mark the washers so as to avoid error when re-
fitting the tank. 5
★ Note the position of the hole “C” as the tank is
levelled by rotating the front washer.

6
F0018637

30-68
 4WD PROPELLER SHAFT

6 - Mark the fuel suction pipe (7) and return pipe (8) and
disconnect them level indicator connector (9).
★ The fuel suction and return pipes are marked on 7
the side of the connection fittings.

9
8

F0078441

7 - Move the fuel tank 8–10 cm towards the outside.

Loosen and remove the bolt (10) securing the spac-
er (11) and the lower guard.

11

10

F0078451

8 - Remove the straps (12) to release the differential

lock pipe (13).

12
13

12
F0044692

9 - While supporting the lower guard (14), remove the

bolt (15).

14
15

F0078461

30-69
4WD PROPELLER SHAFT

10 - Remove the front bolts (16) and remove the lower

guard (14).

16 16

14
F0017842

11 - Disconnect the pipes (17) of the left-hand suspension

cylinder.
★ Plug the ends of the pipes to prevent the entry of
contaminants.
Loosen the fittings of the flexible hoses by a few
turns and, before removing them, push them to
detach them from the couplers and thereby dis-
charge any residual pressure from the system.

17 17

F0044701

12 - Disconnect the pipes (18) from the right-hand sus-

pension cylinder.
★ Label the pipes to avoid confusion on refitting.
18
★ Plug the pipes and the open fittings to prevent the
entry of contaminants.
13 - Remove the bracket (19) and remove the pipes.

19
F0044711

14 - Position a jack “D” under the shaft (20) and remove the
flange bolts and nuts (21).
1
★ In order to remove the upper bolts, lower the jack 21
positioned in step 3.

20

F0078471

30-70
 4WD PROPELLER SHAFT

15 - Separate the flanges, lower the jack “D “and withdraw

the shaft (20) towards the front of the tractor.
2

D 20

F0078483

Refitting
• Refitting is the reverse of removal.

1
Nuts: 43.5±10% Nm (32±10% lb.ft.)
★ Tighten the nuts in a cross-wise sequence.

2
Rear coupling: Grease
1 - Start the engine and engage the front suspension by
pressing the relative button in the cab.
2 - Wait a few seconds and then disengage the front sus-
pension.
3 - Repeat this operation a number of times to purge the
air from the system.
4 - Stop the engine, check the oil level and top up if nec-
essary.

30-71
BRAKE MASTER CYLINDERS

BRAKE MASTER CYLINDERS

Removal
Remove the battery cover and disconnect the nega- 1
tive battery lead (–).
1 - Remove the console shroud. (For details, see "CEN-
TRE CONSOLE AND SHROUD").
2 - Remove the engine hood and side panels. (For de-
tails, see "ENGINE HOOD AND LAMP ASSEM-
BLIES").
3 - Remove the air cleaner. (For details, see "AIR CLEAN-
ER").
F0078550

4 - Unplug the connectors (1) of the brake fluid level warn-

ing light.
5 - Remove the cap (2) and draw off the fluid contained in 2
the brake fluid reservoir (3).
3
6 - Remove the screws and remove the insulation panel
(4).
4

F0078500

7 - Disconnect the pipes (5) from the reservoir (3); remove

the hood support (6) complete with the reservoir.

F0018762

8 - Disconnect the feed pipes (7) and the by-pass pipe (8)
between the cylinders (9).
9

8 F0044730

30-72
 BRAKE MASTER CYLINDERS

9 - Remove the cotter pins (10) and remove the pins (11)
connecting the pedals (12) to the cylinders (9).
14
10 - Unscrew and remove the three bolts (13) with their
washers and remove the cylinders (9).
9
10

11

12 13 F0018780

Refitting
• Refitting is the reverse of removal.
1 - Fill the brake fluid reservoir to the maximum level.
2 - Check the positions of the switches.
(For details, see "BRAKE LIGHT SWITCHES").
3 - Bleed the air from the braking system.
(For details, see "BRAKING SYSTEM").

30-73
BRAKING SYSTEM

BRAKING SYSTEM

Bleeding
1 - Disconnect the two brake pedals (1) by disengaging
1
the latch pin (2).
2 - Bleed the left rear brake.
3 - Bleed the right rear brake.
4 - For tractors with hydraulic or air trailer braking
only: bleed the trailer brake valve before bleeding the 2
service brake system.

F0018791

Brake bleeding procedure

During brake bleeding operations, ensure that the flu-
id in the brake fluid reservoir is always above the min-
imum level.
1 - Remove the dust cap and attach a transparent bleed 1
tube “A” to the bleed screw (1) of the cylinder (2). A
2 - Fully depress the brake pedal corresponding to the 2
brake to be bled.
3 - Slowly open the bleed screw (1) and allow the fluid and
air to flow throughout the entire pedal travel.
F0044740
4 - While holding the pedal fully depressed, tighten the
bleed screw.
5 - Repeat the operation until the fluid flowing from the
bleed screw is entirely free of air bubbles.
6 - Repeat the procedure for the remaining brake cylin-
der.
7 - After bleeding, replace the bleed screw (1) dust caps.

8 - Use the same method also for the service brakes.

Bleed the left brake first and then the right brake. 1

3
F0078510

30-74
 BRAKING SYSTEM

9 - Bleed the braking valve at the bleed screws (1) (pro-

tected by caps) using the method indicated for the
1
A
pumps and choosing from among the following ver-
sions:
A - Pneumatic parking brake control valve.

F0043971

B - Hydraulic braking valve (CUNA).

B
1

F0044760

C - Hydraulic braking valve (EXPORT).

C

F0044061

30-75
BRAKE LIGHT SWITCHES

BRAKE LIGHT SWITCHES

Adjustment
★ The switch for each pedal is adjusted separately.
2
1 - Check that the pedal latch pin (1) slides freely to con-
nect and disconnect the two pedals (2).

F0018790

2 - Force the pedals (2) upwards and check that the brake
light switches (3) have an extra opening travel of 1±0.2 3
mm (0.04±0.008 in.).
★ This extra travel protects the switches from im-
pacts at the end of travel caused by sudden re-
lease of the pedals.

F0018800

3 - If the switches (3) do not have this extra travel, loosen

the screws (4) so that they just grip the switch; move 3
the switch towards the front of the tractor and tighten 4
down the screws (4) to fix it in position. 4

F0018810

30-76
 POWER STEERING UNIT

POWER STEERING UNIT

Testing
1
1 - Disconnect a steering pipe (1) and connect a fitting
“B” with a 400 bar pressure gauge “A”.
2 - Start the engine and turn the wheel back and forth be-
tween the full lock positions to eliminate all air from the
system.
3 - Force the steering to full lock on the side to which the
pressure gauge is connected and read off the maxi- A B
mum continuous pressure on the gauge “A”.
★ Maximum permissible pressure:
191–198 bar (2270–2871 psi) F0044770

4 - If the pressure reading differs from that specified, ad-

just the maximum pressure valve (2) of the power 6
3
steering unit (3). 4

F0012581

Adjustment
1 - Remove the plug (4).
2 - Loosen off the screw (5) using a 4 mm hex socket
wrench.
• To INCREASE the pressure, turn the screw
CLOCKWISE.
• To REDUCE the pressure, turn the screw
COUNTER-CLOCKWISE
3 - Refit the plug (4), checking the gasket (6) is in its seat-
ing.

Plug: 50±10 Nm (36.8±7.4 lb.ft.)

30-77
POWER STEERING UNIT

Removal
1
1 - Remove the console shroud. (For details, see "CEN-
TRE CONSOLE AND SHROUD"). 2

2 - Mark the hoses (1) and disconnect them from the

power steering unit (2).
★ Plug the pipelines and ports to prevent impurities
getting in.
1 1

F0078520

3- Unscrew the retaining bolts (3) and washers (4).

3 4

3 4

F0044790

4 - Remove the power steering unit (2).

★ If necessary, reposition the plate (5) with the rela-
tive bushes (6). 2

2
Refitting
• Refitting is the reverse of removal.
F0044800
1
Pipe fittings: 60 Nm (44.2 lb.ft.)
Eye fitting: 29 Nm (21.4 lb.ft.)

2
5
★ If the fittings have been removed, replace the
seals. Torque reassembled fittings to 70
Nm (51.6 lb.ft.).
6
1 - Start the engine, and steer full lock on each side a few
times to eliminate any air from the power steering cir-
cuit.
2 - Check the fittings and pipelines for leaks.
F0044810

30-78
 POWER STEERING UNIT

Dismantling

26
27
28
29
31 15
14
24 18 13

32 "ç
"çb
33 "ça 19
34
35 21
20
22
16
&)a

&)b
12
10

17

"'a
"'b

"' "'a
8 ça

7 6

11
9
2

5 1

D0001200

30-79
POWER STEERING UNIT

Dismantling the power steering unit

1 - Loosen and remove the screws (1) and (3) and wash-
3
1 2
ers (2) securing the cover (4) (6 bolts plus 1 special
screw).

F0009470

2 - Remove the cover (4) by sliding it off sideways.

4

F0009480

3 - Lift off the rotor assembly (5) complete with O-rings (6)
and distance piece (7). 5

6 7

F0009490

4 - Remove the shaft (8).

F0009500

30-80
 POWER STEERING UNIT

5 - Remove the distributor plate (9).

F0009510

6 - Remove the stop bushing (10) of the safety valve.

10

F0009520

7 - Remove the O-ring (11).

11

F0009530

8 - Withdraw the ball (12) of the check valve, the valve

stems, the springs (14) and the balls (15) of the anti-
cavitation valves.
15 14

14

12 13

F0009540

30-81
POWER STEERING UNIT

9 - Checking through the central hole of the spool valve,

ensure that the pin (16) connecting the inner and outer
sleeves of the spool is positioned horizontally.
Push the entire spool assembly (17) and the bearing
out of the steering unit housing (18).
17

18
F0009550

10 - Remove the outer thrust washer (19), the inner thrust

washer (20) and the needle roller bearing (21) from the
spool; remove also ring (22).
★ The inner thrust washer (20) (thin) can sometimes
remain inside the housing; check that it is re- 22 20
moved.

21
19
F0009560

11 - Remove the trim spin (16), outer sleeve (17b) and the
inner sleeve (17a).
★ Use the special cover bolt (3).

17b

3 16
17a
F0009570

12 - Carefully slide the inner sleeve (17a) out of the outer

sleeve (17b).
17b

17a

F0009580

30-82
 POWER STEERING UNIT

13 - Push the springs (23) into the neutral position and

withdraw them from the inner sleeve (17a).
23

17a

F0009590

14 - Remove the dust seal (24) and the composite seal (25)
(O-ring + gasket).

25

24

F0009600

15 - Remove the plugs (26) of the anti-shock valve.

26 27

F0009611

16 - Remove the seals (27).

27

F0009620

30-83
POWER STEERING UNIT

17 - Remove the calibration screws (28).

28

F0009630

18 - Remove the springs (29) and the two balls (30).

★ The valve seats are force fit in power steering unit
and cannot be removed.

29
30

28
F0009641

19 - Check that all the valve parts are present as show in

the photo. 30 29 28 27 26

30 29 28 27 26
F0009650

Removal of the safety valve

20 - Remove the plug (31) and the relative seal.

31

F0009660

30-84
 POWER STEERING UNIT

21 - Remove the maximum pressure adjustment screw

(33).

33

F0009670

22 - Turn the power steering unit upside down and remove

the spring (34) and valve (35).
★ The valve seat is a force fit in the power steering
housing and cannot be removed.
35

34

F0009680

30-85
POWER STEERING UNIT

Assembly
★ Before assembly, lubricate all components with gear-
box oil. 23b
1 - Insert the two flat springs (23a) and position them cen- 23a
trally relative to the diameter of inner sleeve of the
spool (17a). Insert the four curved springs (23b), ar-
ranged in pairs, between the two flat springs (23a) and
push them in fully.
23b 23a 17a

F0009690

2 - Align the springs (23).

23

F0009700

3 - Insert the inner sleeve (17a) in outer sleeve (17b).

★ Check that the relative positions of the inner and
17b
outer sleeve are as described in stage 1.

17a

F0009580

4 - Simultaneously push the springs (23) and the inner

sleeve (17a) so that the springs locate in the outer
sleeve (17b). 23

17a

17b

F0009710

30-86
 POWER STEERING UNIT

5 - Align the springs (23) and position them centrally rel-

ative to the diameter of the outer sleeve (17b).
23

17b
F0009720

6 - Fit the ring (22) on to its seating on the outer sleeve

(17b).
★ The ring (22) must rotate freely without interfer-
ence with the springs (23). 22

17b
F0009730

7 - Insert the trim pin (16).

16

F0009740

8 - Fit the thrust bearing parts in the order indicated in the

assembly diagram in point 9.

20

22 21 F0009751

30-87
POWER STEERING UNIT

9 - Bearing assembly diagram

17a -Inner sleeve
20
17b -Outer sleeve
21- Needle roller bearing 21
20 -Inner thrust washer
22
22 -Outer thrust washer
X
The chamfer “X” of the outer thrust washer
must be oriented towards the shoulder on the 17a
inner sleeve.

17b
D0001181

10 - Position the steering unit (18) so that the central bore is

horizontal.
Insert the guide of tool T1 (code 5.9030.480.0) into the
bore of the inner/outer sleeve assembly.
T1

18

F0009761

11 - Oil the seal (25a) and O-ring (25b) and fit them on the
plunger of tool T1 (code 5.9030.480.0).
T1

25a 25b

T1 F0009771

12 - Assemble tool T1 (code 5.9030.480.0) and insert it in

the guide previously inserted in the central bore of the
power steering unit.

25
T1
F0009781

30-88
 POWER STEERING UNIT

13 - Push the seal (25) into the seating in the power steer-
ing unit (18), turning it slightly to ensure correct posi-
tioning.

18
F0009790

14 - Withdraw the tool T1 (code 5.9030.480.0) and the

guide from the steering unit housing, leaving the seal
installer plunger in place. T1

18
F0009801

15 - Insert the spool assembly (17) in the bore of the power

steering unit (18), turning its slightly to assist insertion.
★ Insert the assembly while keeping the trim pin in a 17
horizontal position.

18
F0009810

16 - Push the spool assembly (17) fully home in order to ex-

pel the seal installer plunger left in the bore in step 14. 18

17

F0009820

30-89
POWER STEERING UNIT

17 - Turn over the power steering housing (18) so that the

central bore is vertical.
Insert the ball (12) of the safety valve in the hole indi- 12
cated in the photo.

18

F0009830

18 - Screw the stop bush (10) into the safety valve hole.
★ The top of the bush must be positioned lower than
the face of the steering unit housing (18).
10

18

F0009521

Assembly of the anti-cavitation valve

19 - Insert the balls (15) into the two holes indicated by the
arrows.

15

F0010310

20 - Insert the valve stems (13) complete with springs (14)

into the same holes.
13

14

F0009840

30-90
 POWER STEERING UNIT

21 - Oil the O-ring (11) and fit it in its seat.

11
O-ring: gearbox oil

F0009850

22 - Position the distributor plate (9) so that its holes are

aligned with those in the power steering housing (18). 9

18

F0009860

23 - Insert the shaft (8) in to the central bore so that en-

gages the trim pin; check that trim pin engagement is
parallel to the face of the power steering unit by which
it is attached to the steering column.
8

F0009870

24 - Position the shaft vertically and hold it in place using

the specific tool.

F0009880

30-91
POWER STEERING UNIT

25 - Oil the two O-rings (6) and install them in the two seats
in the rotor assembly (5). 6
O-rings: gearbox oil
8

F0009890

Fit the inner rotor (5a) on the shaft (8) so that the lowest
part between two lobes of the rotor is aligned with the
trim pin groove on the shaft. The rotate the outer rotor
(5) to align the fixing holes.

5a

F0009900

26 - Fit the distance piece (7).

7

F0009910

27 - Fit the cover (4).

F0009920

30-92
 POWER STEERING UNIT

28 - Insert the special screw (3) complete with washer (2) in

the hole shown in the photo.

F0009930

29 - Insert the six screws (1) with washers (2).

Tighten the screws(1) and (3) in crosswise pattern to a 3
torque of 30±6 Nm (22.1±4.4 lb.ft.). 1 2

F0009471

Assembly of the pressure relief valve

30 - Insert the valve (35).

35

F0009940

31 - Insert the spring (34)

34

F0009950

30-93
POWER STEERING UNIT

32 - Fit the pressure adjuster screw (33).

★ Set the maximum operating pressure on a test
bench.
★ Pressure: 180+10 bar (2610+145 psi)

33

F0009670

33 - Fit plug (31) complete with seal.

Plug: 50±10 Nm (36.8±7.4 lb.ft.)

31

F0009660

34 - Position the dust seal (24) in the power steering unit

housing (18). 24

18

F0009970

35 - Drive the dust seal (24) into its seating using a suitable
drift and a plastic mallet.

F0009980

30-94
 POWER STEERING UNIT

Assembly of shock valves

36 - Insert the balls (30), springs (29) and setscrews (28) in
their sockets.

29
30

28
F0009641

37 - Lock the setscrews (28) in their seats.

28

F0009630

38 - Fit the seals (27) and screw in the plugs (26).

Plugs: 30 Nm (22.1 lb.ft.)

26 27

F0009611

39 - Close off the oil ports with plastic plugs to prevent im-
purities getting in.
★ Fit the plugs by hand pressure alone; do not
hammer.

F0009990

30-95
FRONT WHEELS

FRONT WHEELS

Removal
On tractors with front suspension, before stopping
the engine to remove the front wheels, disengage
the front axle suspension by pressing the relative
button in the cab.
1 - Apply the parking brake.
• For normal front axles
2 - Position centrally under the pivoting support (1) a trol-
ley jack “A” with a minimum lifting capacity of 5 tons
and maximum lift height of at least 15 cm (6 in.).
★ Drive safety wedges between the axle and the axle
support.
• For suspended front axles
2 - Position centrally under the pivoting support (1) a trol-
ley jack “A” with a minimum lifting capacity of 5 tons
and maximum lift height of at least 15 cm (6 in.).
B
B
• For all versions
3 - Raise the front end of the tractor sufficiently to elim-
inate flexure of the tyre walls and to lift the wheels by 1
approximately 2 cm (0.8 in.).
4 - Position two jacks “B” under the axle; lower the trolley
jack so that the axle is supported on the jacks “B” with
the wheels off the ground and then remove trolley jack A
“A”. F0078530

★ Jack lifting capacity: minimum 2 tons.

5 - Slacken off all the wheel nuts (1); remove the wheel
nuts, leaving one (for safety) at the top of the wheel.
1
1
6 - While holding the wheel vertical, remove the last nut
2
and remove the wheel (2).
7 - Repeat the above operations to remove the other rear
wheel.

F0078540

Refitting
• Refitting is the reverse of removal.
1
4WD wheel nuts: 350 Nm (258 lb.ft.)
★ Tighten the wheel nuts gradually in a crosswise se-
quence.

30-96
 FRONT FENDERS

FRONT FENDERS

Removal
★ Removal of the front fenders is only necessary for ma-
jor repairs and overhauls where additional working
space is required at the side of the tractor and when-
ever the tractor is to be supported on stands.
1 - Remove the front wheels.
(For details, see "FRONT WHEELS").

2 - Attach a hoist to the fender to be removed (1).

Fender assembly: 19 kg (42 lb.)

F0078600

3 - Unscrew and remove the bolts (2) and remove the

fender (1) complete with the mounting bracket (3).

1
2

F0078610

Refitting
• Refitting is the reverse of removal.

30-97
REAR WHEELS

REAR WHEELS

Removal
1 - Position under the rear gearbox a trolley jack “A” with
minimum lifting capacity of 5 tons and a maximum lift-
ing height of at least 15 cm (6 in.).
★ Position the trolley jack “A” so that it is nearer to
the wheel to be removed.
2 - Raise the tractor sufficiently to eliminate the flexure of
the tyre wall.

A
F0044860

3 - Slacken off all the wheel nuts (1); leaving one (for safe-
ty) at the top of the wheel.
1
2 1
4 - While holding the wheel vertical, remove the last
wheel nut and remove the wheel (2).

F0044051

5 - Position under the rear axle an axle stand “B” with lat-
eral retaining wings for safety and lower the trolley jack
until the axle is resting on the axle stand.
★ Axle stand load capacity: 2 tons minimum.
6 - Check that the stand is in exactly the right position and
then remove the trolley jack.
7 - Repeat the above operations to remove the other
wheel.
B

F0078620

Refitting
• Refitting is the reverse of removal.

1
Wheel nuts:
M18x1.5: 350 Nm± 10%(258 lb.ft.±10%)
★ Tighten the wheel nuts gradually in a crosswise se-
quence.

30-98
 LIFT VALVE BLOCK

LIFT VALVE BLOCK

Removal
Fully lower the lift and switch off the engine. 1

1 - With the control levers (1), (2) in the horizontal position,

label the lower pipes (3) and disconnect them from the 2
valve block (4).
4
★ Label the pipes to avoid confusion on reconnec-
tion.
3

F0017940

2 - Disconnect the rigid upper pipes (5), (6).

★ Plug the ends of the pipes to prevent the entry of
contaminants.
6 5

F0018680

3 - Unscrew the bolts (7) and remove the valve block (4)
with the rear spacers (8).

7
F0018710

Refitting
• Refitting is the reverse of removal.

30-99
FRONT LIFT CYLINDERS

FRONT LIFT CYLINDERS

Removal
★ Raise the lift to its full height and switch off the engine.
1 - Remove the lift arms (1) and the pivot pins (2) along 1
with their retaining chains.
2 - Position under the lift assembly (3) a jack”A” which 1
can be lowered at least 10 cm (4 in.).
3 2
2
A
F0017970

3 - Remove the bolts (4) and remove the upper pins (5) of
the cylinders (6).
5

4 6

6
F0017980

4 - Disconnect the cylinder feed pipes (8), (9) from the

valve block (7).
Loosen the fitting by a few turns, but before fully
disconnecting them, push them to detach them
from the couplers and release any residual pres- 7
sure in the system.
★ Label the pipes to avoid confusion on reconnec-
tion. 8

F0017941

5 - Lower the jack”A” until the cylinders (6) can be tilted

outwards in order to access the connection pipes and
to align the hole provided for removal of the spring
pins securing the lower pivot pins of the cylinders. 6 6

F0017990

30-100
 FRONT LIFT CYLINDERS

6 - Disconnect the four pipes (10) from the cylinders (6).

★ Label the pipes to avoid confusion on reconnec-
tion.
10

6 6 10

F0018000

7 - Using a pin punch, remove the spring pins (11) secur-

ing the lower cylinder pivot pins.

11

F0018010

8 - Withdraw the pivot pins (12) and remove the cylinders

(6).
6

12

F0018720

Refitting
• Refitting is the reverse of removal.
1 - Start the engine and repeatedly raise and lower the lift
to the limit of its travel in order to bleed the system and
check for leaks.
2 - Stop the engine, check the gearbox oil level and top
up if necessary.

30-101
FRONT LIFT ASSEMBLY

FRONT LIFT ASSEMBLY

Removal
★ Raise the lift arms to the maximum height and stop the
engine.
1 - Disconnect the lower pipes from the valve block (1).
Loosen the fitting by a few turns, but before fully
disconnecting them, push them to detach them
from the couplers and release any residual pres-
sure in the system. 1
★ Label the pipes to avoid confusion on reconnec-
tion.
★ Plug the ends of the pipes and the open fittings on
the valve block to prevent the entry of contami- F0018020

nants.
2 - Remove the lift arms (2) and the pivot pins (3) complete
with their retaining chains.
3 - Remove the shaft end cover (4) and the shield (5). 2
4
2
5

3
3

F0018030

4 - Position under the lift assembly (6) a jack”A” that can

be lowered by at least 10 cm. (4 in.).

F0017971

5 - Remove the bolts (7) and remove the upper pivot pins
(8) of the cylinders (9). 8

9 9
7

F0017981

30-102
 FRONT LIFT ASSEMBLY

6 - Lower the jack”A” so that the cylinders (9) can be tilted

outwards.
7 - Remove the jack”A” and guide the rocker assembly
9 9
(10) to the vertical position.

10

F0017991

8 - Unscrew and remove the bolts (11) and washers (12)

15
securing the brackets (13); recover the inner brackets 16
(14). 13

9 - Remove the spacer (15) and the lower bushes (16). 11

★ Do not remove the upper bushes yet for safety. 12

14

F0018040

10 - Attach a hoist to the lift assembly (6) and put the lifting
slings under slight tension.
Lift: 80 kg (176 lb.)

F0018050

11 - Unscrew and remove the ten bolts (17) and washers

securing the lift (6) to the front carrier. 6
1
17

F0018060

30-103
FRONT LIFT ASSEMBLY

12 - Remove the upper bushes (16) but leave them in po-

sition for safety.

16

F0018730

13 - Remove the lift assembly (6).

★ If necessary, use a lever to separate the assembly
from the front locating dowels.

F0018070

Refitting
• Refitting is the reverse of removal.

1
Bolts M16: 214 Nm (158 lb.ft.)
Bolts M20: 455 Nm (355 lb.ft.)
1 - Start the engine, repeatedly raise and lower the lift to
its maximum travel to bleed the system and check for
leaks.
2 - Stop the engine, check the gearbox oil level and top
up if necessary.

30-104
 FRONT PTO ASSEMBLY

FRONT PTO ASSEMBLY

Removal
1 - Remove the front lift assembly.
(For details, see "FRONT LIFT ASSEMBLY") 2
2 - Unplug the connector (1) and release the wiring from
the clip (2).

1
F0018080

3 - Fully unscrew the bolts (3) securing the cardan shaft

(4) to the flexible coupling (5) and detach the flange.
5
3

4
F0078013

4 - Unscrew the four bolts (6) but only remove the two
lower bolts.
★ Leave the two upper bolts in position for safety.
1 6
5 - Fit a non-slip block to a trolley jack; position the non-
slip block under the PTO assembly.
6 - Remove the two upper bolts previously left for safety
and remove the PTO assembly (7) while supporting
the cardan shaft (4).
★ If neccessary, use a lever to help separate the as-
sembly from the tractor.
F0018090

PTO: 70 kg (154 lb.)

Refitting
7
• Refitting is the reverse of removal.

1
Screw: 214 Nm (157.7 lb.ft.)

F0018100

30-105
FRONT SUSPENSION CYLINDERS

FRONT SUSPENSION CYLINDERS

(Where fitted)
Removal
All operations must be carried out with the parking
brakes applied.
1 - Operate the button in the cab to activate the front sus- 1
pension, fully extending the suspension cylinders.
2 - Position and tighten a jack “A” under the front carrier A
(1).

F0044880

3 - Deactivate the suspension so that the cylinders are

fully retracted.
4 - Support the swinging support (2) on a stand “B” that
can be lowered through10-12 cm (4- 5 in.) and switch
off the engine. 2
5 - Remove the front wheels.
B
(For details, see "FRONT WHEELS").

F0078630

Discharge the residual pressure from the system by

unscrewing the valve (3) about two full turns
★ Wait a few minutes after discharging the pres-
sure, then re-close the valve.
6 - Remove the reinforcing side members.
(For details, see "REINFORCING SIDE MEMBERS").
3 3

F0078490

7 - Disconnect the pipes (5), (6) from the left cylinder (4).
First loosen the fittings by a few turns, then, be-
fore disconnecting the pipes, push them to de- 5
tach them from the couplers and release any 4
residual pressure.
★ Plug the ends of the pipes to prevent the entry of
contaminants.
8 - Unplug the steering sensor connector (7) 6
7

F0044900

30-106
 FRONT SUSPENSION CYLINDERS

9 - Disconnect the pipes (9), 10 from the right-hand sus-

pension cylinder (8).; disconnect the locking differen-
tial pipe (11).
10 8
★ Plug the pipes to prevent impurities getting in.

11
9

F0044910

10 - Remove the bolts (12) and the plates (13) securing the
upper cylinder pivot pins. 12

13
12

F0018202

11 - Using a slide hammer puller, remove the upper pivot

pins (14).
14

F0018212

12 - Disconnect the steering cylinder pipes (15).

★ Plug the ends of the pipes to prevent the entry of
contaminants.

15

F0044920

30-107
FRONT SUSPENSION CYLINDERS

13 - Lower the support (2) to disengage the upper mount-

ings of the cylinders (4), (8).

4 8

F0044930

14 - Remove the bolts (16) and the plates (17) of the lower
pivot pins.

16

17
F0044940

15 - Using the slide hammer puller, remove the lower pivot

pins (18) and the cylinders (4), (8).
4 8

18

F0018252

Refitting
• Refitting is the reverse of removal.
1 - Start the engine and turn the steering wheel repeat-
edly to full lock in both directions. Activate and deac-
tivate the suspension a number of times to expel air
from the system and check for leaks.
2 - Stop the engine, check the gearbox oil level and top
up if necessary.

30-108
 FRONT SUSPENSION CYLINDERS

Disassembly
1 - Relieve the staking on the lock washer located be-
tween the end cap (1) and the cylinder (2).

1
2

F0041180

2 - Using a pin wrench, unscrew the end cap (1).

1

F0041190

3 - Withdraw the rod (3) complete with end cap (1) and
seals.
2

F0041200

4 - Heat the eye of the piston (4) to a temperature of

100–120 °C (212–248 °F) and unscrew it from the rod
(3).
3 4
3

F0041210

30-109
FRONT SUSPENSION CYLINDERS

5 - Withdraw the end cap (1) from the rod and remove in
order the rod wiper (5), the seals (6), (7) and the guide
(8). 9
2 1
★ Take care not to damage the seatings of the seals.
6 - Remove the O-ring seal (9).
★ Note which way round the seals are fitted.

5
6 7 8
D0005380

7 - Remove the seal (11) and the guide (12) from the pis-
ton (10).
★ Take care not to damage the seal seating. 12 11
10

D0005390

Assembly
• Assembly is the reverse of disassembly.

1
End cap: 320–370 Nm (236–273 lb.ft.)

2
Seals: Gearbox oil

3
Piston eye: Loctite 638

Piston eye: 50–70 Nm (37–52 lb.ft.)

1 - Stake the lock washer tabs into the notch on the cyl-
inder (2) and into one of the notches on the end cap (1).

F0041220

30-110
 FRONT AXLE AND SWINGING SUPPORT

FRONT AXLE AND SWINGING SUPPORT

(Versions with front suspension)
Removal
All operations are to be carried out with the parking
brake applied.
1 - Remove the front suspension cylinders.
(For details, see "FRONT SUSPENSION CYLIN-
DERS").
2 - Position a trolley jack under the axle (2) and the swing-
ing support; raise the jack until it supports both the as-
semblies.

Group assembly: 302 kg (665 lb.) 1

F0044950

3 - Remove the cover and the 4WD shaft.

(For details, see "4WD PROPELLER SHAFT").
Disconnect the differential lock pipe (2).
★ Plug the ends of the pipes to prevent the entry of 2
contaminants.

F0044911

4 - Remove the support (3) of the position sensor (4) and

unplug the connector (5). 1
3
5

F0018282

5 - Remove the plates (6) securing the pivot pins (7) of the
swinging axle support (8).
6 - Loosen the screw of the clips for the rigid steering
pipes and rotate the plate (6) to the left to release the
pivot pin (7).
6

8 7
F0078640

30-111
FRONT AXLE AND SWINGING SUPPORT

7 - Using a suitable drift made of soft material (aluminium,

copper, etc.,), remove the pivot pins (7).

F0044970

8 - Slowly lower the jack and remove the swinging sup-

port (8) complete with the axle (1).

8
F0018311

9 - Remove the screws (9) and remove the plate (10) se-
curing the axle pivot pin (11).

10

11

F0018321

10 - Attach the swinging support (8) to lifting slings and at-

tach the slings to a hoist; put the slings under slight
tension.
11 - Using a suitable drift made of soft material (aluminium, 11
copper, etc.,), drive out the axle pivot pin (11) and re-
move the swinging support. 2

F0044980

30-112
 FRONT AXLE AND SWINGING SUPPORT

Refitting
• Refitting is the reverse of removal.

1
★ Check the calibration of the position sensor.
(For details, see "FRONT SUSPENSION POSI-
TION SENSOR").

2
Pivot pin and plain bearings: grease
1 - On starting the engine, bleed the systems as follows:
a - turn the steering wheel repeatedly to full lock in
both directions;
b - repeatedly activate and deactivate the suspen-
sion;
c - repeatedly engage and disengage the differential
lock.
2 - Stop the engine, check the gearbox oil level and top
up if necessary.
3 - Lubricate fully the axle pivot pins, the swinging sup-
port and cylinder and piston mountings.

30-113
FRONT SUSPENSION VALVES

FRONT SUSPENSION VALVES

Removal
1 - Before switching off the engine, disengage the
front suspension by pressing the pushbutton in
the cab for at least 20 seconds.
2 - Apply the parking brake.
Discharge the residual pressure from the suspension
system by unscrewing the valve (1) about two full 1 1
turns.
★ Wait a few minutes after discharging the pressure,
then re-close the valve.
F0078491

1 - Unplug the connectors (2) from the solenoid valves (3).

★ Label the connectors and solenoid valves to avoid
confusion on reconnection.
2

3 3
F0078650

2 - Disconnect the five connecting pipes (4).

First loosen the fittings by a few turns, then, be-
4
fore disconnecting the pipes, push them to de-
tach them from the couplers and release any
residual pressure.
3 - Remove the bolts (5) and remove the assembly (6). 5

F0078660

Refitting
• Refitting is the reverse of removal.
1 - Start the engine and repeatedly activate and deacti-
vate the front suspension in order to expel any air from
the system and check for leaks.
2 - Stop the engine, check the gearbox oil level and top
up if necessary.

30-114
 FRONT SUSPENSION POSITION SENSOR

FRONT SUSPENSION POSITION SENSOR

Removal
1 - Remove the cover (1).

F0017900

2 - Loosen the rear nut (2).

3 - Unplug the connector (3).
4 - Unscrew and remove the upper retaining bolt (4) of the
support (5) and loosen the lower bolt (6); rotate the 4
7
support (5). 2
5 - Remove the front nut (7) and remove the sensor (8).

3
6 8
5
F0017910

Positioning
1 - Start the engine, fully extend the front suspension cyl-
inders and fit the sensor (8) to the support (5) with the
front nut (2) fully unscrewed.
2

5
F0017930
2 - Fix the support (5) and push the sensor (8) in the di-
rection ”X” until the pin (9) is fully retracted.
3 - Keeping the pin in this position, screw in the rear nut (2)
right up to the support (5). 9 7 2 8

4 - Screw the front nut (7) up to the support (5).

5 - Back off the nut (7) by one turn and tighten the nut (2) to
secure the sensor.
★ This adjustment prevents the possibility of the
sensor sustaining impact damage at the end of its 5
travel.

Nuts: 30±6 Nm (22.1±4.4 lb.ft.) X

D0003930

30-115
FRONT SUSPENSION POSITION SENSOR

Testing
2
1 - Connect the test lead T2 (code 5.9030.743.1) be- T2
tween the sensor (8) and the wiring (3); start the engine
and, using a multimeter, check the voltage when the
cylinders are in the mid-stroke position.
★ Voltage with cylinders in mid-stroke position
= 3.8V
Fully retract the cylinders and check the voltage.
★ Voltage with cylinders retracted = 1.90–1.95V
★ The voltage is measured between the terminals of
the brown (earth) and blue (signal) wires
F0022062
NOTE. The same reading can also be taken using the
suspension section of the ART program.
(For details see ART in section 20)
2- Stop the engine, disconnect the lead T2 (code
5.9030.743.1) and reconnect the wiring to the sensor.
3- Refit the cover (1).

30-116
 REINFORCING SIDE MEMBERS

REINFORCING SIDE MEMBERS

(For versions with front lift only)
Removal
1 - Remove the front lift valve block. (For details, see
"LIFT VALVE BLOCK").
2 - Remove the air reservoir and the battery support.
(For details, see "FUEL TANK")
3 - Attach a hoist to the side member to be removed and
put the lifting sling under slight tension.

Side member: 45 kg (99 lb.)

F0078710

4 - Right side member (1): Unscrew and remove the

front bolts (2) complete with their washers and recover
the spacers (3). 1 3

F0045020

5 - Left side member (4): Unscrew and remove front

bolts (2) as per the right side member and the two rear
bolts (5) complete with washers. 1

4 5
2

2
F0045030

Refitting
• Refitting is the reverse of removal.

1
Bolts M16: 214±21 Nm (158±15.5 lb.ft.)
Bolts M20: 455±21 Nm (335±15.5 lb.ft.)

30-117
FRONT CARRIER

FRONT CARRIER
(Versions with front suspension)
Removal
Before stopping the engine, deactivate the front sus-
pension by pressing the relative button in the cab.
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove:
• the radiator/coolers assembly;
• the alternator and air conditioning compressor
drivebelts;
• the reinforcing side members;
• the lift assembly;
• the front PTO (if present);
• the front suspension cylinders;
• the front axle and swinging support.
(For details, see the corresponding headings).
2 - Loosen the bolts (1) to eliminate the tightening torque.
1 1

F0018340

3 - Attach lifting slings to the front carrier (2), attach the

slings to a hoist and put them under slight tension.
4 - Remove the bolts (1) with their washers and remove
the front carrier (2). 2
★ If necessary, use a lever to separate the locating
dowels from the engine.

F0078670

Refitting
• Refitting is the reverse of removal.

1
Bolts: 260±10% Nm (191.6±10% lb.ft.)

2
Locating dowels: grease
1 - Start the engine and operate the controls to expel air
from the various systems.

30-118
 ACCELERATOR POTENTIOMETER

ACCELERATOR POTENTIOMETER

Renewal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Loosen the grub screw, remove the accelerator pedal
(1) and remove the front floor mat (2). 1

F0030550

2 - Unplug the connector (3).

3 - Remove the screws (4) and remove the potentiometer
(5).

3
F0030560

Refitting
• Refitting is the reverse of removal.
1 - When fitting a replacement potentiometer, check the
engine speed settings with the programming/diag-
nostics tester.

30-119
FUEL TANK

FUEL TANK

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the left rear wheel.
(For details, see "REAR WHEELS").

F0044050

2 - Unplug the fuel level sensor connector (1).

3 - Label the fuel pick-up and return pipes (2), (3).
Loosen the retaining clamps and disconnect the 3
pipes.

F0078680

4 - Remove the bolts (4) and remove the locating discs (5)
of the fuel tank (6). A
★ Label the discs to avoid confusion on reassembly.
★ Note the position of the hole “A” as the tank is 5
levelled by rotating the front washer.

6
F0018638

5 - Support the fuel tank (6) with lifting equipment and

withdraw it from the guide tubes.

Refitting
• Refitting is the reverse of removal.

F0045061

30-120
 GEARBOX GEAR PUMP

GEARBOX GEAR PUMP

Removal
1 - Switch off the engine, remove the key from the ig-
nition and apply the parking brake.
2 - Allow the engine to cool down to ambient tem-
perature.
1 - Remove the right-hand side panel.
(For details see "ENGINE HOOD AND LAMP ASSEM-
BLIES").
2 - Remove the cab.
(For details see "CAB").

3 - Disconnect the connector (1), the pipe (2) and re-

move the fitting (3).
★ Plug the pipes and open fittings to prevent the
entry of impurities. 3

2
1

F0078690

4 - Disconnect the suction and delivery pipes (5) and (6)

from the pump (4). 5
★ Plug the pipes to prevent impurities getting in.

6
F0078700

5 - Remove the screw (7) and remove the complete cover

(8).

F0045081

30-121
GEARBOX GEAR PUMP

Before proceeding, close the passage between the

lower part of the pump gear and the engine sump. 11
★ Use non-crushable material. 9

6 - Remove the nut (9) securing the gear (10) and the
washer (11).

10

F0045091

7 - Turn the engine over by hand so that the slot for the
machine key is in the top position.
Using puller T3 (code 5.9030.895.0) withdraw the T3
pump drive gear (10).
Remove the machine key.
Take care not to drop the key into the crankcase.

10

F0045101

8 - Unscrew and remove the bolts (12) and remove the

13
pump (4).
★ Recover also the gasket (13) that should be re-
newed on reassembly.

12

F0045112

Refitting
13
• Refitting is the reverse of removal.
1 - Position the gasket (13).
★ To hold the gasket in place, apply grease to the
contact surface of the engine.

F0045121

30-122
 GEARBOX GEAR PUMP

2 - Position the machine key (14) on the pump shaft with

the slot facing upwards.
★ Keep the flat face of the key inclined towards the
gear hub spline.

14

F0045131

3 - Fit the pump (4) and gear (10) simultaneously.

★ To help seat the gear and the machine key cor- 4
rectly, gently turn the pump (4).

10

F0045142

4 - Hold the gear (10) in position by hand tightening the

nut (9) with the washer (11). 11
9

10

F0045091

5 - Tighten down the pump with the bolts (12).

★ Tighten alternate bolts gradually in sequence.

M10 bolts: 50±10 Nm (36.9±7.4 lb.ft.)

6 - Secure the gear (10) with the nut (9).

12
M12x2.5 nut: 50±10 Nm (36.9±7.4 lb.ft.)

F0045113

30-123
GEARBOX GEAR PUMP

7 - Remove the material closing the passage between the

engine sump and fit the cover (8).
★ Carefully check the condition of the O-ring (15).

15

7
F0045151

8 - Connect the suction and delivery pipes (5) and (6).

★ Before connecting the upper suction pipe, fill 5
the pump (4) with gearbox oil.
9 - Fit the cab and the hood side panel.
10 - Start the engine and check the gaskets and test the
operation of the gearbox.
4

6
F0078700

30-124
 POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS

POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS

Removal
1 - Switch off the engine, remove the key from the ig-
nition and apply the parking brake.
2 - Allow the engine to cool down to ambient tem-
perature.
1 - Remove the righthand hood side panel (1).
(For details see "ENGINE HOOD AND LAMP ASSEM-
BLIES"). 1

F0077840

1. Removal of the power steering pump

3
1 - Disconnect the suction and delivery pipes (2) and (3)
from the pump (1).
★ Plug the pipes to prevent impurities getting in. 1
★ Renew the O-ring on the suction pipe flange on
reassembly.

F0078720

2 - Unscrew and remove the bolts (4) and remove the

pump (1).

F0078730

3 - Remove the pumps coupling (5) and the O-ring (6).

1 6

F0045180

30-125
POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS

2. Removal of the lift and hydraulic services

pump
1 - Remove the power steering pump as described under 1
the previous heading.
2 - Disconnect the delivery pipe (2) from the gearbox
pump (1).

2
F0078701

3 - Disconnect the suction and delivery pipes (4) and (5)

from the pump (3).
5
★ Renew the O-ring on the suction flange on re-
assembly.

4
F0078740

4 - Loosen and remove the connecting bolt (6) of the

straps (7) and remove the terminal (8).

8 7

F0078750

5 - Remove the relay cover (9).

9

F0078760

30-126
 POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS

6 - Disconnect the gearbox supply pipe (2) from the fil-

ter cap (10).
2
Remove the pipe (2).

10

F0078770

7 - Loosen and remove the bolts (11) securing the

pump (3).

11

3
F0078780

8 - Remove the complete pump assembly (3).

F0045220

9 - Remove the self-locking nut (12).

10 - Using a puller, remove the drive gear (13).

12

13

F0045231

30-127
POWER STEERING - LIFT AND HYDRAULIC SERVICES PUMPS

11 - Remove the key (14) and the O-ring (15).

★ Renew the O-ring on reassembly.

14

15
F0045241

Refitting
• Refitting is the reverse of removal.

1
Coupling: grease

30-128
 REMOTE CONTROL VALVES

REMOTE CONTROL VALVES

Removal
Remove the key from the ignition and apply the
parking brake. 1
Vent residual pressure from the reservoir by remov-
ing the cap (1) and pressing the button (2) on the 3
2
pressure regulator valve (3).

F0043800

1 - Disconnect the control cable (4) from the remote

control valve to be removed.
★ Mark the positions to avoid confusion on reas-
sembly.

F0078795

• Only if the flow control knobs are fitted.

Remove only those knobs relative to the remote con-
trol valve to be removed.
6
2 - Unscrew and remove the grub screws (5) securing
the joints (6). 5

F0078801

3 - Remove the plates (7) and drive out the pins (8).
7

F0078811

30-129
REMOTE CONTROL VALVES

• For left-hand remote control valve only

4 - Remove the external outlet socket (9) and place it to
one side. 9

F0078820

5 - Disconnect the pipes (11) and (12) from the air brak-
ing valves (10).
10
If auxiliary pressure couplers are provided, discon-
nect the supply, return and, if present, the load 12
sensing pipes.

11

F0078830

6 - Remove the two bolts (13).

14
7 - Remove the adjustment knobs assembly (14).

13

F0078840

8 - Unscrew and remove the three nuts (15) and re-

16 16
move the support (16) mounted above the valve to
be removed.

15

F0078850

30-130
 REMOTE CONTROL VALVES

CAUTION!
The instructions refer to removal of the left-hand re-
mote control valve; to remove the right-hand valve, 17
follow the same procedure.
9 - Disconnect the connectors (17) and (18) from the
proportional lift control valve. 1

18

F0078860

10 - Loosen and remove the quick couplers (19) in order

to access the pipes to be disconnected. 2
★ Renew the copper gaskets on reassembly.
★ Plug the holes to prevent the entry of impurities. 19

F0078870

11 - Disconnect the lift return pipe (21) from the fitting

(20).
★ Plug the pipe to prevent the entry of impurities. 20

21

F0078880

12 - Disconnect the lift supply pipe (23) from the Tee fit-
ting (22) and from the control valve.
★ Renew the copper gaskets on reassembly. 23
★ Plug the holes to prevent the entry of impurities.
13 - Remove the pipe (23).

23
22

F0078890

30-131
REMOTE CONTROL VALVES

14 - Disconnect the oil supply and return pipes (24) and

(25) from the fittings on the remote valve end cap. 24

25

F0078900

15 - Disconnect the load sensing signal pipe (26).

26

F0078910

16 - While supporting the remote valve (27), remove the

nut (28).

28
27

F0078920

17 - Remove the remote control valve (27).

27

F0078930

30-132
 REMOTE CONTROL VALVES

Refitting
• Refitting is the reverse of removal
1
★ Attach the connectors to the solenoids of the lift
control valve:
DW upper
UP lower
2
Quick couplers: 60–66 Nm (44.2–48.6 lb.ft.)
1 - Start the engine and fully raise and lower the lift a
number of times to expel air from the circuits and
check for leaks.

30-133
REMOTE CONTROL VALVES

Disassembly
★ The remote control valves are assembled in stacks,
which should only ever be disassembled if a com-
ponent needs to be replaced; overhauls should be
carried out by the Manufacturer or by an Approved
Service Centre.
★ To disassemble the right control valve, follow the
same procedure.

1 - Unscrew and remove the nuts (1) securing the valve

sections. 1
★ Loosen the nuts gradually and sequentially to
accommodate the expansion of the seals be-
tween the sections.
1

F0078940

2 - Remove the end cap (2).

F0078950

3 - Remove the valve section 1 (3) and the proportional

lift control section (4). 2
3 4

F0078960

30-134
 REMOTE CONTROL VALVES

4 - Remove the valve section 3 (6) from the end cap (5).
2 6
5

F0078970

5 - Before removing the seals, note the positions of the

O-rings (7) which require the installation of backup
rings in correspondence with the pressure ports.
7

F0078980

• Left-hand remote control valve.

6
2
5
3

F0078990

• Right-hand remote control valve.

6
2
5

3
4

F0079000

30-135
REMOTE CONTROL VALVES

Assembly
• Refitting is the reverse of removal

1 3 3
★ Tighten the nuts gradually and in sequence to
bring the valve sections together. 2 2
Final tightening torque for nuts: 1 1
30 +0 3 Nm (22 +0 2.2 lb.ft.)
★ Nut tightening sequence: 1-2-3

2
D0005360

★ Ensure that the O-ring seals are correctly posi-

tioned before fitting the sections together

F0079010

30-136
 REMOTE CONTROL VALVES ASSEMBLY

REMOTE CONTROL VALVES ASSEMBLY

Removal
Remove the key from the ignition and apply the
parking brake. 1
Vent residual pressure from the reservoir by remov-
ing the cap (1) and pressing the button (2) on the 3
2
pressure regulator valve (3).

F0043800

1 - Disconnect the control cables (4) from the remote

valves assembly.
★ Mark the positions to avoid confusion on recon-
nection.

F0078795

2 - Disconnect the pipes (6) & (7) from the trailer brakes
coupling heads (5). 5
If auxiliary pressure couplers are fitted, dis-
connect the return pipe and, if present, the 7
load sensing pipe.

F0078831

3 - Disconnect the connectors (8) and (9) from the pro-

portional lift control valve. 1
8

F0078861

30-137
REMOTE CONTROL VALVES ASSEMBLY

4 - Disconnect the supply pipes (10) and (11) from the

remote valves 11

10

F0079020

5 - Remove the fixing bolt (12) of the strap (13).

6 - Disconnect the supply pipes (10) and (11), loosen- 10
ing the fitting (14).

13
12
14
11

F0079030

7 - Loosen and remove the quick couplers (15) in order

to access the pipes to be removed. 2
★ Renew the copper gaskets on reassembly.
★ Plug the holes to prevent the entry of impurities. 15

F0078871

8 - Disconnect the lift return pipe (16) from the left re-
mote valve.

16

F0079040

30-138
 REMOTE CONTROL VALVES ASSEMBLY

9 - Disconnect the lift pipe (18) from the Tee fitting (17)
and from the remote valve.
★ Always renew the copper gaskets.
★ Plug the pipes to prevent dirt from entering the
system.
18
10 - Remove the pipe (18).
18
17

F0079050

11 - Remove the supply pipes (10) and (11).

10
11

F0079060

12 - Disconnect the return pipes (19) and (20) from the

remote valves.

20

19
F0079070

13 - Disconnect the load sensing signal pipes (21) and

(22) from the remote valve end caps.

22

21

F0079080

30-139
REMOTE CONTROL VALVES ASSEMBLY

14 - Loosen the fixing bolts (23) of the remote valve as-

sembly.

23

F0079090

15 - Attach the remote valves assembly to a hoist; re-

move the bolts (23) and remove the complete as-
sembly (24).

24

F0079100

Refitting
• Refitting is the reverse of removal
1
★ Attach the connectors to the solenoids of the lift
control valve:
DW upper
UP lower
2
Quick couplers: 60–66 Nm (44.2–48.6 lb.ft.)
1 - Start the engine and fully raise and lower the lift a
number of times to expel air from the circuits and
check for leaks.

30-140
 LIFT CYLINDERS

LIFT CYLINDERS

Removal
4
Switch off the engine and remove the key from the ig- 3
nition.
1 - Remove the pins (1) and lower the lift rods (2) towards
the rear of the tractor. 1
★ Recover the spacers (3) and washers (4); make a 1
note of their postions.

2 2

F0045370

2 - Disconnect the pipes (6) from the cylinders (5).

★ Plug the ends of the pipes to prevent the entry of
contaminants. 5

F0020320

3 - Using a pin punch “A”, remove the spring pin (7) se-
curing the upper pivot pin (8).

8
7

F0020330

4 - Remove the screws (9) and remove the bracket (10)

securing the lower pivot pin (11).
10

9
11

F0045380

30-141
LIFT CYLINDERS

5 - Support the cylinder (5) while removing the upper piv-

ot pin (12). 1

5
12

F0020340

6 - Rotate the cylinder (5) so that it is horizontal and attach

it to a hoist.
Cylinder: approx. 55 kg (121.2 lb.)
7 - Remove the lower pivot pin (11) and the cylinder.
11
1 5

F0020350

Refitting
• Refitting is the reverse of removal.

1
★ Lubricate the pivot pins.
1 - Start the engine and repeatedly extend the cylinders
to their full extent in order to expel air from the system.

30-142
 LIFT CYLINDERS

Disassembly
1 - Withdraw the piston (1) to the point where the circlip
(2) is visible through the hole of the delivery pipe fitting.
2
2 - Rotate the rod so that the gap in the circlip (2) is visible.

F0009200

3 - Using a screwdriver through the delivery line hole,

push one end of the circlip (2) towards the groove “A”
in the piston (1) while simultaneously rotating the pis-
ton (1) in order to release the circlip (2).
2
4 - Withdraw the complete piston assembly (1).

1
D0000821

5 - Remove in sequence the wiper seal (4), the guide (5),

the seal (6) and the second guide (7).
1 2
★ Note which way round the seal is fitted.

7 6 5 4

D0000830

Assembly
• Assembly is the reverse of disassembly.

1
Seal and guides: Gearbox oil.

2
★ Before inserting the piston, check that the guides
are correctly positioned in the seatings in the cyl-
inder.

30-143
LIFT POSITION SENSOR

LIFT POSITION SENSOR

Testing
Switch off the engine and remove the key from the ig-
nition. 1
1 - Cut the retaining strap and, using a thin blade, dis-
connect the connector (2) from the position sensor (1).

F0021410

2 - Connect the test lead T4 (code 5.9030.743.0) be-

tween the connector (2) and the sensor (1).
3 - Start the engine and with a multimeter check that the
supply voltage and the signal voltages with the lift
raised and lowered are within the specified ranges:
T4
★ Supply voltage (red-blue wires):
5.5±1V (DC)
★ Signal voltage with lift raised (brown-blue wires): 2
1
equal to or greater than 0.5Vdc
★ Signal voltage with lift lowered (brown-blue wires):
less than or equal to 4.5Vdc
★ If the voltage readings are not within the specified
ranges, renew the sensor. F0022071

30-144
 LIFT POSITION SENSOR

Renewal
Switch off the engine and remove the key from the
ignition. 2
1 - Remove the screws (1) securing the cover (2) and the
sensor.
1

F0020360

2 - Remove the sensor (3) and unplug the connector (4).

F0020370

Renewal of the position sensor bush

(only if necessary)
1 - After removing the worn bush, clean and activate the
seating.
Activator: Loctite 7649
19 º
A
2 - Apply sealant to the surfaces of the hole and fit the
new bush, aligning the machined guide surfaces of
19° manteining the protusion “A” of 4.5 –0 0.5 mm.
Sealant: Loctite 648
3 - Allow the sealant to cure for at least 30 minutes before
fitting the sensor. D0004771

Refitting
• Refitting is the reverse of removal.
★ Before finally tightening the screws, rotate the sen-
sor fully in a counter-clockwise direction; adjust
the position sensor as described in the following
paragraph.

30-145
LIFT POSITION SENSOR

Adjusting
1 - Detach any mounted implements from the 3-point
linkage. 1
A
2 - With the engine stopped, raise the lift arms to their
maximum height using suitable lifting equipment.
3 - Make reference marks on the lever (1) and on the bear-
ing support (2).

2
F0021420

4 - Lower the lift to its maximum depth position.

5 - Start the engine, push the external pushbutton (3) to 3
rise the lift arms up to it stop. Hold the pushbutton (3)
depressed and at the same time rotate the sensor (4) in
clockwise.

F0021430

6 - As the sensor (4) is rotated, the lift will start to rise; top
rotating the sensor and release the pushbutton (3)
when the reference marks made in step 3 are apart a
distance of “D” of 5–6 mm (0.20 - 0.24 in.). D

F0021440

7 - Fix the sensor (4) in position by tightening the screws

(5).
4

F0020361

30-146
 LIFT POSITION SENSOR

8 - Check the adjustment by first lowering the lift (using

external pushbutton (3)) to an intermediate position 3
and then raising to the maximum height by holding the
pushbutton pressed; the lift arms should stop before
reaching the mechanical limit and thus over-pres-
surising the hydraulic system, at which point the ref-
erence marks should be the distance apart indicated
in step 6.
If the hydraulic system is maintained at maximum
pressure for more than 30 seconds during the adjust-
ment procedure, the system will automatically switch
to neutral and the error code “37” will be signalled.
F0021430
In this case, before repeating the adjustment proce-
dure, first turn the ignition key to the “O” position.
9 - If necessary, alter the position of the sensor by turning
it a few degrees in a counter-clockwise direction.

30-147
LIFT DRAFT SENSOR

LIFT DRAFT SENSOR

Removal
1 - Remove the screws (1) and remove the cover (2) and 1
the spacers (3).

F0020380

2 - Support the lever and remove the bracket (4) and then
the sensor (5).
4
5

F0020390

3 - Release the wiring from the retaining straps and un-

plug the sensor connector (6).
★ The connectors are located under the cab and can
be accessed from the left-hand side of the tractor.

Refitting
• Refitting is the reverse of removal.
★ Make sure the sensor is installed the right way
round.

30-148
 DRIVER'S SEAT

DRIVER'S SEAT

Removal
Remove the battery cover and disconnect the nega- 1
tive battery lead (–).
1 - Lift the rear floor mat (1) and withdraw the feed wire (2)
for the compressor for the seat.

F0018900

2 - Remove the four nuts (3) and remove the complete

seat assembly (4).

F0018910

Refitting
• Refitting is the reverse of removal.

30-149
STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL

STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND

INSTRUMENT PANEL
Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–). 1
3
1 - Remove the centre cover (1) and remove the nut (2)
with its washer.
2 - Remove the locknut (3) for telescopic adjustment of 2
the steering wheel.

F0041460

3 - Remove the nut (4), the toothed washer (5) and re-
move the steering wheel (6). 1 6

4 5

F0041470

4 - Remove the circlip (7) and remove the steering col-

umn switch unit (8) from the steering column.

F0041480

5 - Insert a thin blade “A” under the gasket and prise off
the instrument panel (9).
★ Alternatively, withdraw the right and left switch
9
groups “B” and push the instrument panel from the
inside.

B
F0041490

30-150
 STEERING WHEEL, STEERING COLUMN SWITCH UNIT AND INSTRUMENT PANEL

6 - Unplug the connectors (10) and (11) from the in-

strument panel (9); remove the assembly.

10
9

11

F0018950

Refitting
• Refitting is the reverse of removal.

1
Steering wheel nut:
M18x1.5: 40±10% Nm (29.5±10% lb.ft.)
M8: 10 +0 2 Nm (7.4 +0 1.5 lb.ft.)

30-151
STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER

STEERING COLUMN SWITCH UNIT

AND THE SHUTTLE CONTROL LEVER
Removal 1 1
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the steering wheel (1).
(For details, see "STEERING WHEEL, STEERING
COLUMN SWITCH UNIT AND INSTRUMENT PAN-
EL").

F0041471

2 - Remove the lower screws (2) joining the shrouds (3) of

the shuttle control lever (4) and remove the safety bar 4
(5).

F0018970

3 - Unscrew and remove six screws (6) securing the

shrouds of the steering column switch unit (7).

6 7

F0041500

4 - Remove the circlip (8) of the steering column switch

unit (7).

7 8

F0041510

30-152
 STEERING COLUMN SWITCH UNIT AND THE SHUTTLE CONTROL LEVER

5 - Lift off the switch unit (7) and place it to one side.
The contacts of the switch unit are protected by 7
adhesive insulation material; recover this insu-
lation as it will have to be repositioned.

F0041520

6 - Unplug the connector (9), remove the screws (10) and

detach the shuttle control lever assembly (11).
11

10

9
F0041530

7 - Remove the shuttle control lever (11), detaching it

from the cover (12).
11
12

F0041540

Refitting
• Refitting is the reverse of removal.
1 - Turn the ignition key to position “I” and check oper-
ation of the direction indicators, lights and windscreen
wiper.
2 - Start the engine and run it at idle speed ; engage a
gear and check that the shuttle control lever functions
correctly.

30-153
CENTRE CONSOLE AND SHROUD

CENTRE CONSOLE AND SHROUD

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1- Remove the seat.
(For details, see "DRIVER'S SEAT". 1
2- Remove the floor mats.
3- Remove the steering wheel and steering column
switch unit.
(For details, see "STEERING WHEEL, STEERING 1
COLUMN SWITCH UNIT AND INSTRUMENT PAN-
EL").
4- Unscrew and remove the screws (1).
F0019030

5 - Remove the upper centre console (2) by lifting it up-

wards.
2

F0019040

6 - Rotate the console (2) towards the rear of the tractor

and unplug the connectors (3), (4) and (5). 3a
3
★ Note that connectors and pushbuttons all bear
identification marks with the exception of the 2nd
pushbutton “C” from the left. 5
★ The unmarked pushbutton is to be connected to its 4
connector only on models equipped with a front
lift.
★ The connector marked 3a is not to be connected. 2
C

F0019050

7 - Loosen the grub screw (6), remove the accelerator

pedal (7) and remove the front floor mat (8).

8
6

F0030551

30-154
 CENTRE CONSOLE AND SHROUD

8 - Fully lower the steering column.

Pull outwards the lock handle (9) of the steering tilt ad-
justment; remove the cotter pin (10) and remove the
handle.
★ Renew the cotter pin at each reassembly. 10

F0019070

9- Unscrew and remove the retaining screws (11) of the

air duct fascia (12).

11

11

12

F0045691

10 - Detach the air duct (14) from the centre shroud (13)
and remove it.
13

14
F0019090

11 - Remove the cable ties (15) to release the wiring from

the guide fixed to the footplate. 15
★ Note that the cable ties are located in grooves. 15

F0019100

30-155
CENTRE CONSOLE AND SHROUD

12 - Withdraw the wiring (17) from the right-hand console

(16).
1
17

16

F0019110

13 - Release the wires of the pushbutton connectors from

the cable ties (18).
18

F0019120

14 - Release the vertical wiring (20) from the cable tie (19);
withdraw the complete wiring harness through the ap-
erture exposed by tilting the console forwards.

19

20

F0019130

15 - Rotate the shroud (21) to align the rotation lock key

with the spring (22); remove the shroud (21).
2
16 - Remove the complete console assembly (2).

22
21

F0019140

30-156
 CENTRE CONSOLE AND SHROUD

17 - Remove the screws (23).

23

F0019150

18 - Lift and tilt the console shroud (13) towards the rear of
the tractor to disengage it from the clutch and brake
pedals.
13

F0019160

Refitting
• Refitting is the reverse of removal.

1
★ Check the condition of the fascia gasket; renew it if
damaged.

30-157
RIGHT-HAND CONSOLE

RIGHT-HAND CONSOLE

Removal e opening
• The right-hand console can be partially opened to in-
spect the wiring and the air conditioning blower and
for removal of the hand throttle assembly.
Remove the battery cover and disconnect the neg-
ative battery lead (–). 2
1 - Remove the seat.
(For details, see "DRIVER'S SEAT").
2 - Remove the gaiter (1) and unplug the connector (2).
1

F0019581

3 - In case of removal only: disconnect the control ca-

bles (3) from the auxiliary service control valves.
1

F0078791

4 - Disconnect the control cable (5) from the lever (4).

Detach also the cable sleeve (6).

4
F0045390

5 - Remove the front floor mat and remove the plate (7) of
the cable guide (8) in order to free the control cables
(5).

8 5
F0045400

30-158
 RIGHT-HAND CONSOLE

6 - Drive out the spring pin (9) and remove the creeper en-
gagement lever (10).

10

F0019852

7 - Remove the screw (11) move the support (12).

12
11

F0019862

8 - Unplug the connector (13) of the lever position sensor 5 0+1

(14).
If the sensor (14) has been removed or re-
placed, on refitting adjust the protrusion to 5 +0 1
mm (0.197 +0 0.04 in.) relative to the tightened
nut. 14

13

F0019872

9 - Withdraw the pin (15) and disconnect the creeper con-

trol cable (16). 1

15
16

F0019882

30-159
RIGHT-HAND CONSOLE

10 - Unscrew and remove the lower bolt (17) of the console

(18).

18

17

F0020052

11 - Position a hydraulic jack “A” with a non-slip block un-

der the tow hook (20) so that it is inclinded towards the
right-hand wheel; raise the tractor so that the right
wheel is off the ground (20).
19

A 20

F0018873

12 - Position a jack “B” with safety wings under the right

brake assembly; remove the right wheel and lower the
tractor onto the stand.
1
★ Stand load capacity: minimum 2 tons.
21

F0078621

13 - In case of console removal only:

Remove the four screws (22) and remove the cover
plate (23).
23

22

F0019900

30-160
 RIGHT-HAND CONSOLE

14 - In case of console removal only: disconnect from

the bulkhead fitting the connectors of the lift line (24)
(TKAB2), the transmission (25) (TKAB1), the front sus-
24
pension (26), the feed cable (27), the creeper engage- 28 25
ment indicator cable (28),the cab lights connector (29)
and the feed cable (30).

30

29

26
27

29

F0019910

15 - Disconnect the engine line connector (31) and the

connector (32) from the bulkhead fitting. 31 32

F0045410

16 - Remove the grille (33) and the filter (34) from the right-
hand cab pillar.
34

33

F0019920

30-161
RIGHT-HAND CONSOLE

17 - Unscrew and remove the trim panel retaining screws

(35). 35

35

F0019930

18 - Insert a thin blade between the cab pillar (36) and the
interior trim (37) and detach the clips (38) from the pil-
lar and the trim.
Remove the trim (37).

38
36

37
F0019940

19 - Unplug the lower connectors (39), (40) and (41) and the
upper connector (42). 39

40
42

41

F0019950

20 - Disconnect the gas spring (43) of the right-hand door

and remove the mounting pin (44).

44

43

F0019960

30-162
 RIGHT-HAND CONSOLE

21 - Remove the bolts, lift the seat support (45) and dis-
connect the hose (46).

46 45

F0000771

22 - In case of console removal only: unplug the con-

nectors (47) and (48).

48
47

F0019990

23 - Open the rear right cable hatch (49) to access the

screw (50).
50

49

F0019970

24 - Remove the screws (51) and remove the flanged nut

(52) located under the right fender.
51

51
52

F0019980

30-163
RIGHT-HAND CONSOLE

25 - Loosen and remove the bolt (53).

53

F0020020

26 - Unscrew and remove the front retaining screws (54).

54

F0020010

27 - Raise the front of the right-hand console (55) and

move it away from the side of the cab; if necessary, re-
move the console.
★ When removing the console, support the electrical 55
wiring and control cables.

F0019631

Refitting
• Refitting is the reverse of removal.

1
★ Connect the control cables following the opera-
tions described in the heading "PTO ENGAGE-
MENT AND SELECTION CONTROL CABLES" e
"AUXILIARY SERVICE VALVE CONTROL CA-
BLES").

30-164
 LEFT-HAND CONSOLE

LEFT-HAND CONSOLE

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the seat. (For details, see "DRIVER'S SEAT").
1
2 - Remove the accelerator pedal (1) and remove the front
floor mat (2).

F0030550

3 - Only where fitted.

Remove the passenger seat (3). 3

F0021460

4 - Remove the rear floor mat (4).

F0021470

5 - Remove the parking brake cover (5).

6 - Remove the seat support (6) and remove the strap (7) 8
to disconnect the hose (8).
Remove the screw (9).
5 7

6 9

F0021480

30-165
LEFT-HAND CONSOLE

7 - Remove the interior trim (10) from the cab pillar.

8 - Disconnect the gas spring of the left door and remove
the mounting pin.
(For details, see "RIGHT-HAND CONSOLE").

10

F0021490

9 - Remove the fixing screws and move the left-hand

console (11) away from the side of the cab.
11

F0021500

10 - Unplug the four connectors (12).

13
11 - Disconnect the heating valve control cable (13).
12 - Remove the left-hand console (11). 12

12

12
F0021510

Refitting
• Refitting is the reverse of removal.

30-166
 LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS

LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC

CONTROL UNITS
Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the rear hatch of the right-hand console. 1
2 - Withdraw the switch assembly (1).
3 - Label the switches and the corresponding connec-
tors to avoid confusion on reconnection; unplug the 2
connectors (2) and remove the switches.
2
F0019170

1. Transmission ECU
1 - Unscrew and remove the screws (3) securing the ECU
(4).
2 - Unplug the connector (5). 3

5
F0045420

2 - Withdraw the ECU (4).

F0045430

2. Lift ECU
1 - Unplug the connectors (7) and (8) from the ECU (6).

6 8

7
F0045440

30-167
LIFT, FRONT SUSPENSION AND TRANSMISSION ELECTRONIC CONTROL UNITS

2 - Unscrew and remove the fixing screws and withdraw

the ECU (6).

F0045450

3. Front suspension ECU

1 - Unscrew and remove the fixing screws (9).

F0045460

2 - Unplug the connectors (10), (11) and withdraw the

ECU.

11 9
10
F0045470

Refitting
• Refitting is the reverse of removal.

30-168
 FUSE AND RELAY BOARD

FUSE AND RELAY BOARD

Removal
Remove the battery cover and disconnect the nega- 1
tive battery lead (–).
1 - Remove the ECUs of the lift, the front suspension and
the transmission.
(For details, see "LIFT, FRONT SUSPENSION AND
TRANSMISSION ELECTRONIC CONTROL UNITS"). 2

2 - Unplug the connectors (1) and (2) from the signal out-
let sockets and the external outlet socket for trailer-
mounted implements.
F0019260

3 - Remove the bracket (3) of the diagnostics outlet (4)

and place it to one side.

F0019270

4 - Disconnect the connectors (P2), (P6), (P3), (P5), (J1),

(J2) and (J3) from the fuse/relay board. 5
★ The connectors are marked with the same sym-
bols as the sockets on the circuit board. 6
5 - Remove the cover and disconnect the earth lead (6).

F0019280

6 - Disconnect the connector (7) (P5), which is accessed

through the ECU compartment.

F0019290

30-169
FUSE AND RELAY BOARD

7 - Remove the relays from the board (5) which prevent its
removal
RL4 - front windscreen (8) 8
RL14 - direction indicators (9)

F0019300

8 - Disconnect the lead (10) and remove the five fixing

screws (11).

11

10
F0019310

9 - Remove the board (5).

5

F0019320

Refitting
• Refitting is the reverse of removal.

30-170
 ENGINE ECU

ENGINE ECU

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the ventilation and heater control panel.
(For details, see "CLIMATE CONTROL PANEL").
2 - Disconnect the air hose (1) from the outlet vent and
position it to one side.
1 1

F0020000

3 - Loosen the fixing screws (2) and partially withdraw the

ECU (3).

2
3
F0019700

4 - Label and unplug the connectors (4) and (5).

5 - Remove the ECU (3).

F0019710

Refitting
• Refitting is the reverse of removal.

1
★ The air hose must be routed over the top of the
ECU between the two connectors.

30-171
CLUTCH PEDAL AND RELATED DEVICES

CLUTCH PEDAL AND RELATED DEVICES

Removal of the potentiometer

1 - Remove the centre console and console shroud.
(For details, see "CENTRE CONSOLE AND
SHROUD"). 2
2 - Disconnect the tie-rod (2) from the clutch pedal (1).
1

F0019340

3 - Unplug the connector (4) from the potentiometer (3).

5
4 - Remove the screws (5) and remove the potentiometer
3
complete with the tie-rod.

F0019350

★ If a new potentiometer is to be fitted, disconnect the

tie-rod (2), remove the cotter pin (6) and the lever (7).
★ Renew the cotter pin at each re-assembly. 3 2

6
F0021520

Refitting the potentiometer.

• Refitting is the reverse of removal.
After refitting the potentiometer, check the po-
sition of the pedal and its travel; check also the
calibration values using the programming/diag-
nostics tester.
NOTE. After adjusting the height of the clutch pedal,
check using the EDS program in section 20
that the output voltage of the potentiometer is
4.3V. If necessary, adjust the length of the tie-
rod (2) to obtain this value

30-172
 CLUTCH PEDAL AND RELATED DEVICES

Adjustment of the clutch pedal position and

travel
1 - Check that the distance between the top edge of the
clutch pedal (1) and floor is the same as that of the
brake pedals.
If necessary, adjust the pedal height by adjusting the
1
buffer (8).
8

F0019380

2 - Adjust the stop (9) so that the pedal travel “A” of

155+0 5 mm (6.107+0 0.197 in.)
NOTE. With the EDS program in section 20, check
that the voltage reaches a value of 0.9–1.1V.

9 A
D0005401

Renewal of the proximity sensor

1 - Unplug the connector (10).
2 - Unscrew the nut (11) sufficiently to disengage it from 10
the sensor (12).
3 - Check that the axial play of the pedal is within the
range of 0.1–0.6 mm (0.004 – 0.024 in.); if the play ex-
ceeds the permitted maximum, adjust it before ad- 11 12
justing the position sensor (12).

F0019360

4 - Fit the new sensor (12) following the removal proce-

dure in reverse.
Fully depress the clutch pedal.
5 - Adjust the position of the sensor relative to the lever by D
way of the adjuster nuts (11). 11
★ Distance “D” between the lever and the sensor:
12
0.5–1 mm (0.02 – 0.04 in.)

F0019370

30-173
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO

CONTROL PANELS AND LEVERS OF THE

AUXILIARY SERVICE VALVES AND THE PTO
• The illustrations refer to a model equipped with a
front PTO.
Disconnect the negative lead (-) from the battery. 2

Removal
1. Remove the lift control panel
1 - Unscrew and remove fixing screws (1) of the lift control 1
panel (2).

F0045480

2 - Unplug the connector (3) and remove the assembly

(2). 2

F0045490

3 - Only in the case of testing or renewal of the po-

tentiometers. 4 5
Unscrew and remove the screws (4) and remove the
lower cover (5).

F0045500

2. Removal of the auxiliary service valve

control levers
1 - Remove the lift control panel as described in the pre- 7
vious paragraph.
2 - Unscrew and remove fixing screws (6) of the control
levers assembly (7).

6
F0045510

30-174
 CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO

3 - Lift the assembly (7) and rotate it through 90°.

F0045520

3. Removal of the cross-gate control lever

assembly
1 - Remove the yokes (8) securing the outer cables and
disconnect the cables (9) and (10). 1 9
★ Label the control cables to avoid confusion on re-
connection.

10
8 F0045530

2 - Unscrew and remove the nuts (11) with their washers;

withdraw the control assembly (12) from the panel (7).

11

12
F0045540

4. Removal of the individual service valve

control levers 14

1 - Remove the yokes (13) securing the outer cables and

disconnect the inner cables (14). 1
★ Label the cables to avoid confusion on reconnec-
tion.

13
F0045550

30-175
CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO

2 - Unscrew and remove bolts(15) with their washers and

remove the levers (16) and the lever pivot supports
(17).
15
16

17

F0045560

5. Removal of the PTO control panel

1 - Unscrew and remove the screws (18).

18
F0045570

2 - Lift the control panel (19) and unplug the connectors

(20).
★ Label the connectors to avoid confusion on recon-
nection. 19

20

F0019512

3 - Remove the yoke (21) securing the outer cable (22),

disconnect the cable (23) and remove the assembly 19
(19).
1

23

22
21

F0019545

30-176
 CONTROL PANELS AND LEVERS OF THE AUXILIARY SERVICE VALVES AND THE PTO

6. Removal of the lift control assembly and the

hand throttle
1 - Unscrew and remove the two outer fixing screws (24)
of the assembly (25).

25

24

F0045580

2 - Release the right-hand console (26) from its fixings

and tilt it towards the centre of the cab in order to re- 26
move the inner screws (27) and unplug the connectors
(28). 27
★ (For details, see "RIGHT-HAND CONSOLE").
3 - Remove the lift control assembly. 2

28

F0045590

Refitting
• Refitting is the reverse of removal.

1
★ The slotted bush “A” securing the cable must be
oriented towards the outer end of the fixing pin.
A
1 - Adjust the length of the control cables.
(For details, see "AUXILIARY SERVICE VALVE CON-
TROL CABLES").

2
★ If a new hand throttle is fitted, it will have to be cal- F0019550

ibrated. (See the SERDIA program in section 20).

30-177
PTO ENGAGEMENT AND SELECTION CONTROL CABLES

PTO ENGAGEMENT AND SELECTION CONTROL CABLES

Removal
• Figures refer to the speed selector
1 - Remove the lever assembly relative to the cable to be
renewed.
(For details, see "AUXILIARY SERVICE VALVE CON-
TROL CABLES").

F0045620

2 - Disconnect the control cable (1) from the control lever

(2) and remove the yoke (3) to remove the outer cable
(4).

4 3

F0019543

3 - Remove the front floor mat and remove the plate (5) of
the cab guide (6) in order to release the outer cable to
be renewed.

6
F0045401

4 - Loosen the fixing screw (7) of the gear lever gaiter (8).
5 - Raise the gaiter (8), unplug the connector (9) and with-
draw the control cable to be renewed.
7

F0019580

30-178
 PTO ENGAGEMENT AND SELECTION CONTROL CABLES

6 - Disconnect the control cable end (11) from the lever

(10); remove the outer cable retaining yoke and re-
move the controlcable.

11
10

F0045391

Refitting
1 - Extend the new cable and engage it in the cable guide
(6).
2 - Connect the end fitting of the inner control cable (2) to
the control lever (1) and secure the outer cable (3) with
the yoke (4).
3
1
2

6
4
F0045600

3 - Fix the lever assembly (12) to the right-hand console.

4 - Move lever (13) to the position corresponding to the
position of lever (10).
13 12

10

F0045610

5 - Secure the outer cable with the yoke.

6 - Stretch the cable slightly to connect it to the fitting on
the lever (10), making sure that the lever on the con-
sole is still in the correct position.

10

F0045392

30-179
PTO ENGAGEMENT AND SELECTION CONTROL CABLES

7 - Move the lever (13) in the cab and make sure that the
selector lever on the transmission moves through its 13
full travel distance and effects the gear change.
★ Check that the travel of the new lever (13) is prop-
erly centred relative to the symbols stamped on
the console.

F0045630

8 - Secure the outer cable in the cab guide (6) with the
yoke (5).
9 - Reconnect the connector, position the gaiter (8) and
tighten the screw (7)

7
5 8
6
F0045640

30-180
 AUXILIARY SERVICE VALVE CONTROL CABLES

AUXILIARY SERVICE VALVE CONTROL CABLES

Removal
1 - Remove the seat.
(For details, see "DRIVER'S SEAT").
2 - Remove the control levers assembly and disconnect
the control cables to be renewed from the levers.
(For details, see "CONTROL PANELS AND LEVERS
OF THE AUXILIARY SERVICE VALVES AND THE
PTO").

F0045511

3 - Detach the right-hand console (1) from the cab, but do

not unplug any of the connectors. 1
(For details, see "RIGHT-HAND CONSOLE").

F0019630

4 - Disconnect the outer cables (2) and inner cables (3)

from the control valve assembly.

F0078792

5 - Remove the screws and remove the plate (4) securing

the bulkhead gasket (5).
Release the control cables (6) from the bulkhead fitting
4
and withdraw them towards the rear of the tractor.

F0019650

30-181
AUXILIARY SERVICE VALVE CONTROL CABLES

Refitting
• Refitting is the reverse of removal.
1 - Check that the control cable lever and the corre-
sponding control valve lever are both in neutral.

F0045650

2 - Fix the outer cables with the yokes (1).

3 - Connect the inner cables (2) to the control levers.
2

2
1

1
F0045521

4 - With the control lever in neutral position, lift the re-

taining bush (3) and, while keeping the cable under
slight tension, insert the end in the fitting (4).
3

F0078793

5 - Lower the retaining bush (3); check that the control

valve spool travels through its full stroke and that the
control lever is positioned centrally in its slot when the
control valve is in neutral.
★ For the cross-gate control lever, check the spool
travel for both side-to-side and vertical move-
ments of the lever.

F0021550

30-182
 PARKING BRAKE SWITCH

PARKING BRAKE SWITCH

Adjustment
1 - Remove the screws (1) and (2) and remove the shroud 3
(3).
4
2

F0045660

2 - Operate the lever (4) repeatedly to eliminate any play in

the mechanism. 4

3 - With the lever (4) fully lowered, adjust the height of the
microswitch (5) by raising it to its maximum height and
then lowering it to obtain the correct amount of resid-
ual travel.
★ Residual travel: 1 mm (0.04 in.)
5
4 - Replace the shroud (3).

F0045670

30-183
CLIMATE CONTROL PANEL

CLIMATE CONTROL PANEL

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Pull off the air conditioning on/off knob (1).
1

F0019660

2 - Unscrew and remove the fixing screws (2) of the con-

trol panel (3).

F0019670

3 - Detach the control panel (3) by pressing the spring

clips (4) securing it to the left-hand console.
3

4
4

F0019680

4 - Lift the panel (3), disconnect the connectors (4) and

(5), the wiring (6), and the heater control cable (7).

Refitting
7
• Refitting is the reverse of removal. 4

F0041810

30-184
 HEATER VALVE

HEATER VALVE

Removal
Switch off the engine and remove the key from the
ignition.
1 - Drain the coolant from the engine cooling system.

Coolant:

Mod. 80 90 100 105

ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

2 - Disconnect the inner control cable (2) and the outer

cable (3) from the valve (1). 1
1

F0021560

3 - Loosen the retaining straps (4) and remove the valve

(1).

4
4

F0045840

Refitting
• Refitting is the reverse of removal.
MAX.
1
★ Connect the heating valve control cable as follows: +2
a - Turn the heater control knob fully to the left (blue
section) and then two notches back to the right
(red section).

D0004730

30-185
HEATER VALVE

b - Turn the lever (5) of the heater valve (1) up to the

stop (6). 1
5
c - Fix the outer part (7) of the control cable (2) with
the spring clip (8) and the inner cable (2) with the
screw (9).

6
8
9 7
2

F0021580

1 - Fill the cooling system.

Coolant:

Mod. 80 90 100 105

ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

2 - Fully open the heater valve.

3 - Start the engine: allow the coolant to circulate and
check for leaks.
4 - Stop the engine and top up the coolant level.

30-186
 HEATER MATRIX

HEATER MATRIX

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the seat. (For details, see "DRIVER'S SEAT").
1
2 - Loosen the grub screw, remove the accelerator pedal
(1) and remove the front floor mat (2).

F0030550

3 - Remove the rear floor mat (3).

F0021471

4 - Remove the retaining strap (4) and the air hose (5).

5
F0045691

5 - Remove the bolts and lift the seat support (6).

6 - Remove the bolts and remove the upper cover (7) of 6
the air conditioning assembly.

F0021590

30-187
HEATER MATRIX

7 - Turn the heater control knob to the MAX position (red

section).
Drain the coolant from the engine and the heater ma-
trix by disconnecting the pipes (8).
Coolant:

Mod. 80 90 100 105

8
ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

★ After draining the system, reconnect the pipes (8).

F0079110

8 - Remove the evaporator.

(For details, see "AIR CONDITIONING EVAPORA-
TOR").
9 - Remove the hose clamp (9) and disconnect the ver- 9
tical return hose (10) from the matrix.

10

F0021610

10 - Remove the hose clamp and disconnect the horizon-

tal delivery pipe (11) from the matrix.

11

F0021620

11 - Remove the matrix (12) by lifting the right side verti-

cally and then rotating it towards the rear of the tractor.
12

F0021630

30-188
 HEATER MATRIX

Refitting
• Refitting is the reverse of removal.
1 - Fill the cooling system.
Coolant:

Mod. 80 90 100 105

ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

2 - Start the engine: allow the coolant to circulate and

check for leaks.
3 - Stop the engine and top up the coolant level.

30-189
AIR CONDITIONING EVAPORATOR

AIR CONDITIONING EVAPORATOR

Removal
Remove the battery cover and disconnect the nega-
tive battery lead (–).
1 - Remove the seat. (For details, see "DRIVER'S SEAT").
1
2 - Loosen the grub screw, remove the accelerator pedal
(1) and remove the front floor mat (2).

F0030550

3 - Remove the rear floor mat (3).

F0021471

4 - Connect the quick-fit couplers of the high (R) and low

(S) pressure pipes to the refrigerant (R134A) charging,
testing and recovery machine. R
Set the machine for recovery operation and start it; al- S
low the machine to run until all the refrigerant has been
recovered, then disconnect it. 1

★ Measure the quantity of oil recovered and conse-

quently to be reintroduced into the system.

F0079120

5 - Remove the hose clamp (4) and the air hose (5).

5
F0045691

30-190
 AIR CONDITIONING EVAPORATOR

6 - Remove the bolts and lift the seat support (6).

7 - Remove the screws and remove the cover (7) of the air 6
conditioning assembly.

F0021590

8 - Disconnect the inlet (8) and outlet (9) pipes from the
evaporator. 2
Immediately seal the ends of the pipes (8) and (9) to
prevent atmospheric moisture from getting into the
air conditioning system. 8
9 - Release the rubber diaphragm (10).
9
10 - Lift up the evaporator (11); remove the temperature
sensor (12) and place it on one side. 3
11 - Remove the evaporator (11).
F0021650

Refitting
• Refitting is the reverse of removal.

1
★ Quantity of R134a: 1600 g (56.4 oz.)
10
★ After recharging the system, check the seals on
the pipes (R and S) and throughout the system us-
ing a leak detector.

2
High pressure fitting (5/8’ - 18UNF):
13.6–20.3 Nm (10 – 15 lb.ft.) F0001062

Low pressure fitting (7/8’ - 14UNF):

35.3–42 Nm (26 – 31 lb.ft.)

3 11
★ Check that the temperature sensor is securely
fixed.
1 - Carefully check the seal around the upper cover (7).

12

F0000941

30-191
RIGHT-HAND AIR CONDITIONING FAN

RIGHT-HAND AIR CONDITIONING FAN

Removal
Remove the battery cover and disconnect the nega- 1
tive battery lead (–).
1 - Remove the seat.
(For details, see "DRIVER'S SEAT".
2
2 - Remove the centre console shroud. (For details, see
"CENTRE CONSOLE AND SHROUD").
3 - Remove the fixing screws of the right-hand console
(For details, see "RIGHT-HAND CONSOLE").
4 - Remove the seat support (1) and upper cover (2) of the
air conditioning assembly. F0021592

5 - Remove the evaporator. (For details, see "AIR CON-

DITIONING EVAPORATOR").
4 3
6 - Remove four bolts (3) securing the fan (4).
7 - Remove the fan (4) and turn it over.

F0001000

8 - Unplug the connectors (5) and (6). 1

If a new fan is to be fitted, the support block (7) 7
should also be renewed. 4

5
6
F0001010

Refitting
• Refitting is the reverse of removal.

1
★ Stick the support block on to the fan screw before
positioning the fan

Block: Loctite 401

1 - Carefully check the seal around the upper cover.

30-192
 LEFT-HAND AIR CONDITIONING FAN

LEFT-HAND AIR CONDITIONING FAN

Removal
Remove the battery cover and disconnect the nega- 6
tive battery lead (–).
1 - Remove the seat.
(For details, see "DRIVER'S SEAT"). 7
2 - Remove the left-hand console without disconnecting
the control cable of the heater valve. (For details, see
"LEFT-HAND CONSOLE").
3 - Remove the seat support (1) and the upper cover (2) of
the air conditioning assembly
4 - Withdraw the evaporator. (For details, see (For details, F0021590

see "AIR CONDITIONING EVAPORATOR").

5 - Remove the four screws (3) securing the fan (4)
6 - Remove the fan (4) and turn it over. 3 4

F0001020

7 - Unplug the connectors (5) and (6). 1 7

If a new fan is to be fitted, the support block (7)
should also be renewed. 4

6
F0001030

Refitting
• Refitting is the reverse of removal.

1
★ Stick the block to the fan screw before positioning
the fan.

Block: Loctite 401

1 - Carefully check the seal around the upper cover.

30-193
PARKING BRAKES

PARKING BRAKES

Adjustment
1 - Before proceeding with the adjustment, operate the
handbrake lever (1) repeatedly in order to eliminate
any play and check that the control cable slides freely.
2 - Apply a dynamometer with a scale of up to 500 Nm to
the handgrip, and raise the handbrake lever to the first
notch; check that the force applied to reach the first
notch is within the normal limits.
1
★ Normal force: 300 +0 30 N (55 +0 5 lb.)

F0021660

3 - If the force is outside these limits, screw out the nut (2)
with the least clearance and screw in the nut (3) with

m m
2

5 m
m
0, ,5
most clearance.

IN 1
M AX
M
4 - Then check that the distances between the nuts (2)
and (3) of the tie-rods (4) are 0.5–1.5 mm (0.02 -- 0.06 3
in.).

F0079130

5 - Take the tractor to straight section of apshalted road

at least 50 m (97 yard) in length.
6 - Engage gear and move off.
7 - With the tractor in motion, depress the clutch pedal
and fully apply the handbrake (1); check that the rear
wheels lock up simultaneously.
8 - If the rear wheels do not lock up at the same time,
screw in gradually and by just a few degrees the nut
(2) corresponding to the wheel that fails to lock up
and screw out the nut corresponding to the other
wheel.
9 - Repeat the previous operations until both rear wheels
lock up simultaneously when the handbrake is fully
applied.
10 - Check that parking lever travel is within the normal lim-
its.
★ Lever travel: max. 5 notches
If adjustment is required, turn the two nuts (2) by equal
amounts.

30-194
 CAB DOOR CABLE

CAB DOOR CABLE

Renewal
1 - Unscrew and remove the four screws (1) securing the
two halves of the handle (2).
2

1 1

F0019740

2 - Remove the two halves of the handle and recover the

bushes (3) and the pin (4).
3

4
2
3
F0019750

3 - Unscrew and remove the fixing screws (5) of the door

lock cover (6).
5

F0019760

4 - Loosen the clamp nut (7) and withdraw the cable (8).

8 F0019770

30-195
CAB DOOR CABLE

5 - Feed the new cable starting from the handle side; en-
gage it with the pin (4) and the clamp nut (7).
With the cable under slight tension, tighten down the
clamp nut.
7

4
8
F0019780

6 - Lubricate the bushes (3) and the slide ways for the
handle; fit the bushes to the pin and refit the handle (2).
3
Slide ways and bushes: Molikote
2
7 - Check that the door opens correctly and complete the
refitting procedure.

F0019790

30-196
 TRAILER BRAKING AIR PRESSURE GAUGE

TRAILER BRAKING AIR PRESSURE GAUGE

Removal
Remove the key from the ignition.
2
1 - Unscrew and remove fixing screws (1) of the upper
1
cover (2); remove the cover.

F0019800

2 - Remove the gauge (3); if a new gauge is to be fitted,

unplug the connectors (4) and (5).
★ Label the connectors (5) to avoid confusion on re-
connection. 3

5
F0019810

3 - To replace the bulb, unplug the connectors (4) and

withdraw the bulb holder (6).

F0019820

Refitting
• Refitting is the reverse of removal.

30-197
TRANSMISSION STATUS DISPLAY

TRANSMISSION STATUS DISPLAY

Removal
Remove the key from the ignition switch.
1 - Insert a thin blade “A” between the cab pillar and the
display unit (1).
A
2 - Prise off the display (1).

F0019830

3 - Unplug the connector (2).

F0019840

Refitting
• Refitting is the reverse of removal.

30-198
 CAB

CAB

Removal
Remove the battery cover and disconnect the nega- 1
tive battery lead (–).
Discharge any residual pressure from the trailer brak-
ing air reservoir and the cab suspension system.
1 - Remove the rear wheels.
(For details, see "CAB").
2 - Remove the air cleaner.
(For details, see "AIR CLEANER").

F0045700

3 - Remove the cover plate (1) and disconnect from the

bulkhead fitting the connectors of the electrical leads
of the transmission (2) (TKAB1), the lift (3) (TKAB2) and
the connector (4) and power supply lead (5) for the
front axle (if present) 2

(3) TKAB2 CAB

SERVICES
3

SUPER-REDUCTION
CONTROL

4
(2) TKAB1
F0021701

(4) FRONT (5)

SUSPENSION

F0019911

4 - Disconnect from the front bulkhead plate the connec-

tor (6) and the connector (7) of the engine wiring. 7 6
5 - Remove the bolts and nuts (8) of the gear lever (9).

8
9

F0045411

30-199
CAB

6 - Remove the gear lever gaiter (10), unplug the connec-

tor (11) and remove the complete lever assembly (12).
12

11

10

F0019583

7 - Disconnect the control cables (13) from the auxiliary

service control valves.
★ Label the cables to avoid confusion on reconnec-
tion.
★ Disconnect also the outer cables.
13

F0078794

8 - Disconnect the control cable (15) from the PTO speed

and operating mode selector lever (14).
★ Disconnect also the outer cables.

15

14

F0045393

9 - Disconnect the control cable (16) from the creeper

control lever (17).
★ Disconnect also the outer cable.

16
17
F0045710

30-200
 CAB

10 - Remove the cab access steps (18).

11 - Remove the fuel tank.
(For details, see "FUEL TANK").

18

F0043751

12 - Disconnect the system feed wire from the positive ter-

minal (19) (+) of the battery (20).

19

20
F0017143

13 - Disconnect the earth leads (21) from the engine.

21
21

F0045720

14 - Draw the fluid out of the brake fluid reservoir (22); dis-
connect the suction pipes (23) and remove the panel
(24).
22

23
24

F0018763

30-201
CAB

15 - Disconnect the delivery pipes (25) of the brake cylin-

ders (26) and remove them by disconnecting the lower 25
coupling.
★ Plug the ends of the pipes to prevent the entry of
contaminants. 26 25

26

F0079140

16 - Disconnect the pipes (27) and (28) coming from the

power steering.
★ Plug the pipes and the open fittings to prevent
the entry of impurities.
27

28

F0079150

17 - Drain off the engine coolant.

Coolant: 29
Mod. 80 90 100 105
ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62
30
18 - Loosen the clips (29) and disconnect the cab heater
pipes (30).

F0079111

19 - Disconnect the suction pipe (31) of the air condi-

tioning compressor and the outlet pipe (32). 31
1

32

F0079160

30-202
 CAB

20 - Disconnect the control cable (33) from the parking

brake lever (34).
34
★ Disconnect also the outer cable from the support
(35).

35

33
F0020221

21 - Remove the exhaust pipe end fitting (36) from the cab.
(For details, see "EXHAUST PIPE").

36

F0021681

22 - Remove the cover of the rear screen wiper and unplug

the connector (37) and the screen wash pipe (38).
38

37

F0020243

23 - Disconnect the gas springs (40) from the rear window

(39); lower the window (39).

39

40

F0020253

30-203
CAB

24 - While supporting the rear window, remove the hinge

pins (41) with a pin punch. 41 41

25 - Remove the complete rear window assembly (39).

F0020261

26 - Remove the front centre screws fixing the cab to the

vibration damping mountings (43).
42

43

F0045770

27 - Remove the covers (44), nuts (45) and front fixing bolts
(46) of the cab.

46

45

44
F0045780

30-204
 CAB

28 - Fold the rearview mirrors (47) against the cab win-

dows.
29 - Attach the cab lifting frame “A” to a hoist.
Attach slings “B” of different length to the cab using
the holes “F” provided on the rear supports and the
supports (48) for the work lights and direction indica-
tors.

47

48

F0020292

30 - Slowly raise the cab by about 15 cm and check that all

the lower cables and connection pipes are discon-
nected.
Complete cab assembly:
approx 780 kg (1718 lb.)
31 - Release the wiring from all the clips and remove the
cab while guiding the pipes and control cables.

30-205
CAB

Refitting
• Refitting is the reverse of removal.

1
Air conditioning pipes fittings:
delivery (5/8” - 18UNF):13.6–20.3 Nm (10–15 lb.ft.)
suction (7/8” - 14UNF): 35.3–42 Nm (26–31 lb.ft.)
1 - Fill the engine cooling system.

Coolant:
Mod. 80 90 100 105
ᐉ 15.5 15.5 15.5 17.5
US.gall. 4.10 4.10 4.10 4.62

2 - Fully open the cab heater valve.

3 - Start the engine and check the hydraulic, pneumatic
and heating systems for leaks.
4 - Turn the steering wheel back and forth between the
full lock positions to expel any air from the power
steering circuit.
5 - Switch off the engine; check the coolant level and top
up if necessary.
6 - Bleed the hydraulic brake system.
(For details, see "BRAKING SYSTEM").

30-206
 ENGINE -TRANSMISSION

ENGINE -TRANSMISSION

Separation
There are two methods used for separating the engine and transmission ac-
cording to the operation to be carried out:
1 - Renewal of the front crankshaft oil seal.
2 - Overhaul of the clutch or renewal of the rear crankshaft oil seal.
3 - Removal of the engine for overhaul or renewal.

CAUTION!
• The illustrations depict the basic machine without optional front-
mounted equipment (Pto, lift, front axle suspension).
• For removal of individual components, see the specific paragraphs in
this manual.

1. Renewal of the front crankshaft oil seal.

For this operation it is sufficient to remove the front support complete with the
front axle, radiator/coolers assembly, front Pto (if present), front axle sus-
pension (if present) and front lift (if present).
To do this:
1 - Remove the guard and disconnect the front axle drive shaft.
2 - Remove the battery and its support.
3 - Disconnect the pipes of the valves of the front lift (if present) and remove
the side members.
4 - Disconnect the connection pipes of the radiator/coolers assembly.
5 - Disconnect the wiring looms and pipes, and direct them towards the
rear of the tractor.
6 - Disconnect the steering pipes, the front suspension cylinder pipes (if
present), the wiring for the front PTO (if present) and for the sensor for the
suspension (if present).
7 - Disconnect the drive coupling of the front PTO (if present).
8 - Position a stand capable of supporting the weight of the gearbox as-
sembly under the engine sump.
9 - Position two trolley jacks under the front support to prevent any rotation
of the support.
10 - Loosen and remove the bolts securing the front support to the engine.
11 - Move the complete front support assembly on the front wheels away
from the rear of the tractor.
NOTE - if necessary use a lever to separate the parts.
12 - Renew the oil seal following the procedure indicated in the engine work-
shop manual.

30-207
ENGINE -TRANSMISSION

2. Overhaul of the clutch or renewal of the rear crankshaft oil seal.

For these operations it is sufficient to separate the engine from the gearbox.
To do this:
1 - Remove the guard and remove the front axle drive shaft.
2 - Remove the battery and its support.
3 - Disconnect the pipes of the valves of the front lift (if present) and remove
the side members.
4 - Disconnect the steering pipes, the air conditioning, the gearbox oil cool-
er and the fuel pipes.
5 - Remove the intake pipe and the air cleaner connection manifold.
6 - Detach the silencer and remove the exhaust pipe.
7 - Disconnect the supply and return pipes from the gear pump and remove
them.
8 - Remove the outlet pipe from the air compressor.
9 - Disconnect the earth leads, the main connector and the temperature
sensor connector from the engine.
10 - Position a stand tight under the transmission and a trolley jack under the
engine.
11 - Loosen and remove the bolts (1), the nuts (2) and (3); separate the engine
from the transmission, moving the complete front assembly on the front
wheels away from the rear of the tractor.
NOTE - If necessary, use a lever to separate the engine from the
transmission.

1
F0079180
F0079170

12 - Overhaul the clutch or renew the crankshaft oil seal following the pro-
cedures indicated in the engine workshop manual.

30-208
 ENGINE -TRANSMISSION

3. Removal of the complete engine

This operation requires the prior separation of the front assembly (described
in paragraph “1. Renewal of the front crankshaft oil seal" and then removal of
the engine using the procedure described in paragraph "2. Overhaul of the
clutch or renewal of the rear crankshaft oil seal" up to step 10); then:
1 - Apply the lifting brackets or support the engine using a hoist.
2 - Remove the nuts and bolts securing the engine to the transmission and
remove the engine (for details, see paragraph "2. Overhaul of the clutch
or renewal of the rear crankshaft oil seal").
NOTE - if necessary use a lever to separate the engine from the
transmission.

Reconnection
• Refitting is the reverse of removal
1 - Bleed the braking system.
(For details, see "BRAKING SYSTEM").
2 - First tighten the nuts, then the bolts, proceeding in and alternate diag-
onal sequence.
M12 nuts and bolts: 110±10% Nm (81±10% lb.ft.)

M16 nuts and bolts: 260±10% Nm (191.7±10% lb ft.)

3 - Clean mating faces thoroughly; lubricate faces and locating dowels.

Locating dowels: Engine oil

4 - Fill all the systems with the appropriate fluids. Start the engine and run
for a few minutes to allow the fluids to circulate, then check for leaks.
5 - Expel the air from the dismantled hydraulic circuits by performing a few
manoeuvres
6 - Stop the engine, check all fluid levels and top up if necessary.

30-209
 CONTENTS

SECTION 40

CONTENTS

THE STRUCTURE OF THE UNIT .......................................... 1 5. WIRING ............................................................................ 69

• ENGINE WIRING (4 CYLINDERS) (1/2) 69
HOW TO CONSULT THE UNIT ............................................. 2 • ENGINE WIRING (4 CYLINDERS) (2/2) 70
1. INTRODUCTION ............................................................... 3 • ENGINE WIRING (6 CYLINDERS) (1/2) 71
• 1.1 LIST OF WIRING HARNESSES............................................... 3 • ENGINE WIRING (6 CYLINDERS) (2/2) 72
• 1.2 DEFINITION OF COMPONENTS AND SYMBOLS.................. 4 • ENGINE WIRING (1/2) 77
• 1.3 GENERAL RULES ................................................................... 4 • ENGINE WIRING (2/2) 78
• • 1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/ • TRANSMISSION WIRING (1/2) 87
ELECTRONIC CIRCUITS ...................................................... 4 • TRANSMISSION WIRING (2/2) 88
• • 1.3.2 MAIN WIRING FAULTS ............................................. 4 • TRAILER BRAKE WIRING (ITALY) 97
• • 1.3.3 REMOVAL, REFITTING AND DRYING OF • TRAILER BRAKE WIRING 98
CONECTORS AND WIRING ................................................. 5 • FRONT AXLE SUSPENSION WIRING (CAB) 101
• 1.4 DIAGNOSTIC INSTRUMENTS ................................................ 6 • CAB POWER SUPPLY WIRING 105
• 1.5 WIRE COLOUR CODES.......................................................... 6 • FRONT AXLE SUSPENSION WIRING 111
• FENDER WIRING - NARROW 115
2. INDICES ............................................................................. 7 • NUMBER PLATE LIGHT WIRING 116
• 2.1 INDEX BY PART DESCRIPTION ............................................. 7 • FRONT CONSOLE WIRING (1/2) 121
• 2.2 INDEX BY PART CODE......................................................... 12 • FRONT CONSOLE WIRING (2/2) 122
• 2.3 INDEX BY CONNECTOR ...................................................... 16 • SIDE CONSOLE WIRING (1/2) 127
3. COMPONENTS ............................................................... 24 • SIDE CONSOLE WIRING (2/2) 128
• 3.1 CONNECTOR LAYOUTS ...................................................... 24 • AIR CONDITIONING WIRING (CAB) 137
• 3.2 COMPONENT TECHNICAL DATA ........................................ 29 • DISPLAY WIRING 143
• ROOF WIRING (1/2) 147
• 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC
CONTROL UNITS.................................................................. 38 • ROOF WIRING (2/2) 148
• • 3.3.1 ENGINE CONTROL UNIT ....................................... 38 • CAB LOWER HEADLIGHTS WIRING 155
• WINDSCREEN WIPER MOTOR WIRING 155
• • 3.3.2 TRANSMISSION CONTROL UNIT .......................... 40
• • 3.3.3 INFOCENTER ......................................................... 42 • CAB LOWER FRONT WORKLIGHTS WIRING
• • 3.3.4 HPSA CONTROL UNIT .......................................... 44 (MACHINE WITHOUT FRONT LIFT) 156
• CAB LOWER FRONT WORKLIGHTS WIRING
• • 3.3.5 FRONT SUSPENSION CONTROL UNIT ................ 46
(WITH FRONT LIFT) 156
4. SYSTEMS ........................................................................ 47 • CAB ROOF FRONT AND REAR WORKLIGHTS WIRING 157
• 4.1 GROUND POINTS................................................................. 47 • LIGHTS SELECTOR SWITCH 163
• 4.2 ENGINE START..................................................................... 48 • ARMREST WIRING 167
• 4.3 PREHEATING........................................................................ 49 • FUSES AND RELAYS CONTROL UNIT (1/2) 169
• 4.4 ELECTRICAL ENGINE CONTROL ........................................ 50 • FUSES AND RELAYS CONTROL UNIT (2/2) 170
• 4.5 LIGHTS - LIGHT SELECTOR SWITCH
(MACHINE WITHOUT FRONT LIFT)...................................... 51
• 4.6 LIGHTS - LIGHT SELECTOR SWITCH
(MACHINE WITH FRONT LIFT) ............................................. 52
• 4.7 CAB ACCESSORY................................................................ 53
• 4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)...... 54
• 4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT) ............. 55
• 4.10 WINDSCREEN WIPER .......................................................... 56
• 4.11 INFOCENTER........................................................................ 57
• 4.12 ELECTRICAL POWER SUPPLY............................................ 58
• 4.13 AUTORADIO - CB ................................................................. 59
• 4.14 AIR CONDITIONING - HEATING FAN................................... 60
• 4.15 BRAKES ................................................................................ 61
• 4.16 TRAILER BRAKES................................................................. 62
• 4.17 FRONT AXLE SUSPENSION................................................. 63
• 4.18 TRANSMISSION ................................................................... 64
• 4.19 ASM - 4WD - DIFFERENTIAL ............................................... 65
• 4.20 REAR LIFTER ........................................................................ 66
• 4.21 FRONT AND REAR PTO ....................................................... 67

40-i
 THE STRUCTURE OF THE UNIT

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 trouble-
shooting and repairs, and the instruments required for troubleshooting.

2. Indices
Contains the indices arranged by connector name, by component code and by component de-
scription.

3. Components
Contains the layouts of the connectors used in the electrical system, descriptions of the com-
ponents installed on the tractor,the technical data necessary for functional testing and the pi-
nouts of the electronic control units.

4. Systems
Contains the electrical diagrams of the tractor's systems.

5. Wiring harnesses
Contains the layouts, the wiring diagrams and the positioning of connectors on the tractor.

40-1
 HOW TO CONSULT THE UNIT

HOW TO CONSULT THE UNIT

How to consult the table
The quickest way to determine the cause of a malfunc-
tion of a component (e.g. the starter motor) is to check all
A B the components in the system in which the component is
incorporated.
2 E In this example, the problem is a malfunction of the start-
er motor, which fails to start the engine.

Start enable switch 1- Look in paragraph “2.1. Component description

0441.6066 11 START 2
(green) index” for the starter motor and identify the system
in which it is incorporated.
Starter motor X47 2 The system is indicated in the column “System
(para 4.xx)” and in this case is “2” (figure A).
2- Consult paragraph “4.2 Starting” (figure B), in
which the electrical diagram indicates all the com-

0443.7847
ponents in the system; these components are ac-
C START
12
companied by numbers that correspond to the key
on the same page.
2 3- Check all the components in the system, starting,
for example, with the switch “2”.
11 START 4- Look in paragraph “2.1. Component description
index” (figure A) for “Starting enabling switch
2 Starter enable switch (green)
(Green)” and check in the column “Technical (para
3.2.xx)” if there is a technical description of the
0443.7847/20 component (in this case it is given at n° 11 of the
paragraph “3.2 Component technical data”) (fig-
D ure C).
Note down also the name of the connector to which
t h e c o mp o n e n t i s c o n n e c t e d ( i n t h i s c a s e
“START”).
F
Only if the position of the component is not known
0443.7847 5 - Look in paragraph “2.3 Connector index” (figure
START 10 Start enable switch
(green) D) for the name of the connector to which the com-
ponent is connected (in this case “START”) and
G note down the wiring harness in which it is incor-
porated (in this case “0443.7847” or
“0.012.3639.4”) and the type of connector (in this
10 case “10”).
6 - Look for the wiring harness in chapter “5. Layouts,
electrical wiring diagrams, connector posi-
START tions” using the index at the beginning of the chap-
ter.
7 - Look for the name of the connector in the photos at-
tached to the electrical diagrams and determine its
position on the tractor from the drawing (figure E).
NOTE.
In the electrical diagrams (figure F) are indicated
the names of the connectors and the descrip-
tions that are used in all the tables of chapter 2.
8 - Using the data contained in the paragraph “3.2
Component technical data” (figure C) in position
START n° 11, check the operation of the switch.
0443.7847/20 If the pinout of the connector is not known, look in
paragraph “3.1 Connector layouts” (figure G) for
0443.7847/20 the number found in the column “Type” of para-
graph “2.3 Connector index”.

40-2
1. INTRODUCTION 1.1 LIST OF WIRING HARNESSES

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 regarding the
tractor's systems and components.
Due to the possible time difference between the introduction of technical modifications (in line
with our policy of continuous product improvement) and the corresponding amendment of our
printed documentation, 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 HARNESSES

DESCRIPTION CODE PAGE

Cab power supply wiring 0443.7846/20 40-107

Air conditioning wiring 0.010.2562.2 40-139

Armrest wiring 0443.7354.4 40-169

Front console wiring 0.012.8894.4/30 40-123

Side console wiring 0.012.8732.4/40 40-129

Lights selector switch wiring 0443.8656 40-165

Display wiring 0443.7875 40-145

Cab lower headlights wiring 0441.1923.4 40-157

Cab roof front and rear worklights wiring 0443.4993 40-159

Cab lower front worklights wiring (machine without front lift) 0442.5602 40-158

Trailer brake wiring 0443.7355.4 40-100

Trailer brake wiring (Italy) 0443.7356.4 40-99

Engine wiring 0.013.5915.4/20 40-79

Number plate light wiring (Narrow fenders) 0441.4114 40-118

Cab full and dipped beam headlights (with front lift) 0441.6727 40-158

Engine wiring (4 cylinders) 0421.3182 40-71

Engine wiring (6 cylinders) 0421.3172 40-73

Windscreen wiper motor wiring 0441.2045 40-157

Fender wiring - narrow 0442.9835/10 40-117

Front axle suspension wiring (cab) 0443.7850/10 40-113

Front axle suspension wiring (ROPS) 0443.7849 40-103

Roof wiring 0443.7851/10 40-149

Transmission wiring 0.012.8672.4 40-89

Fuses and relays control unit 0441.9533.4/10 40-171

40-3
1. INTRODUCTION 1.2 DEFINITION OF COMPONENTS AND SYMBOLS

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 Electrical component that converts the temperature of a medium (air, water, oil,
sensor etc.) into a voltage or resistance
Pressure Electrical component that converts the pressure of a medium (air, water, etc.)
sensor into a voltage or resistance
Electrical component that converts the angular or linear position of an object
Position sensor into a voltage
Pressure Switch that changes state (opens or closes a contact) according to the oper-
switch ating pressure in the circuit in which it is installed
Switch that changes state (opens or closes a contact) according to the tem-
Thermostat perature 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 Description of components” shows the wiring diagrams for certain switches and
buttons. The following symbols are used for ease of identification
SYMBOL DESCRIPTION

Contact between CLOSED pins (stable position of switch)

Contact between CLOSED pins (non-stable position of switch)

Indicator LED

Indicator lamp

Diode

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.
1.3.1 MODIFICATION OF THE TRACTOR'S ELECTRICAL/ELECTRONIC CIRCUITS
The manufacturer prohibits any modification or alteration of the electrical wiring for the
connection of any non-approved electrical applicances 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.

1.3.2 MAIN 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 ox-
idisation of the pin contact surfaces.
b. Defective pin welding or crimping
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 insu-
lation or the wire itself and a poor connection.

40-4
1. INTRODUCTION 1.3 GENERAL RULES

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 dam-
age 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 com-
pressed 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 non-
conductors) .
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 not lubricated compressed air.

1.3.3 REMOVAL, 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 togther, 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 nec-
essary, with water or steam.
If the wiring has to be cleaned with water, avoid directing the water or steam jet on the
connectorsi; if water penetrates the connector, proceed as described in paragraph 1.3.2.
★ Check that the connector is not short circuited by water by testing the continuity
across the pins.
★ After checking the connector is in good condition, degrease the contacts using a
deoxidising product.

40-5
1. INTRODUCTION 1.4 DIAGNOSTIC INSTRUMENTS

d. 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, ecc.) DIN 72581/3C
- fuse F51 (100A) e F52 (200A) ISO 8820
The fitting of replacement fuses that do not comply with these standards will in-
validate 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 instru-
ments 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 - Computer loaded with the “SERDIA”
3 - All Round Tester

1.5 WIRE COLOUR CODES

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

40-6
2. INDICES 2.1 INDEX BY PART DESCRIPTION

2. INDICES
2.1 INDEX BY PART DESCRIPTION
Technical.
Component description Code descr'n Connector System
Component (Chap. 3.2.xx) (Chap. 4.xx)

4WD switch 0441.1496.4 38 8 19

50S lights switch 0441.1496.4 37 4 8-9
Accelerator pedal position sensor 2.7099.740.0/10 23 X31 4
Actuator 0211.2588 4 Y3 4
Air cleaner clogged sensor 0441.9014 L 11
Air conditioning compressor 0443.7338 K 14
Air conditioning control panel illumination
connector X24 14

Air conditioning on/off switch 0.010.2532.0 X26 14

Air conditioning thermostat 0.010.2537.1 X25 14
Alternator 0117.8607 B+ D+ 2 - 21
Armrest 0443.8670.4 X21 4-8-20
ASM switch 0441.1498 42 6 19
Auxiliary power socket 0114.3529 X15 12
Auxiliary power supply connector (in cab) X19 12
Axle Down solenoid 0442.3803 S 17
Axle Up solenoid 0442.3803 H 17
Battery +30
Brake fluid level sensor X81 15
Brake pedal switch 0439.1395 8 X32 - X35 15-17-19
Camshaft speed sensor 0419.9792 5 B40 4
(pickup)
CB power connector X44 13
Cigar lighter 0441.2338 X7 7
Clock 0441.2337 X49 7
Clutch pedal depressed proximity sensor 0442.4165/10 19 X33 18
Clutch pedal position sensor 0443.2708 24 X34 18
Compressed air pressure gauge 0442.5709 20 X39 16
Compressed air pressure gauge light X38 5-6
Compressed air pressure sensor 0.011.9428.0 2 X71 16
for trailer braking system
Compressor and condenser fan
pressure switch 0442.3185 X74 14

Configuration connector (LS/PS)

Configuration connector (Powershuttle) PS
Diagnostics connector X18 4-17-18-20
Differential lock solenoid valve 0442.3824 EVDF 19
Differential lock switch 0441.1498 43 7 19
Direction indicators flasher unit 0441.9531 X1-X2 5-6
Door open warning signal switch 0441.4097 X45 7
Driver seat air suspension compressor 0.010.2274.1 X5 7
Engine boost pressure sensor 0419.4078 B48 4

40-7
2. INDICES 2.1 INDEX BY PART DESCRIPTION

Code Technical. System

Component description Component descr'n Connector (Chap. 4.xx)
(Chap. 3.2.xx)
Engine control unit 0419.4998 MX1 - MX2 2-3-4-12
Engine coolant temperature sensor 0419.9410 B43 4
Engine coolant temperature sensor (for Infocent-
er) 0419.9809 7 T 11

Engine ECU circuit board 0.010.3627.1 X8 2-4

Engine oil pressure switch 0118.2227 3 P 11
Engine speed keypad 0443.7505 X20
Engine speed sensor 0443.8438 1 NLSE 18
Engine starter relay RL40 2
Fan speed selector switch 0.010.2528.1 X27 14
Field/road selection solenoid valve 0.010.3343.0 49 EV F/S 18
Field/road sensor 0441.6157 50 F/S SWITCH 18
Four wheel drive (4WD) solenoid valve 0443.1661 21 EVDT 15-19
Front axle suspension
ECU 2.8519.008.0/10 JX3-JX4 12-17

Front axle suspension load sensing

solenoid 0442.3803 X68 17

Front axle suspension position sensor 0439.1530 10 X69 17

Front left side lights 0441.1920.4 X59 5-6
direzione anteriore sinistro
Front left sidelights connector G7
Front left worklight on cab 0441.4087.4 X63 6
(with front lift)
Front left worklight on cab
(without front lift) 0442.5599.4 X61 8-9

Front PTO pushbutton (in cab) 0441.1533 13 X9 21

Front PTO solenoid valve HZW 21
Front right side lights 0441.1921.4 X60 5-6
and direction indicators
Front right sidelights connector G9
Front right worklight on cab 0442.5599.4 X62 8-9
(without front lift)
Front right worklight on cab
(with front lift) 0441.4087.4 X64 6

Front suspension pushbutton 0442.2763 46 5 17

Fuel level sensor 0445.2016 FUEL 11
Fuel temperature sensor 0419.9552 6 B37 4
Gearbox control lever F/S LEVER 18
Gearbox output shaft speed sensor 0443.8449 27 NLSA 18
Gearshift lever 0445.0961.4 X12 18
Gearshift solenoid valves (Y1, Y2, Y3, Y4) 0441.6685 18 EVGROUP 18
Glowplug warning light ON relay RL41 3
Handbrake switch 0439.1395 9 X6 15-16
Hazard warning lights on/off switch 0442.9401 47 X36 5-6
Headlights low beam switch (on cab) 0441.1496.4 35 3 6
(with front lift)
Heater fan speed 1 relay RL32 14

40-8
2. INDICES 2.1 INDEX BY PART DESCRIPTION

Code Technical. System

Component description Component descr'n Connector (Chap. 4.xx)
(Chap. 3.2.xx)
Heater fan speed 3 relay RL30 14
Heater fan speed 4 relay RL31 14
Horn 0116.9304 X87 5-6
3-4-5-6-11-15-
Instrument panel 0443.7488/10 ST1-ST2 16-18-20-21
Interior roof light 0442.6316 X46 7
ISO4 socket 0442.2323.4 ISO4 12
(power supply to implements)
ISO7 socket 0442.2324.4 ISO7 4-12-21
(implement connection)
Left front loudspeaker 0.012.1725.0 X50 13
Left headlamp 0443.5914.4 X86 5-6
Left headlamp (UK) 0443.5913.4 X86 5-6
Left rear loudspeaker 0.012.1726.0 X41 13
Lh heater fan 0.010.2537.0 X22 14
Lh heater fan resistor 0.010.2535.1 X23 14
LH rear lift Down
pushbutton 0441.2688 14 DWSX 20

LH rear lift Up
pushbutton 0441.2688 14 UPSX 20

Lift and hand throttle 0441.9425.4/10 48 EHR-EMR 4-20

console
Lift control panel 0442.9597.4 X14 20
Lift Down solenoid valve EVDW 20
Lift draft sensor (left) 0441.5586.4 15 LEFT DRAFT 20
Lift Up solenoid valve EVUP 20
Lower front worklights switch
(on cab) (without front lift) 0441.1496.4 36 3A 8

Lower rear left worklights X65SX 8-9

Lower rear right worklights X65DX 8-9
Main heating fuse FU131 14
Main power supply fuse FU100
Number plate light 0441.4115 X67 5-6
Preheating device 0425.8670 X78 3

Preheating relay 0419.4081 RL42 - RL42A 3

RL42B
Preheating relay power fuse FU101
Proportional valve solenoid 0443.4425 25 EVPROP 18
PTO AUTO switch 0441.1496.4 40 PTO AUTO 21
Radar 0443.8654 29 RADAR 20
Radar (UK) 0443.8655 30 RADAR 20
Radar control switch 0441.4584 X13 20
Radio X51 - X52 5-6-13
Rear left side lights 0442.9833.4/30 X66SX 5-6-15
and direction indicators
12-15-17-19-
Rear lift control unit 2.8519.013.0 JX1-JX2 20-21

40-9
2. INDICES 2.1 INDEX BY PART DESCRIPTION

Code Technical. System

Component description Component descr'n Connector (Chap. 4.xx)
(Chap. 3.2.xx)
Rear lift draft sensor (Right) 0441.5586.4 15 RIGHT DRAFT 20
Rear lift position sensor 0443.8667.0 31 POS SEN 20
Rear PTO pushbutton (in cab) 0441.1533 12 X10 21
Rear PTO solenoid valve 0.010.2628.2 EVPTO 21
Rear PTO speed sensor 0443.8352 PTO SEN 21
Rear right side lights 0442.9833.4/30 X66DX 5-6-15
and direction indicators
Rear screen washer pump 0441.4105 RP 10
Rear screen wiper motor 0441.3192 X42 10
Rear screen wiper switch 0441.9283 45 REAR WIPER 10
Rear worklights switch 0441.1496.4 34 WORK LIGHT 8-9
Relay for front upper worklights RL21 6-8-9
on cab (50S)
Rh heater fan 0.010.2535.0 X29 14
Rh heater fan resistor 0.010.2535.1 X28 14
RH rear lift Down
pushbutton 0441.2688 14 DWDX 20

RH rear lift Up
pushbutton 0441.2688 14 UPDX 20

RH rear PTO control button 0441.1533 11 PTODX 21

(on fender)
Right front loudspeaker 0.012.1725.0 X48 13
Right headlamp 0443.5914.4 X88 5-6
Right headlamp (UK) 0443.5913.4 X88 5-6
Right rear loudspeaker 0.012.1726.0 X43 13
Rotating beacon X47 8-9
Rotating beacon on/off switch 0441.1496.4 39 FLASHING LIGHT 8-9
Shuttle control lever 0.012.6472.4 33 X37 18
Side console courtesy light 0441.2616 X53 7
Sidelights switch 0441.1497 41 1 5-6
Speed sensor for odometer 0443.8450 26 NAB 18
Start enable switch (Green) 0441.6066 16 X80 2
Starter motor 0118.0928 +30C +50 2
2-3-4-5-6-7-8-
Starter switch 0441.1512.4 44 X17 9-10-11-12-13-
14-15-16-17-
18-19-20-21
Steering angle sensor 0441.5266 32 X82 19
Steering column switch unit 0443.8656 AS4 5-6-10
Trailer brake lights fuse FU121 15
Trailer braking low pressure switch X73 16
Trailer parking brake X72 16
solenoid
Trailer socket 0442.4116 X70 12-15
(for lights and auxiliary power)
Transmission display 0441.9280.4 X40 5-6-18
Transmission ECU 0443.8083/10 ECU PS 2-18

40-10
2. INDICES 2.1 INDEX BY PART DESCRIPTION

Code Technical. System

Component description Component descr'n Connector (Chap. 4.xx)
(Chap. 3.2.xx)
Transmission oil low pressure switch 0441.1690 22 PRESS SWITCH 18
Transmission oil temperature sensor 0441.6649 17 TEMP 18
Transmission speed sensor 0.010.3342.2 28 NHK 18
Upper front left worklight 0445.0666 X56 8-9
Upper front right worklight 0445.0666 X57 8-9
Upper rear left worklights 0445.0666 X55 8-9
Upper rear right worklights 0445.0666 X54 8-9
Windscreen washer pump 0441.4105 FP 10
Windscreen wiper motor 0441.3192 X58 10

40-11
2. INDICES 2.2 INDEX BY PART CODE

2.2 INDEX BY PART CODE

Technical.
Code Description descr'n Connector System
(Chap. 3.2.xx) (para. 4.xx)

0114.3529 Auxiliary power socket X15 12

0116.9304 Horn X87 5-6

0117.8607 Alternator B+ D+ 2 - 21

0118.0928 Starter motor +30C +50 2

0118.2227 Engine oil pressure switch 3 P 11

0211.2588 Actuator 4 Y3 4

0419.4078 Engine boost pressure sensor B48 4

0419.4081 Preheating relay RL42 - RL42A 3

RL42B

0419.4998 Engine control unit MX1 - MX2 2-3-4-12

0419.9410 Engine coolant temperature sensor B43 4

0419.9552 Fuel temperature sensor 6 B37 4

0419.9792 Camshaft speed sensor 5 B40 4

(pickup)

Coolant temperature
0419.9809 sensor (for Infocenter) 7 T 11

0425.8670 Preheating device X78 3

0439.1395 Brake pedal switch 8 X32 - X35 15-17-19

0439.1395 Handbrake switch 9 X6 15-16

0439.1530 Front axle suspension position sensor 10 X69 17

0441.1497 Sidelights switch 41 1 5-6

0441.1498 ASM switch 42 6 19

0441.1498 Differential lock switch 43 7 19

0441.1533 RH rear PTO control button 11 PTODX 21

(on fender)

0441.1533 Rear PTO pushbutton (in cab) 12 X10 21

0441.1533 Front PTO pushbutton (in cab) 13 X9 21

0441.1690 Transmission oil low pressure switch 22 PRESS SWITCH 18

0441.2337 Clock X49 7

0441.2338 Cigar lighter X7 7

0441.2616 Side console courtesy light X53 7

RH rear lift Down

0441.2688 pushbutton 14 DWDX 20

0441.2688 LH rear lift Down 14 DWSX 20

pushbutton

0441.2688 RH rear lift Up pushbutton 14 UPDX 20

40-12
2. INDICES 2.2 INDEX BY PART CODE

Technical. System
Code Description descr'n Connector (para. 4.xx)
(Chap. 3.2.xx)

LH rear lift Up
0441.2688 pushbutton 14 UPSX 20

0441.3192 Rear screen wiper motor X42 10

0441.3192 Windscreen wiper motor X58 10

0441.4097 Door open warning signal switch X45 7

0441.4105 Windscreen washer pump FP 10

0441.4105 Rear screen washer pump RP 10

0441.4115 Number plate light X67 5-6

0441.4584 Radar control switch X13 20

0441.5266 Steering angle sensor 32 X82 19

0441.6066 Start enable switch (Green) 16 X80 2

0441.6157 Field/road sensor 50 F/S SWITCH 18

0441.6649 Transmission oil temperature sensor 17 OC 18

0441.6685 Gearshift solenoid valves (Y1, Y2, Y3, Y4) 18 EVGROUP 18

0441.9014 Air cleaner clogged sensor L 11

0441.9283 Rear screen wiper switch 45 REAR WIPER 10

0441.9531 Direction indicators flasher unit X1-X2 5-6

0442.2763 Front suspension pushbutton 46 5 17

0442.3185 Compressor and condenser fan X74 14

pressure switch

0442.3803 Axle Up control solenoid H 17

0442.3803 Axle Down control solenoid S 17

0442.3803 Front axle suspension load sensing X68 17

solenoid

0442.3824 Differential lock solenoid valve EVDF 19

Trailer socket
0442.4116 (for lights and auxiliary power) X70 12-15

0442.5709 Compressed air pressure gauge 20 X39 16

0442.6316 Interior roof light X46 7

0442.9401 Hazard warning lights on/off switch 47 X36 5-6

0443.1661 Four wheel drive (4WD) solenoid valve 21 EVDT 15-19

0443.2708 Clutch pedal position sensor 24 X34 18

0443.4425 Proportional solenoid valve 25 EVPROP 18

0443.7338 Air conditioning compressor K 14

0443.7505 Engine speed keypad X20

0443.8352 Rear PTO speed sensor PTO SEN 21

0443.8438 Engine speed sensor 1 NLSE 18

40-13
2. INDICES 2.2 INDEX BY PART CODE

Technical. System
Code Description descr'n Connector (para. 4.xx)
(Chap. 3.2.xx)

0443.8449 Gearbox output shaft speed sensor 27 NLSA 18

0443.8450 Speed sensor for odometer 26 NAB 18

0443.8654 Radar 29 RADAR 20

0443.8655 Radar (UK) 30 RADAR 20

0443.8656 Steering column switch unit AS4 5-6-10

0445.0666 Upper rear right worklights X54 8-9

0445.0666 Upper rear left worklights X55 8-9

0445.0666 Upper front left worklight X56 8-9

0445.0666 Upper front right worklight X57 8-9

0445.2016 Fuel level sensor FUEL 11

0.010.2274.1 Driver seat air suspension compressor X5 7

0.010.2528.1 Fan speed selector switch X27 14

0.010.2532.0 Air conditioning on/off switch X26 14

0.010.2535.0 Rh heater fan X29 14

0.010.2535.1 Lh heater fan resistor X23 14

0.010.2535.1 Rh heater fan resistor X28 14

0.010.2537.0 Lh heater fan X22 14

0.010.2537.1 Air conditioning thermostat X25 14

0.010.2628.2 Rear PTO solenoid valve EVPTO 21

0.010.3342.2 Transmission speed sensor 28 NHK 18

0.010.3343.0 Field/road selection solenoid valve 49 EV F/S 18

0.010.3627.1 Engine ECU circuit board X8 2-4

Compressed air pressure sensor

0.011.9428.0 trailer braking system 2 X71 16

0.012.1725.0 Right front loudspeaker X48 13

0.012.1725.0 Left front loudspeaker X50 13

0.012.1726.0 Left rear loudspeaker X41 13

0.012.1726.0 Right rear loudspeaker X43 13

0.012.6472.4 Shuttle control lever 33 X37 18

Headlights low beam switch (on cab)

0441.1496.4 (with front lift) 35 3 6

0441.1496.4 50S lights switch 37 4 8-9

0441.1496.4 4WD switch 38 8 19

Lower front worklights switch (on cab)

0441.1496.4 (without front lift) 36 3A 8

0441.1496.4 Rotating beacon on/off switch 39 FLASHING LIGHT 8-9

0441.1496.4 PTO AUTO switch 40 PTO AUTO 21

40-14
2. INDICES 2.2 INDEX BY PART CODE

Technical. System
Code Description descr'n Connector (para. 4.xx)
(Chap. 3.2.xx)

0441.1496.4 Rear worklights switch 34 WORK LIGHT 8-9

2-3-4-5-6-7-8-
9-10-11-12-13-
0441.1512.4 Starter switch 44 X17 14-15-16-17-
18-19-20-21

0441.1920.4 Front left sidelight and direction indicator X59 5-6

0441.1921.4 Front right sidelight and direction indicator X60 5-6

Front left worklight on cab

0441.4087.4 (with front lift) X63 6

0441.4087.4 Front right worklight on cab X64 6

(with front lift)

0441.5586.4 Lift draft sensor (left) 15 LEFT DRAFT 20

0441.5586.4 Rear lift draft sensor (Right) 15 RIGHT DRAFT 20

0441.9280.4 Transmission display X40 5-6-18

0441.9425.4/10 Lift and hand throttle console 48 EHR-EMR 4-20

0442.2323.4 ISO4 socket (power supply to implements) ISO4 12

0442.2324.4 ISO7 socket (implement connection) ISO7 4-12-21

0442.4165/10 Clutch pedal depressed proximity sensor 19 X33 18

Front left worklight on cab

0442.5599.4 (without front lift) X61 8-9

0442.5599.4 Front right worklight on cab X62 8-9

(without front lift)

0442.9597.4 Lift control panel X14 20

0442.9833.4/30 Rear right sidelight and direction indicator X66DX 5-6-15

0442.9833.4/30 Rear left sidelight and direction indicator X66SX 5-6-15

0443.5913.4 Left headlamp (UK) X86 5-6

0443.5913.4 Right headlamp (UK) X88 5-6

0443.5914.4 Left headlamp X86 5-6

0443.5914.4 Right headlamp X88 5-6

3-4-5-6-11-15-
0443.7488/10 Instrument panel ST1-ST2 16-18-20-21

0443.8083/10 Transmission ECU ECU PS 2-18

0443.8667.0 Rear lift position sensor 31 POS SEN 20

0443.8670.4 Armrest X21 4-8-20

0445.0961.4 Gearshift lever X12 18

2.7099.740.0/10 Accelerator pedal position sensor 23 X31 4

2.8519.008.0/10 Front axle suspension control unit JX3-JX4 12-17

2.8519.013.0 Rear lift control unit JX1-JX2 12-15-17-19-

20-21

40-15
2. INDICES 2.3 INDEX BY CONNECTOR

2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

+30 Battery

+30A 0443.7846 Battery

+30B Battery

+30C 0.013.5915.4/20 0118.0928 Starter motor

+50 0.013.5915.4/20 0118.0928 Battery

1 28 0.012.8894.4/30 0441.1497 Sidelights switch

3 28 0.012.8894.4/30 0441.1496.4 Cab headlights low beam switch

3A 28 0.012.8894.4/30 0441.1496.4 Lower front worklights switch

(on cab)

4 28 0.012.8894.4/30 0441.1496.4 50S lights switch

5 28 0.012.8894.4/30 0442.2763 Front suspension pushbutton

6 28 0.012.8894.4/30 0441.1498 ASM switch

7 28 0.012.8894.4/30 0441.1498 Differential lock switch

8 28 0.012.8894.4/30 0441.1496.4 4WD switch

APS 28 0.012.8732.4/40 Not utilised

AS1 20 0.012.8732.4/40 0.012.8894.4/30

AS2 19 0.012.8732.4/40 0.012.8894.4/30

AS3 18 0.012.8732.4/40 0.012.8894.4/30

AS4 20 0.012.8732.4/40 0443.8656 Steering column switch unit

AS5 14 0.012.8732.4/40 0443.7875

AS6 15 0.012.8732.4/40 0.012.8894.4/30

B+ 0.013.5915.4/20 0117.8607 Alternator (B+)

0421.3172 Not utilised

B1
0421.3182

0421.3172 Fuel temperature sensor

B37 0419.9552
0421.3182

0421.3172
B40 0419.9792 Camshaft speed sensor
(Pickup)
0421.3182

0421.3172
Coolant temperature
B43 0419.9410 sensor
0421.3182

0421.3172
B48 0419.4078 Engine boost pressure sensor
0421.3182

0421.3172
B6 Not utilised
0421.3182

40-16
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

CLEANFIX 28 0.012.8732.4/40 Not utilised

D+ 0.013.5915.4/20 0117.8607 Alternator (D+)

DS1 15 0.012.8732.4/40 0443.7851

DWDX 3 0442.9835 0441.2688 RH lift Down

pushbutton

LH lift Down
DWSX 3 0442.9835 0441.2688 pushbutton

ECU PS 44 0.012.8732.4/40 0443.8083/10 Transmission ECU

0443.7354.4
EHR 3 0.012.8732.4/40
Lift and hand throttle console
0441.9425.4/10 (EHR)

0443.7354.4
EMR 3 0.012.8732.4/40
0441.9425.4/10 Lift and hand throttle console
(EMR)

EV F/S 0.012.8672.4/10 0.010.3343.0 Field/road selection solenoid valve

EVDF 12 0.012.8672.4/10 0442.3824 Differential lock solenoid valve

EVDT 12 0.012.8672.4/10 0443.1661 Four-wheel drive control solenoid valve

(4WD)

EVDW 12 0.012.8672.4/10 Lift Down solenoid valve

EVGROUP 11 0.012.8672.4/10 0441.6685 Gear change solenoid valves

(Y1, Y2, Y3, Y4)

EVPROP 12 0.012.8672.4/10 0443.4425 Proportional solenoid valve

EVPTO 12 0.012.8672.4/10 0.010.2628.2 Rear PTO solenoid valve

EVUP 12 0.012.8672.4/10 Lift Up solenoid valve

F/S LEVER 1 0.012.8732.4/40 Gearbox control lever

F/S SWITCH 0.012.8672.4/10 0441.6157 Field/road sensor

0421.3172
F30 Not utilised
0421.3182

FE1 16 0.012.8732.4/40 0443.7850

FE2 0443.7850 0443.7849

FLASHING LIGHT 28 0.012.8732.4/40 0441.1496.4 Rotating beacon on/off switch

FP 0.012.8672.4/10 0441.4105 Windscreen washer pump

FU100 0443.7846 Main power supply fuse

FU101 0.013.5915.4/20 Preheating relay power fuse

FU121 0.012.8732.4/40 Trailer brake lights fuse

FU131 0.012.8732.4/40 Main heating fuse

FUEL 2 0.012.8672.4/10 0445.2016 Fuel level sensor

G1 0.012.8732.4/40 0.010.2562.2

40-17
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

G2 32 0.012.8732.4/40 0.010.2562.2

G3 33 0.012.8732.4/40 0443.7354.4

G4 0.012.8894.4/30 0443.8656

G5 1 0443.7851 0443.4993

G6 1 0443.7851 0443.4993

Front left sidelights

G7 5 0443.7851 0441.1923.4 connector

G8 5 0443.7851 0443.4993

Front right sidelights

G9 5 0443.7851 0441.1923.4 connector

G10 6 0443.7851 0441.2045

G11 5 0443.7851 0443.4993

0441.6727
G12 5 0441.1923.4
0442.5602

0441.6727
G13 5 0441.1923.4
0442.5602

G14 0443.7846 0442.9835

G15 0443.7846 0442.9835

G16 0442.9835 0441.4114

0443.7355.4
G17 4 0.012.8672.4/10
0443.7356.4

0421.3172
G18 0.013.5915.4/20
0421.3182

H 12 0443.7849 0442.3803 Axle Up control solenoid

HZW 2 0.013.5915.4/20 Front PTO solenoid valve

ISO4 24 0.012.8732.4/40 0442.2323.4 ISO4 socket

(power supply to implements)

ISO7 25 0.012.8732.4/40 0442.2324.4 ISO7 socket

(implement connection)

J1 9 0.012.8732.4/40 To fuses

J2 3 0.012.8732.4/40 To fuses

J3 3 0.012.8732.4/40 To fuses

JX1 31 0.012.8732.4/40 2.8519.013.0 Rear lift control unit

JX2 31 0.012.8732.4/40 2.8519.013.0 Rear lift control unit

JX3 31 0443.7850 2.8519.008.0/10 Front axle suspension

control unit

Front axle suspension

JX4 31 0443.7850 2.8519.008.0/10 control unit

40-18
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

K 0.013.5915.4/20 0443.7338 Air conditioning compressor

L 0.013.5915.4/20 0441.9014 Air cleaner clogged sensor

LEFT DRAFT 13 0.012.8672.4/10 0441.5586.4 Lift draft sensor (left)

LS 0.012.8672.4/10 Not utilised

LS/PS 2 0.012.8672.4/10 Configuration connector

MS1 41 0.012.8732.4/40 0.013.5915.4/20

MS2 29 0.012.8894.4/30 0.013.5915.4/20

MX1 43 0.012.8732.4/40 0419.4998 Engine control unit

MX2 43 0.012.8732.4/40 0419.4998 Engine control unit

NAB 3 0.012.8672.4/10 0443.8450 Speed sensor for odometer

NEUTRAL LS 0.012.8672.4/10 Not utilised

NHK 3 0.012.8672.4/10 0.010.3342.2 Transmission speed sensor

NLSA 3 0.012.8672.4/10 0443.8449 Gearbox output shaft speed sensor

NLSE 3 0.012.8672.4/10 0443.8438 Engine speed sensor

P 12 0.013.5915.4/20 0118.2227 Engine oil pressure switch

P1 0.012.8732.4/40 To fuses

P2 14 0.012.8732.4/40 To fuses

P3 22 0.012.8732.4/40 To fuses

P4 0.012.8732.4/40 To fuses

P5 22 0.012.8732.4/40 To fuses

P6 16 0.012.8732.4/40 To fuses

POS SEN 3 0.012.8672.4/10 0443.8667.0 Lift position sensor

switch

Transmission oil
PRESS SWITCH 2 0.012.8672.4/10 0441.1690 sensor

PS 2 0.012.8672.4/10 Configuration connector

(Powershuttle)

PTO AUTO 28 0.012.8732.4/40 0441.1496.4 PTO AUTO switch

PTO SEN 3 0.012.8672.4/10 0443.8352 Rear PTO speed sensor

PTODX 3 0442.9835 0441.1533 RH rear PTO control button

(on fender)

PTOSX 3 0442.9835 Not utilised

0443.8654 Radar
RADAR 13 0.012.8672.4/10
0443.8655 Radar (UK)

REAR WIPER 28 0.012.8732.4/40 0441.9283 Rear screen wiper switch

RIGHT DRAFT 13 0.012.8672.4/10 0441.5586.4 Rear lift draft sensor (Right)

RL21 0443.7851 Front upper worklights on cab relay

(50S)

40-19
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

RL30 0.010.2562.2 3rd heater fan speed

relay

4th heater fan speed

RL31 0.010.2562.2 relay

1st heater fan speed

RL32 0.010.2562.2 relay

RL40 27 0.013.5915.4/20 Engine starter relay

Preheating warning light ON

RL41 0.012.8732.4/40 relay

RL42 2 0.013.5915.4/20 0419.4081 Preheating relay

RL42A 0.013.5915.4/20 0419.4081 Preheating relay

RL42B 0.013.5915.4/20 0419.4081 Preheating relay

RP 0.012.8672.4/10 0441.4105 Rear screen washer pump

S 12 0443.7849 0442.3803 Front axle Down solenoid

ST1 17 0.012.8894.4/30 0443.7488/10 Instrument panel

ST2 21 0.012.8894.4/30 0443.7488/10 Instrument panel

T 12 0.013.5915.4/20 0419.9809 Coolant temperature

sensor (for Infocenter)

OC 12 0.012.8672.4/10 0441.6649 Transmission oil temperature sensor

TKAB1 42 0.012.8732.4/40 0.012.8672.4/10

TKAB2 41 0.012.8732.4/40 0.012.8672.4/10

TKAB3 0.012.8732.4/40 0443.7846

UPDX 3 0442.9835 0441.2688 RH rear lift Up

pushbutton

UPSX 3 0442.9835 0441.2688 LH rear lift Up

pushbutton

Rear worklights
WORK LIGHT 28 0.012.8732.4/40 0441.1496.4 switch

X1 0.012.8732.4/40 0441.9531 Direction indicators flasher unit

(Red)

X2 0.012.8732.4/40 0441.9531 Direction indicators flasher unit

(black)

X4 12 0.012.8732.4/40 Not utilised

X5 1 0.012.8732.4/40 0.010.2274.1 Driver seat air suspension

compressor

X6 0.012.8732.4/40 0439.1395 Handbrake switch

X7 1 0.012.8732.4/40 0441.2338 Cigar lighter

X8 0.012.8732.4/40 0.010.3627.1 Engine ECU circuit board

X9 3 0.012.8732.4/40 0441.1533 Front PTO button

(in cab)

Rear PTO button

X10 3 0.012.8732.4/40 0441.1533 (in cab)

40-20
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

X11 34 0.012.8732.4/40 Not utilised

X12 1 0.012.8732.4/40 0445.0961.4 Gearshift lever

X13 0.012.8732.4/40 0441.4584 Radar control switch

X14 26 0.012.8732.4/40 0442.9597.4 Lift control panel

X15 0.012.8732.4/40 0114.3529 Auxiliary power socket

X16 1 0.012.8732.4/40 Not utilised

X17 7 0.012.8732.4/40 0441.1512.4 Starter switch

X18 8 0.012.8732.4/40 Diagnostics connector

X19 1 0.012.8732.4/40 Auxiliary power supply connector (in cab)

0443.7354.4
X20 0.012.8732.4/40
0443.7505 Engine speed keypad

X21 0443.7354.4 0443.8670.4 Armrest

X22 0.010.2562.2 0.010.2537.0 Lh heater fan

X23 0.010.2562.2 0.010.2535.1 Lh heater fan resistor

X24 0.010.2562.2 Air conditioning control panel illumination

connector

X25 0.010.2562.2 0.010.2537.1 Air conditioning thermostat

X26 0.010.2562.2 0.010.2532.0 Air conditioning on/off switch

X27 0.010.2562.2 0.010.2528.1 Fan speed selector switch

X28 0.010.2562.2 0.010.2535.1 Rh heater fan resistor

X29 0.010.2562.2 0.010.2535.0 Rh heater fan

X30 30 0.012.8894.4/30 Not utilised

X31 30 0.012.8894.4/30 2.7099.740.0/10 Accelerator pedal position sensor

X32 36 0.012.8894.4/30 0439.1395 Right brake pedal switch

X33 13 0.012.8894.4/30 0442.4165/10 Clutch pedal depressed proximity

sensor

X34 30 0.012.8894.4/30 0443.2708 Clutch pedal position sensor

X35 36 0.012.8894.4/30 0439.1395 Left brake pedal switch

X36 0443.8656 0442.9401 Hazard warning lights on/off switch

X37 0443.8656 0.012.6472.4 Shuttle control lever

X38 0443.7875 Compressed air pressure gauge light

X39 0443.7875 0442.5709 Compressed air pressure gauge

X40 0443.7875 0441.9280.4 Transmission display

X41 0443.7851 0.012.1726.0 Left rear loudspeaker

X42 0443.7851 0441.3192 Rear screen wiper motor

X43 0443.7851 0.012.1726.0 Right rear loudspeaker

40-21
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

X44 0443.7851 CB power connector

X45 0443.7851 0441.4097 Door open warning signal switch

X46 0443.7851 0442.6316 Interior roof light

X47 0443.7851 Rotating beacon

X48 1 0443.7851 0.012.1725.0 Right front loudspeaker

X49 10 0443.7851 0441.2337 Clock

X50 1 0443.7851 0.012.1725.0 Left front loudspeaker

X51 23 0443.7851 Radio (grey)

X52 23 0443.7851 Radio (brown)

X53 0443.7851 0441.2616 Side console courtesy light

Upper rear right

X54 2 0443.4993 0445.0666 worklights

X55 2 0443.4993 0445.0666 Upper rear left

worklights

X56 2 0443.4993 0445.0666 Upper front left

worklight

Upper front right

X57 2 0443.4993 0445.0666 worklight

X58 5 0441.2045 0441.3192 Windscreen wiper motor

X59 0441.1923.4 0441.1920.4 Front left sidelight and

direction indicator

Front right sidelight and

X60 0441.1923.4 0441.1921.4 direction indicator

X61 0442.5602 0442.5599.4 Front left worklight

on cab

X62 0442.5602 0442.5599.4 Front right worklight on cab

(without front lift)

Front left worklight

X63 0441.6727 0441.4087.4 on cab

X64 0441.6727 0441.4087.4 Front right worklight on cab

(with front lift)

X65DX 0442.9835 Rear right lower

worklights

Rear left lower

X65SX 0442.9835 worklights

X66DX 0442.9835 0442.9833.4/30 Rear right sidelight and

direction indicator

X66SX 0442.9835 0442.9833.4/30 Rear left sidelight and

direction indicator

X67 0441.4114 0441.4115 Number plate light

X68 0443.7849 0442.3803 Front axle suspension load sensing

solenoid

X69 0443.7849 0439.1530 Front axle suspension

position sensor

40-22
2. INDICES 2.3 INDEX BY CONNECTOR

Connection wiring or
Connector Type Wiring code component code Component description

X70 39 0.012.8672.4/10 0442.4116 Trailer socket

(for lights and auxiliary power)

0443.7355.4
X71 40 0.011.9428.0 Compressed air pressure sensor
trailer braking system
0443.7356.4

X72 35 0443.7356.4 Solenoid valve for

trailer parking brake

Trailer braking
X73 0443.7356.4 low pressure switch

Compressor and condenser fan

X74 0.013.5915.4/20 0442.3185 pressure switch

X78 0.013.5915.4/20 0425.8670 Preheating device

X79 0.013.5915.4/20 Not utilised

X80 2 0.013.5915.4/20 0441.6066 Start enable switch (Green)

X81 0.013.5915.4/20 Brake fluid level sensor

X82 4 0.013.5915.4/20 0441.5266 Steering angle sensor

0443.5914.4 Left headlamp

X86 37 0.013.5915.4/20
0443.5913.4 Left headlamp (UK)

X87 0.013.5915.4/20 0116.9304 Horn

0443.5914.4 Right headlamp

X88 37 0.013.5915.4/20
0443.5913.4 Right headlamp (UK)

0421.3172
Y3 0211.2588 Actuator
0421.3182

40-23
3. COMPONENTS 3.1 CONNECTOR LAYOUTS

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

2 1 3 2 1

1 2 3
1 2

4 1
4 2 5 6
1
3 4

3 2

1 4
3 4

1 2
4 3 2 1 2 3

7 X
8 3 1
9 2
3 1
15
7 4
6 4
S 50 11 8 5

P
30 14 12 9 8 7

40-24
3. COMPONENTS 3.1 CONNECTOR LAYOUTS

10 11 C B 12
D A

E F

1 3 5
1 2

13 14 15
6 5
8 7
7 8
2 1
5 6 2
2 1 1
1 2
1 2 3

16 17 6 12 18
14 13
13 14
10 9 9 10

1 2
2 1
2 1 1 2
1 7

19 20 21
17 21 22
18 22 21 13 26
17 18

2 1 1 2 1 2 1 14
2 1

40-25
3. COMPONENTS 3.1 CONNECTOR LAYOUTS

22 23 24
14 1
13
1 1 2

25 13 3 4
4 16
8 12

25 26 27 5
8 9
1 3
1 2 1
6

7 12

7 6
4 6
3

28 1 7 29 30
1 12 12 1 4 6

1 3
2 8
6 7 7 6

1
31 32 33
3 1

8 1

23 16
6 4
6

40-26
3. COMPONENTS 3.1 CONNECTOR LAYOUTS

34 35 2 36 1

2
3 4
1

3 3

2
1

37 38 39 54
56B L
58R

31 58L
56A

R 54
1 5 31

40 41
6 31 20
9 20 31 19 8
30 30 19 9 21
21 7
3 3
10 18 18 7 10
22 29 22
2
29
11 4
1
6 17 17 11
5

23 28 28 23
12 16
16 12
25 13 27 27 25
15
24 14 26 15 26 24 13
14

42 X
K J W H J X K
B
L
B V A H W L
V A
M U U M
C G G C
N T T N
F F
D
O S R D O
R S
P E Q P
Q E

40-27
3. COMPONENTS 3.1 CONNECTOR LAYOUTS

1 13
43

14 25

44 2 22

45
24

68
46

40-28
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

Pin1 = earth
Pin2 = square wave signal
1 Engine speed 0443.8438 Pin3 = 12V power NLSE
sensor High level: 3.5-4.3 V
Low level: 0.6-1.2 V

Trailer braking air 12 Vdc power

2 pressure sensor 0.011.9428.0 Resistance at 0 bar 10-13 Ohm X71
Resistance at 6 bar 119-129 Ohm

Engine oil pressure Normally closed contact (NC)

3 switch 0118.2227 Operating pressure: 0.5 ± 0.2 bar to 90 ± 5 °C P

Measured across pin 3 and pin 4: ~ 25 Ohm

4 Actuator 0211.2588 Measured across pin 3 and pin 5: ~ 25 Ohm Y3
Measured across pin 1 and pin 2: ~ 1.3 Ohm

5 Camshaft speed 0419.9792 Resistance: 336 ± 34 Ohm B40

sensor (Pickup) Inductance: 128.8 ± 13 mH

Fuel temperature
6 sensor 0419.9552 Resistance at 21.5 °C: ~2.3 kOhm B37

Engine coolant
7 temperature sensor 0419.9809 Resistance at 21.5 °C: ~2.3 kOhm T
(for Infocenter)

Across Pin 1 and Pin 2:

Normally closed contact (NC)
8 Brake pedal switch 0439.1395 Resistance with contact closed 3.9 Ohm X32
Across Pin 3 and Pin 4: X35
Normally open contact (NO)
Resistance with contact closed 3.9 Ohm

Across Pin 1 and Pin 2:

Normally closed contact (NC)
Resistance with contact closed 3.9 Ohm
9 Handbrake switch 0439.1395 Across Pin 3 and Pin 4: X6
Normally open contact (NO)
Resistance with contact closed 3.9 Ohm

Pin1 = earth
Front axle Pin2 = analog signal
10 suspension 0439.1530 Pin3 = 8VDC power X69
position sensor Output 1.8 +0.1V
(Cylinders fully retracted)

Rear PTO Resistance between pin 1 and pin 2 with switch

11 pushbutton 0441.1533 depressed: ~160 Ohm PTODX
(on fender) Diode test between pin 1 (positive) and pin 3 (negative)

Resistance between pin 1 and pin 2 with switch

12 Rear PTO 0441.1533 depressed: ~160 Ohm X10
pushbutton (in cab) Diode test between pin 1 (positive) and pin 3 (negative)

Front PTO Resistance between pin 1 and pin 2 with switch

13 pushbutton 0441.1533 depressed: ~160 Ohm X9
(in cab) Diode test between pin 1 (positive) and pin 3 (negative)

DWDX
14 Rear lift pushbutton 0441.2688 Normally open contact (NO) DWSX
UPDX
UPDX

Pin1 = earth
Pin2 = analog signal LEFT DRAFT
15 Lift draft sensor 0441.5586.4 Pin3 = 8V power RIGHT DRAFT
Signal with no implement hitched: 4V ± 0.2 V

40-29
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

Normally closed switch (NC)

16 Start enable switch 0441.6066 resistance with contact closed 3.9 Ohm X80
Colour: Green

Resistance between pin 1 and pin 2:

Transmission oil at 25°C 1000 ±15 Ohm
17 temperature sensor 0441.6649 at 100°C 1696 ±35 Ohm TEMP
at 150°C 2211 ±80 Ohm

Gearshift Pin1 = earth

18 solenoid valves 0441.6685 Pin2 = power EVGROUP
(Y1, Y2, Y3, Y4) Resistance between pin 1 and pin 2: 28 ± 2 Ohm

Pin1 = earth
Clutch pedal Pin2 = analog signal:
19 depressed proximity 0442.4165/10 0 Volt with sensor covered by metal X33
sensor 12 Volt with sensor exposed
Pin3 = 12V power

Pin G = input from sensor

20 Compressed 0442.5709 Pin + = 12V power X39
air pressure gauge Pin - = earth

Four wheel drive Pin1 = earth

21 (4WD) clutch 0443.1661 Pin2 = power EVDT
solenoid valve Resistance between pin 1 and pin 2: 10 Ohm

Engine oil low Normally open contact (NO)

22 pressure switch 0443.1690 Operating pressure: 18 bar PRESS SWITCH
Colour: red

Pin1 = 5.0V DC power

Pin2 = earth
Pin4 = analog signal
23 Accelerator pedal 2.7099.7400/10 Output 0.5V DC X31
position sensor (Pedal fully released)
Output 4.5V DC
(Pedal fully depressed)

Pin1 = 5.0V DC power

Pin2 = earth
Clutch pedal Pin4 = analog signal
24 position sensor 0443.2708 Output 0.5V DC X34
(Pedal fully released)
Output 4.5V DC
(Pedal fully depressed)

Proportional Pin1 = earth

25 solenoid valve coil 0443.4425 Pin2 = power EV PROP
Resistance between pin 1 and pin 2: ~ 5 Ohm

Pin1 = earth
Pin2 = square wave signal
26 Speed sensor 0443.8450 Pin3 = 12V power NAB
for odometer High level: 3.5-4.3 V
Low level: 0.6-1.2 V

Pin1 = earth
Gearbox output Pin2 = square wave signal
27 shaft speed sensor 0443.8449 Pin3 = 12V power NLSA
High level: 3.5-4.3 V
Low level: 0.6-1.2 V

Pin1 = earth
Transmission speed Pin2 = square wave signal
28 sensor 0.010.3342.2 Pin3 = 12V power NHK
High level: 3.5-4.3 V
Low level: 0.6-1.2 V

40-30
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

Pin 1 = earth
Pin 2 = square wave signal (100 pulses per metre)
29 Radar Italy 0443.8654 Pin 3 = 12 V power supply RADAR
With the radar powered up, a variation in voltage should register
at pin 2 when a hand is passed over the sensing element
Nominal radar frequency: 24125 GHz ± 25 MHz

Pin 1 = earth
Pin 2 = square wave signal (100 pulses per metre)
Pin 3 = 12 V power supply
30 Radar (UK) 0443.8655 With the radar powered up, a variation in voltage should register RADAR
at pin 2 when a hand is passed over the sensing element
Nominal radar frequency: 24300 GHz ± 25 MHz

Pin1 = earth
Pin2 = 5.0V DC power supply
Pin3 = analog signal
31 Rear lift position 0443.8667.0 Output 0.6V DC POS SEN
sensor (Lift links fully Up)
Output 4.5V DC
(Lift links fully Down)

Pin1 = signal 1
Pin2 = 8V power
Pin3 = earth
Pin4 = signal 2

Steering angle right

PIN
0°÷15° 15°÷25° 25°÷30° >30°

1 0V 8V 8V 8V
32 Steering angle 0441.5266 4 0V 0V 8V 8V X82
sensor

Steering angle left

PIN
0°÷15° 15°÷25° 25°÷30° >30°

1 0V 8V 8V 8V

4 0V 8V 8V 0V

1 3

4 6

33 Shuttle control 0.012.6472.4 Pin X37

lever 1 2 3 4 5 6
Pos

Avanti

Folle

Indietro
NOTE: In every position the resistance
must be 3.9 Ohm

40-31
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

7 5 3 1

8 6 4 2

Rear worklights
34 switch 0441.1496.4 WORK LIGHT

Pin 1 2 3 4 5 6 7 8
Pos

7 5 3 1

8 6 4 2

Cab headlights
35 dipped beam switch 0441.1496.4 3

Pin 1 2 3 4 5 6 7 8
Pos

7 5 3 1

8 6 4 2
Lower front
36 worklights (on cab) 0441.1496.4 3A
switch

Pin 1 2 3 4 5 6 7 8
Pos

40-32
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

7 5 3 1

8 6 4 2

37 50S lights switch 0441.1496.4 4

Pin 1 2 3 4 5 6 7 8
Pos

7 5 3 1

8 6 4 2

38 4WD switch 0441.1496.4 8

Pin 1 2 3 4 5 6 7 8
Pos

7 5 3 1

8 6 4 2

39 Rotating beacon 0441.1496.4 FLASHING LIGHT

on/off switch

Pin 1 2 3 4 5 6 7 8
Pos

40-33
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

7 5 3 1

8 6 4 2

PTO AUTO
40 switch 0441.1496.4 PTO AUTO

Pin 1 2 3 4 5 6 7 8
Pos

0
1
2

7 5 3 1

8 6 4 2

41 Sidelights switch 0441.1497 1

Pin 1 2 3 4 5 6 7 8
Pos

7 5 3 1

8 6 4 2

42 ASM switch 0441.1498 6

Pin 1 2 3 4 5 6 7 8
Pos

40-34
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

7 5 3 1

8 6 4 2

43 Differential 0441.1498 7
lock switch

Pin 1 2 3 4 5 6 7 8
Pos

83
50
30
86s

75 15

44 Starter switch 0441.1512.4 X17

Pin 30 15 50 75 83
Pos

0
1
2

7 5 3 1

8 6 4 2

45 Rear screen 0441.9283 REAR WIPER

wiper switch

Pin 1 2 3 4 5 6 7 8
Pos

40-35
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

7 5 3 1

8 6 4 2
Front suspension
46 pushbutton 0442.2763 5

Pin 1 2 3 4 5 6 7 8
Pos

7 5 3 1

8 6 4 2

Hazard warning
47 lights on/off switch 0442.9401 X36

Pin 1 2 3 4 5 6 7 8 9 10
Pos

40-36
3. COMPONENTS 3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Connector

Hand throttle lever (EMR)

Pin1 = earth
Pin2 = analog signal
Pin3 = 8V power
Resistance between pin 1 and pin 3: ~ 4.5 kOhm
With throttle lever on minimum:
- Resistance between pin 2 and pin 3: ~ 3.9 kOhm
- Resistance between pin 1 and pin 2: ~ 0.6 kOhm
With throttle lever on maximum:
- Resistance between pin 2 and pin 3: ~ 0.6 kOhm
- Resistance between pin 1 and pin 2: ~ 3.9 kOhm
48 Lift control 0441.9425.4/10 Lift control lever (EHR) EMR
console Pin1 = earth EHR
Pin2 = analog signal
Pin3 = 8V power
Resistance between pin 1 and pin 3: ~ 5.0 kOhm
Lever in “UP” position:
- Resistance between pin 2 and pin 3: ~ 1.45 kOhm
Lever in “STOP” position:
- Resistance between pin 2 and pin 3: ~ 2.6 kOhm
Lever in “DOWN” position:
- Resistance between pin 2 and pin 3: ~ 3.8 kOhm
Lever in “FLOAT” position:
- Resistance between pin 2 and pin 3: ~ 4.2 kOhm

Field/road selection
49 solenoid valve 0.010.3343.0 Resistance between Pin1 e Pin2: 6,0±0.3 Ohm (a 20°C) EV F/S
(T7100)

50 Field/road sensor 0441.6157 Normally closed contact (NC) F/S SWITCH

40-37
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3.1 ENGINE CONTROL UNIT (0419.4998)

CONNECTOR MX1

1 13

14 25

Pin Volts. Code Description

1 Not utilised
2 Not utilised
3 Power, relay power fuse
4 Not utilised
5 Input, fuel temperature signal
6 Not utilised
7 Not utilised
8 0V GND Reference voltage for signal on pin 5 and 9
9 Analog input, coolant temperature sensor
10 Not utilised
11 Not utilised
12 0V GND Reference voltage for signal on pin 13
13 Digital input, speed 1 (camshaft)
14 STG- PWM output, actuator electromagnet signal
15 STG+ PWM output, actuator electromagnet signal
16 Shielding of control rack position sensor (for pins 17, 18 and 19)
17 RF- Common connection for measurement and reference coils
18 RF REF Analog input, reference coil signal
19 RF MESS Analog input, measurement coil signal
20 Not utilised
21 Not utilised
22 Not utilised
23 0V GND Reference voltage for signal on pin 24
24 Analog input, turbo charge pressure sensor signal
25 +5V +5V LDA 5V reference voltage for signal on pin 24

40-38
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

CONNECTOR MX2

1 13

14 25
Pin Volts. Code Description
1 0V –31 Battery negative
2 0V –31 Battery negative
3 Digital output, glowplugs control light
4 Not utilised
5 Not utilised
6 Input, gearbox in neutral
7 Input, wheel speed signal
8 Not utilised
9 Not utilised
10 L ISO 9141 serial interface (Diagnostics connector)
11 K ISO 9141 serial interface (Diagnostics connector)
12 Not utilised
13 Not utilised
14 +12V +15 Battery positive (15+)
15 Engine memory LED
16 Engine speed output
17 0V GND Reference voltage for signal on pins 18, 19, 20, 21
18 “MAX” key signal
19 “HOLD” key signal
20 Hand throttle signal
21 “MIN” key signal
22 Not utilised
23 0V GND Reference voltage for signal on pin 24
24 Analog input, signal from accelerator pedal sensor (SWG)
25 +5V +5V REF 5V reference voltage for signal on pin 24

40-39
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3.2 TRANSMISSION CONTROL UNIT (0443.8083/10)

ECU CONNECTOR (PS)

2 22

45
24

68
46

Pin Volts. Code Description

1 0V VM1 Battery negative
2 0V VM2 Battery negative
3 0V VMG1 Reference voltage for signal on pins 16, 17, 40 and 62
4 0V VMG2 Reference voltage for signal on pin 44
5 ADM4 Output for fault warning light
6 Not utilised
7 Not utilised
8 VPS2 Power (–) common, solenoid valves Y2, Y4
9 Not utilised
10 Not utilised
11 ADM6 Power, solenoid valve Y4
12 Not utilised
13 +12V VPS1 Power (+), proportional solenoid valve and solenoid valves Y1, Y3
14 SD1 Display control signal
15 SDDK Diagnostics connector
16 EF5 Digital input, main clutch rpm sensor (nAb)
17 EF7 Digital input, input rpm sensor (nLse)
18 Not utilised
19 Not utilised
20 ED3 Analog input, reverse drive control signal
21 ED10 Not utilised
22 ED7 Digital signal, range downshift pushbutton
23 VPE1 Battery positive (+30)
24 VMGA1 Power (-), clutch pedal position sensor and temperature sensor
25 Not utilised
26 Not utilised
27 Not utilised
28 Not utilised

40-40
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

29 ED11 Analog input, low transmission oil pressure signal

30 Not utilised
Pin Volts. Code Description
31 EDM1 Signal, mechanical gearbox neutral
32 AIP3 Power, solenoid valve Y3
33 ADM8 Not utilised
34 ADM7 Not utilised
35 Not utilised
36 SD4 Vehicle speed output
37 AU Power (+) clutch pedal angular position sensor
38 EU1 Analog input, angular position of clutch pedal sensor signal
39 ER1 Analog input, temperature sensor signal
40 EF6 Digital input, output rpm sensor (nLsa)
41 Not utilised
42 Not utilised
43 Not utilised
44 ED8 Digital input, clutch pedal full travel sensor
45 VPI Battery positive (+15)
46 Not utilised
47 Not utilised
48 Not utilised
49 Not utilised
50 AIP7 Not utilised
51 Not utilised
52 Not utilised
53 Not utilised
54 Not utilised
55 AIP4 Power, solenoid valve Y1
56 0V AIP1 Power (-), proportional solenoid valve
57 +12V ADM5 Power, solenoid valve Y2
58 Not utilised
59 Not utilised
60 Not utilised
61 Not utilised
62 EF4 Digital input, rpm sensor (nHk)
63 ED1 Analog input, forward drive control signal
64 Not utilised

40-41
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

65 ED2 Analog input, neutral control signal

66 ED9 Battery positive (+15)
67 ED6 Digital signal - range upshift pushbutton
68 +12V VPE2 Battery positive (30+)

40-42
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3.3 INFOCENTER (0443.7488/10)

ST1 6 12 ST2
13 26

1 14
1 7
CONNECTOR ST1
Pin Volts. Code Description
1 TXD Diagnostics interface transmission
2 +12V KL15-ST +15 key
3 KL31 Lamps earth
4 +12V KL58 +58 lights
5 GROUT Actual vehicle speed output (radar)
6 RPOUT Rear PTO speed output
7 GETOEL Transmission oil pressure
8 HANDBR Handbrake on and brake fluid warning light
9 0V KL30-ST Vehicle earth
10 RXD Diagnostic interface reception
11 VHOUT Theoretical vehicle speed output (wheels)
12 0V KL31E Electronics earth
CONNECTOR ST2
Pin Volts. Code Description
1 DIFF Differential lock indicator light
2 BLINK2 2nd trailer flasher indicator light
3 BLINK1 1st trailer flasher indicator light
4 BLINK Tractor flasher indicator light
5 SLOW GEAR indicator light
6 HIGH GEAR indicator light
7 LADEK Battery charge indicator light
8 LUFTF Air cleaner clogged
9 MOTOEL Engine oil pressure warning light
10 FRONTZ Front PTO indicator light
11 HECKZ Rear PTO indicator light
12 MOTOR Engine rpm
13 TANK Fuel gauge
14 ALLRAD 4WD indicator light
15 KUEHLT Engine coolant temperature

40-43
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

Pin Volts. Code Description

16 FERNL Main beam indicator light
17 Not utilised
18 Not utilised
19 VORGL Glowplugs test
20 RPTO Rear PTO rpm
21 GROUND Input, actual ground speed (radar)
22 WHEEL Input, theoretical vehicle speed
23 TRAILER Input, trailer braking indicator light (Italy)
24 Not utilised
25 EMR Input, engine indicator light
26 Not utilised

40-44
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3.4 HPSA CONTROL UNIT (2.8519.013.0)

CONNECTOR JX1 (BLACK)

8 1

23 16

Pin Volts. Code Description

1 Up solenoid valve
2 Down solenoid valve
3 8V Power input to draft sensors
4 12V Power input to ECU (F34)
5 12V Power input to ECU (F34)
6 Control lever: Transport 5.5 V
Stop: 3.8 V
Control: 2.1 V
Float: 1.7 V
7 0.3–8.0V Depth potentiometer
8 0.3–8.0V Lowering speed potentiometer
9 Manual UP key
10 0–8.0V Input, left draft sensor
11 PTO AUTO switch output
12 Not utilised
13 Output, status indicator LED
14 0.3–8.0V Maximum height potentiometer
15 5.0 V Power input to position sensor
16 Manual DOWN key
17 0–8.0V Input, right draft sensor
18 0V Earth for potentiometer panel
19 0.3–8.0V Mix potentiometer
20 0V Control unit earth
21 0V Sensors earth
22 8V Power input to panel and lever
Lift position sensor:
23 High position: 0.6V (± 0.1V)
low position: 4.5V (± 0.1V)

40-45
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

CONNECTOR JX2 (WHITE)

8 1

23 16

Pin Volts. Code Description

1 Not used
2 Differential output
3 Radar input
4 Not used
5 Not used
6 Not used
7 Not used
8 4WD output
9 8V External sensor power (ISO4 socket)
10 8V Steering sensors power
11 ASM AUTO input
12 Wheelslip control input
13 Differential input
14 External sensor input (ISO4 socket)
15 ISO9141 K Line
16 Steering sensor 1 input
17 0V External sensor earth (ISO4 socket)
18 Steering sensor 2 input
19 Wheel speed input
20 Brakes input
21 Not used
22 ISO9141 L Line
23 0V Steering sensors earth

40-46
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3.5 FRONT SUSPENSION CONTROL UNIT (2.8519.008.0/10)

8 1

23 16

CONNECTOR JX3 (BLACK)

Pin Volts. Code Description
1 Output, Up solenoid valve
2 Output, Down solenoid valve
3 Not utilised
4 +12 V +12 V
5 +12 V +12 V
6–19 Not utilised
20 0V Control unit earth
CONNECTOR JX4 (WHITE)
Pin Volts. Code Description
1 Not utilised
2 Output, load sensing solenoid valve
3–7 Not utilised
8 Control light output
9 Power input to external sensor
10 Not utilised
11 Input, 4WD status
12 Input, control button
13 Input, brakes switches
14 Input, position sensor
15 ISO 9141 K diagnostic line
16 Not utilised
17 0V Earth for external sensor
18 Not utilised
19 Input, wheel speed
20 Not utilised
21 Not utilised
22 ISO 9141 L diagnostic line
23 Not utilised

40-47
3. COMPONENTS 3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

40-48
 4.1 GROUND POINTS

4. SYSTEMS
4.1 GROUND POINTS

GND5

GND6

P4

F0024531 F0033510

GND4
GND1
GND4

F0075380
F0077550

GND2
GND3

F0077560 F0024281

F0077540 40-49
 4.2 ENGINE START

4.2 ENGINE START

8 1
0 1 2

0.012.8732.4
68 23 1 2 31 50 15 X 30 6 +30 7
ECU PS X17 J2 P1 J1 MX2
1 GDN POWER
GND4 2 GDN POWER
14 +21VCC POWER (+15)
2
6 INPUT, GEARBOX IN NEUTRAL

2
4
3
X8
TKAB3 MS1
1 31 20

FU100

0.013.5915.4
0443.7846

100A
+30A +50 +30C D+ B+ RL40 X80
3 1 2 5 2 1
+
GND2
M G

- 4
7
6 5

+ -

BATTERY

1 Starter switch
2 Engine control unit
3 Engine ECU circuit board
4 Start enable switch
5 Engine starter relay
6 Alternator
7 Starter motor
8 Transmission ECU

D023030 40-50
 4.3 PREHEATING

4.3 PREHEATING

0441.9533
RL1(40A)

30 85 86 87

F27

F16

F30
0 1 2

7.5A

7.5A
3A
0.012.8894.4 50 15 X 30 +30 9 -31 7 6 7

0.012.8732.4
X17 P1 J2 P4 J3 J1

AS6
ST2 7
RL41
PRE HEATING 19 12 30
85
+15 2 9
AS3 86 2
6 +30 9 5 87

GND 3 21 MX1
GND 12 AS1
10 GND POWER
ST1 3 PRE HEATING RELAY OUTPUT COMMAND

MX2 3
3 PRE HEATING LIGHT OUTPUT SIGNAL

2 GDN POWER

1 GDN POWER

+12VCC POWER (+15)

14

GND4
11 4 18 1
MS2 MS1 TKAB3

FU100 +30A
0.013.5915.4

100A
FU101
125A

+30B
RL42B
+ -
X78 RL42A RL42
2 1 BATTERY
0443.7846

4
5

1 Starter switch
2 Glowplug warning light ON relay
3 Engine control unit
4 Preheating relay
5 Preheating device
6 Instrument panel

D023040 40-51
 4.4 ELECTRICAL ENGINE CONTROL

4.4 ELECTRICAL ENGINE CONTROL

RL1 (40A)

0441.9533
30 85 86 87

F27

F16

F30
0 1 2

7.5A

7.5A
3A
0421.3182
0421.3172 GND2 0.013.5915.4 0.012.8732.4
50 15 X 30 +30 9 -31 7 6 7
X17 P1 J2 P4 J3 J1 X8
1
2 1Kohm
3
4 2
t°
2
B37 2.2Kohm
G18 5
14 1 15 6

MS1 MX1
15 5 FUEL TEMP. SENS. INPUT SIGNAL
t° B43 8
2 22 8 FUEL AND WATER TEMP SENS. GND

13 1 9 24 9 WATER TEMP. SENS. INPUT SIGNAL

4 14 PWM (-) ACTUATOR

15 PWM (+) ACTUATOR

1
B40 12 16 12 PICK UP SUPPLY (-)

12 2 13 28 13 PICK UP SUPPLY SIGNAL INPUT

14 10 GND POWER

15 6
1
Y3 16 ACTUATOR SHIELD

2 17 10 17 ACTUATOR REFERENCE COM.

11 3
4
18 19
11
18 ACTUATOR REFERENCE SIGNAL

19 19 ACTUATOR MEASURED SIGNAL

5 25
B48 29 24 CHARGE AIR PRESSURE SIGNAL INPUT
p,t 4 27 25
2 CHARGE AIR PRESSURE SUPPLY (+5V)

1 23 17 23 CHARGE AIR PRESSURE SUPPLY (-)

10 4 24
3 25 MX2 3
1 GND POWER

2 GND POWER

6 INPUT, GEARBOX IN NEUTRAL

GND4 7 INPUT, SPEED SIGNAL

X18
3 10 ISO9141

9 4 11 ISO9141

21 PRESS. SIGN.

19 “HOLD” KEY SIGNAL

1 Starter switch 1
2
18
17
“MAX” KEY SIGNAL

REFERENCE VOLTAGE FOR

SIGNAL ON PINS 18, 19, 20

2 Engine ECU circuit board X4 15 ENGINE MEMORY LED

14 +21VCC POWER (+15)

3 Engine control unit

EMR
4 EMR ALARM
ACTUATOR SHIELD
Versione con bracciolo 16
4 Accelerator pedal position sensor 3 25 ACCELERATOR PEDAL SUPPLY (+5V)

1 2 3 5 2 4 3 1 6 8 2 20 HAND THROTTLE SIGNAL

5 Instrument panel EMR X20

1 23 ACCELERATOR PEDAL SUPPLY (-)

ACCELERATOR PEDAL SIGNAL INPUT

24
6
0443.7354.4

ISO7 socket (implement connection) X20 ISO7 TKAB3 AS3 AS1 AS2 AS6
5 2 4 3 1 6 3 1 9 5 4 21 4 10 11 9 10
7 Engine speed keypad

0.012.8894.4
8

FU100
Lift and hand throttle console

0443.7846
9 Diagnostics connector 6

100A
X21
10 Turbo charge pressure sensor 6 7 8 20 17 19 18 16 21
7
11 Actuator +30A ST1 ST2 X31
12 Camshaft speed sensor (Pickup) 2 9 11 3 12 25 12 2 1 4

WHEEL RPM OUTPUT

EMR ALARM
ENGINR RPM
+15
+30

GND
GND
13 Engine coolant temperature sensor + -

14 Fuel temperature sensor 15 BATTERY

4
15 Armrest
5

D023050 40-52
 4.5 LIGHTS - LIGHT SELECTOR SWITCH (MACHINE WITHOUT FRONT LIFT)

4.5 LIGHTS - LIGHT SELECTOR SWITCH (MACHINE WITHOUT FRONT LIFT)

0441.9533
+ -
16 17
RL 11 RL 6
BATTERY FULL BEAM RL 10 RL 5 HALF BEAM RL 7 RL 14

F9
RL 1
TOP FULL BEAM POSITION (40A) TOP HALF BEAM HAZARD

7.5A
G

1 2 4 5 6 1 2 1 2 1 2 85 86 1 2 1 2

0443.7875
X38 X40 +30A 4 5 3 4 5 3 4 5 3 30 87 4 5 3 4 5 3 C3 C2 C1 49A 49 31
D9 D8 D8 1N4007 D4 D5
D2

0443.7846
+30A 1N4007 1N4007 1N4007
D1
1N4007 1N4007

1N4007

15 1

FU100

F33

F24

F25

F20
F26

F23

F15
F16

F12

F31
F32

F27
13 14

7.5A

7.5A

7.5A
7.5A
100A
0 1 2

15A

30A
15A

15A

15A

15A

7.5A
3A
0443.7851 GND4 P5 P4
3 1 2 3 1 2 14 1 2 50 15 X 30 1 3 2 25 12 7 3 9 1 8 23 10 9 13 6 +30 -31 7 3 6 17 2 1 22 2 1 4 11 8 9
X17

0.012.8732.4
X60 X59 AS5 TKAB3 J1 P6 P5 P5 P6 J1 P6 J1 P5 P1 J3 J1 P5 J3 P5 J2
X51
G7
-31
1
2
3
4

G9
-31
1
2 DS1
3 13
4
11
6
0441.1923.4 5

LOW BEAN
HIGH BEAN
CONTROL
Abb
Flash 0
HORN
CONTROL AS4
H
17
15/1
12
56a
11
56b
10
12 56
9

DIRECTION 8
LIGHT -31
7
CONTROL 49
6
0

15
5
30
R
L

4
L
3
1
0443.8656

R
49a
2
1
Starter switch
G4 2 Instrument panel
3 Sidelights switch
X36 X1-X2 GND4 TKAB3 MS1 AS1 AS3 AS2
7 10 6 8 2 5 3 1 49b RE LE 49 31 49a RA LA 3 4 5 6 12 9 8 7 26 22 20 19 18 16 21 5 9 8 2 1 18 7 4 Right headlamp

0.012.8894.4
0443.7846

0.013.5915.4
5 Left headlamp
GND2 6 Horn
G4 7 Rear right tail light and direction indicator
10 1 ST1 ST2 8 Rear left tail light and direction indicator
G15 G14 X87 X86 X88
11 4 1 5 4 1 5 1 2 2 1 3 2 1 3 2 1 10 9 3 8 12 3 4 9 2 2 3 4 16
9 Number plate light
0442.9835

TRAILER 2
TRAILER 1
DIRECTIONS LIGHT
GND
GND
+58
+30
+15

HIGH BEAM
10 Direction indicators flasher unit
X66 DX
X66 SX

6 5 4 11 Hazard warning lights on/off switch

G16 12 Steering column switch unit
1 2 2 1 3 2 1 3 2
13 Front right sidelight and direction indicator
0441.4114

3
14 Front left sidelight and direction indicator
8 7 15 Radio
X67
1 2 16 Compressed air pressure gauge light
9 17 Transmission display

D023060 40-53
 4.6 LIGHTS - LIGHT SELECTOR SWITCH (MACHINE WITH FRONT LIFT)

4.6 LIGHTS - LIGHT SELECTOR SWITCH (MACHINE WITH FRONT LIFT)

0441.9533
20 21
+ -
1 2 4 5 6

0443.7875
X38 X40 BATTERY
RL 11
FULL BEAM RL 10 RL 5
RL 6
HALF BEAM RL 7 RL 14

F9
RL 1
TOP FULL BEAM POSITION (40A) TOP HALF BEAM HAZARD

7.5A
G

1 2 1 2 1 2 85 86 1 2 1 2

4 5 3 4 5 3 4 5 3 30 87 4 5 3 4 5 3 C3 C2 C1 49A 49 31
D9 D8 D8 1N4007 D4 D5
D2

0443.7846
+30A 1N4007 1N4007 1N4007
D1
1N4007 1N4007

1N4007

18 1

FU100

F33

F24

F25

F20
F26

F23

F15
F16

F12
F10

F31
F32

F21
F22

F27
16 17 19

7.5A

7.5A

7.5A
7.5A

7.5A
7.5A
100A
0 1 2

15A

30A
15A

15A

15A

15A
7.5A

7.5A
3A
0441.6727 3 1 2 3 1 2
0443.7851 1 2 50 15 X 30 1
P5 P4 P5
3 1 2 5 4 15 3 2 25 12 7 3 9 1 8 23 10 9 13 6 +30 -31 7 3 6 17 18 2 1 5 1 22 2 1 4 11 8 9
AS5 X17

0.012.8732.4
X60 X59 RL21 X51 TKAB3 J1 P6 P5 P5 P6 J1 P6 J1 P5 P1 J3 J1 P2 P5 J3 P5 J2
15
X63 G7
2 G12 -31
1 1 1
56b 2 2
-31 3 3

not used
56a 4 4

X64 G9
2 G13 -31 DS1
1 1 1 20
56b 2 2 16
-31 3 3 13
56a 4 4 12
11
14 6
0441.1923.4 5
1 Starter switch
GND4
2 Instrument panel
3 Cab headlights dipped beam switch LOW BEAN
HIGH BEAN
4 Sidelights switch CONTROL
Abb
5 Right headlamp Flash 0
HORN
CONTROL AS4
6 Left headlamp H
15/1
17
12
56a
7 Horn 56b
11
10
56
8 Rear right tail light and direction indicator 13
9

DIRECTION 8
9 Rear left tail light and direction indicator LIGHT
CONTROL
-31
49
7
6
10 Number plate light
0

15
5
30
R
L

4
11 Direction indicators flasher unit L
3
0443.8656

R
2
12 Hazard warning lights on/off switch
49a
1

G4
13 Steering column switch unit
14 Front right worklight on cab X36 X1-X2 GND4 TKAB3 MS1 AS1 AS3 AS2
7 10 6 8 2 5 3 1 49b RE LE 49 31 49a RA LA 3 4 5 6 12 9 8 7 26 22 20 19 18 17 5 16 21 5 9 8 2 1 18 7
15 Front left worklight on cab

0443.7846

0.012.8894.4
0.013.5915.4
16 Front right sidelight and direction indicator GND2
17 Front left sidelight and direction indicator
G4
18 Front upper cab (50S) worklights relay
11 G15 X87 X86 X88 1 3 ST1 ST2
19 Radio 12 4 1 5 4 1 5
2 1 3 2 1 3 2 1 10 9 3 8 1 10 9 5 12 3 4 9 2 2 3 4 16

0442.9835
1 2
G14

TRAILER 2
TRAILER 1
DIRECTIONS LIGHT
GND
GND
+58
+30
+15

HIGH BEAM
20 Compressed air pressure gauge light

X66 DX
X66 SX

21 Transmission display
7 6 5
G16
1 2 2 1 3 2 1 3
3 2
0441.4114

4
9 8
X67
1 2

10

D023070 40-54
 4.7 CAB ACCESSORY

4.7 CAB ACCESSORY

0441.9533/10
RL 5 RL 1
POSITION (40A)

5A
1 2 85 86

F8
4 5 3 30 87
D3

1N4007

4 6 1
2 3 5 7

F24

F20

F18

F28

F7
0 1 2

7.5A

30A

30A

15A

20A
30 58
15
- GND4
- 30 4 3 2 1 2 1 1 2 3 50 15 X 30 7 3 4 +30 -31 7 21 6 3
0443.7851

0.012.8732.4
X45 X46 X49 X53 X5 X7 X17 P5 P6 P3 P1 P4 J3 P3 P2

GND 5

DS1
13
21
18

TKAB3
1

0443.7846
FU100
100A
+30A

+ -

BATTERY

1 Starter switch
2 Door open warning signal switch
3 Interior roof light
4 Clock
5 Side console courtesy light
6 Driver seat air suspension compressor
7 Cigar lighteri

D018880 40-55
 4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)

4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT)

11 12

2 1 2 1

0441.1923.4 0442.5602
X62 X61

9 10 14 15

1 2 1 2 3 1 3 1 1 2 1 2

0443.4993
0443.4993
X55 X54 G13 G12 X56 X57

13
8

0441.9533
1 2 1 2 1 2 -31 1 -31 1 3 1 2 5 4 1 3 -31 1 3 -31
RL 2 RL 3 RL 1 RL 10 RL 11

0443.7851
X47 G6 G5 G9 G7 RL21 G8 G11 (40A) (40A) (40A) FULL BEAM FULL BEAM TOP

F20
F6

F4
85 86 85 86 85 86 1 2 1 2

30A

30A
30A
87 30 87 30 30 87 4 5 3 4 5 3
D8 D7
1N4007 1N4007

F10

F14
F33

F2
7.5A

30A
15A
15A
0 1 2
GND5

7 8 9 10 12 17 19 50 15 X 30 5 6 9 4 2 +30 -31 7 21 18 14 12 2 6
DS1 X17 J1 J3 P2 P1 P4 J3 P5 P6 P3

0.012.8732.4
FLASHING WORK
AS1 TKAB3 LIGHT LIGHT
1 Starter switch 15 21 5 14 13 2 1 1 10 9 5 1 10 9 5
0442.9936.4

2 Rear worklights switch GND4

3 Rotating beacon on/off switch

100A
4 Lower rear right worklights

FU100
5 Lower rear left worklights 3A 4 +30A 3 2

0443.7846
1 10 9 5 5 9 10 1
6 50S lights switch
7 Lower front worklights (on cab) switch GND3
8 Rotating beacon
+ -
9 Upper rear left worklights 3 2 3 2
7 6 G15 G14 BATTERY
10 Upper rear right worklights
11 Front right worklight on cab
12

0442.9835
Front left worklight on cab
13 Front upper cab (50S) worklights relay

X65 DX
X65 SX
14 Upper front left worklight
15 Upper front right worklight 2 1 2 1

5 4

D023080 40-56
 4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT)

4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT)

10 11

2 1 2 1

0441.1923.4 0442.5602
X62 X61

8 9 13 14

1 2 1 2 3 1 3 1 1 2 1 2

0443.4993
0443.4993
X55 X54 G13 G12 X56 X57

12
7

0441.9533
1 2 1 2 1 2 -31 1 -31 1 3 1 2 5 4 1 3 -31 1 3 -31
RL 2 RL 3 RL 1 RL 10 RL 11
0443.7851

X47 G6 G5 G9 G7 RL21 G8 G11 (40A) (40A) (40A) FULL BEAM FULL BEAM TOP

F20
F6

F4
85 86 85 86 85 86 1 2 1 2

30A

30A
30A
87 30 87 30 30 87 4 5 3 4 5 3
D8 D7
1N4007 1N4007

F10

F33

F2
7.5A

30A
15A
GND5 0 1 2

8 9 10 12 17 19 50 15 X 30 5 6 9 4 2 +30 -31 7 21 18 12 2 6
DS1 X17 J1 J3 P2 P1 P4 J3 P5 P6 P3

0.012.8732.4
FLASHING WORK
AS1 TKAB3 LIGHT LIGHT
21 5 13 2 1 1 10 9 5 1 10 9 5
1
0442.9936.4

GND4 Starter switch

2 Rear worklights switch
100A

3 Rotating beacon on/off switch

FU100

4 +30A 3 2 4 Lower rear right worklights

5
0443.7846

5 9 10 1
Lower rear left worklights
GND3
6 50S lights switch
7 Rotating beacon
+ -
3 2 3 2 8 Upper rear left worklights
BATTERY
6 G15 G14 9 Upper rear right worklights
10 Front right worklight on cab
11 Front left worklight on cab
0442.9835

12 Front upper cab (50S) worklights relay

X65 DX
X65 SX

13 Upper front left worklight

2 1 2 1 14 Upper front right worklight

5 4

D023090 40-57
 4.10 WINDSCREEN WIPER

4.10 WINDSCREEN WIPER

7

31b
53a
31
53
2 1 3 4

0441.2045
X58

RL4

0441.9533
6 FRONT GLASS W.

RL1
BATTERY (40A)

31b
53a
31
53
- +
85 86
2 1 3 4 2 1 3 4

0443.7851
30 87
X42 G10 2 5 8 4 1 6

+30

0443.7846
GND5

FU100

F10

F12
F2
2
1

100A
1

30A

15A
7.5A
0

0 1 2

GND4 TKAB3
4 3 2 1 15 14 50 15 X 30 4 5 9 10 7 2 1 +30 -31 6 5 18 16 17 10 4 7 5 8
DS1 X17 REAR P1 P4 P3 P5 P6 J3
WIPER

0443.8656
FRONT WIPER
CONTROL
31b

53

16
5 7 15
14
15/1 13
H
12
AS4
1

r
FRONT WASHER
0
PUMP CONTROL
26 27
TKAB2 0.012.8732.4

0.012.8672.4
FP RP
1 2 2 1

M
GND2 M

4 3

1 Starter switch
2 Rear screen wiper switch
3 Rear screen washer pump
4 Windscreen washer pump
5 Steering column switch unit
6 Rear screen wiper motor
7 Windscreen wiper motor

D023100 40-58
 4.11 INFOCENTER

4.11 INFOCENTER

0441.9533
RL1
(40A)
6
30 85 86 87

1
ENGINE PRESSURE

F27

F16
ENGINE TEMP.

0 1 2
AIR FILTER

7.5A

3A
FUEL
GND
GND
+15
+30

2 9 3 12 15 8 9 13 50 15 X 30 +30 9 -31 7 6
0.012.8894.4

0.012.8732.4
ST1 ST2 X17 P1 J2 P4 J3

9
13
AS2
5
9
AS3
21 GND4
AS1
TKAB3
2 5 3 14 8 1

0.012.8672.4
MS2 MS1 TKAB2
FU100

8
100A

+30A
0.013.5915.4

0443.7848

+ -

BATTERY

T L P FUEL
1 2 1 2 1 1 2

GND2 P
GND2
P

5 4 2
3

1 Starter switch
2 Fuel level sensor
3 Engine oil pressure switch
4 Air cleaner clogged sensor
5 Engine coolant temperature sensor (for Infocenter)
6 Instrument panel

D023110 40-59
 4.12 ELECTRICAL POWER SUPPLY

4.12 ELECTRICAL POWER SUPPLY

8 10

0441.9533
012.8894.4 RL1
19 2 1 (40A)

0.012.8672.4
0443.7850
JX4 X70 GND2
ST1
GND 12
30 85 86 87
GND 3
+30 9
7 9 1
6

F18

F19
+15 2

F27

F16

F10
F1
WHEEL RPM OUTPUT 11 0 1 2

100A

7.5A

7.5A
RPM PTO OUTPUT 6

30A

30A

3A
RADAR OUTPUT 5
GND4
7 6 4 9 5 21 11 5 - + 30 31 50 15 X 30 3 1 2 +30 9 -31 7 6 18

0.012.8732.4
AS3 AS1 MX1 FE1 X15 TKAB1 X17 P3 P1 J2 P4 J3 P5

ISO7
2
4
5 3
5 1
1 2 2
X19
ISO4
1
4 2
3

JX1 JX2 TKAB3

11 9 14 17 19 1

FU100

0443.7846
100A
3
+30

+ -

BATTERY

1 Starter switch
2 Auxiliary power supply connector (In cab)
3 Rear lift control unit
4 ISO4 socket (power supply to implements)
5 ISO7 socket (implement connection)
6 Instrument panel
7 Engine control unit
8 Front axle suspension control unit
9 Auxiliary power socket
10 Trailer socket (lights and auxiliary power)

D023120 40-60
 4.13 RADIO - CB

4.13 RADIO - CB

0441.9533

RL1
(40A)

30 85 86 87

F7

F8
20A

5A
0 1 2

0443.7851 50 15 X 30 +30 -31 7 6 3

X17 P1 P4 J3 P2
-
X41
7 +

GND4
X50
1
6 2

X44 DS1
30 3 18

5 15 2
- 1
21

GND5

X51
- 16
30 14
15 12
58 15
4 - rechts 6
+ rechts 2
- links 7
+ links 3
X52
0.012.8732.4
+

3 -
X43

2
2 1
X48 TKAB3
1
FU100

0443.7846
100A

+30A

+ -

BATTERY

1 Starter switch
2 Right front loudspeaker
3 Right rear loudspeaker
4 Radio
5 CB power connector
6 Left front loudspeaker
7 Left rear loudspeaker

D022820 40-61
 4.14 AIR CONDITIONING - HEATING FAN

4.14 AIR CONDITIONING - HEATING FAN

0441.9533

0443.7846
RL5 RL1
(POSITION) (40A)

+30A + - 1 2

30 85 86 87

4 5 3

FU100

F3
BATTERY D7

F24
1N4007

30A
7.5A
100A
0 1 2 F20
30A

1 50 15 X 30 7 +30 -31 7 15 14

0.012.8732.4
X17 P5 P1 P4 J3 P3
TKAB3

0.013.5915.4

K
15
2
14 P
1 5
X74 MS1

G2 G1 FU131
4 1 2 3 5 6 1 2 3 1 2
GND4
30A
F50

0.010.2562.2
X24 X25 X26 RL30 RL32 X28 X23 X22 X29 X27 RL31
2 1 A B C 2 1 87b 87 86 85 30 30 85 86 87 87b 4 3 2 1 4 3 2 1 2 1 1 2 2 3 4 5 1 30 85 86 87 87b
1 2 3 4 C

M M

12 11 10 8 7 6 5 3
13 4
9

1 Starter switch
2 Main heating fuse
3 Heater fan speed 4 relay
4 Fan speed selector switch
5 Rx heater fan
6 Lx heater fan
7 Lx heater fan resistor
8 Rx heater fan resistor
9 Heater fan speed 1 relay
10 Heater fan speed 3 relay
11 Air conditioning on/off switch
12 Air conditioning thermostat
13 Air conditioning control panel illumination connector
14 Compressor and condenser fan pressure switch
15 Air conditioning compressor

D023130 40-62
 4.15 BRAKES

4.15 BRAKES
8 9 10

54

0.012.2010.4
X66 DX
X66 SX
X70

0442.9835
+30A

0441.9533
RL1 RL 8 RL 9
(40A) (STOP) (DT/BRAKE)
-- +

1 2 1 2
BATTERY G15 G14 30 85 86 87
4 5 3 4 5 3
1 6 1 6 D6 D7

0443.7846
1N4007 1N4007

6 7

F16

F11

F27
GND3
1
12

7.5A
20A
3A
FU100
100A 11 0 1 2

50A

2 3 4 1 2 3 4 1 25 1 7 1 2 2 4 3 1 50 15 X 30 -31 +30 7 6 4 20 24 17 19 8 9

0.012.8732.4
0.012.8894.4

X35 X32 TKAB1 TKAB3 FU121 X6 X17 P1 P4 J3 J1 P5 P3 J2

AS3
11
ST1 10
+15 2 9
+30 9 5

5 HAND BRAKE OIL LEVEL 8 1

GND 3 21 GND4
12
GND
AS1

MS2 JX2 TKAB2

1 20 8 14
0.013.5915.4

0.012.8672.4
2 3
4 1
X81

EVDT
GND2 2 1
GND2

2
1 Starter switch
2 Four wheel drive (4WD) clutch solenoid valve
3 Rear lift control unit
4 Brake fluid level sensor
5 Instrument panel
6 Brake pedal switch (Left)
7 Brake pedal switch (Right)
8 Trailer socket (lights and auxiliary power)
9 Rear left tail light and direction indicator
10 Rear right tail light and direction indicator
11 Trailer brake lights fuse
12 Handbrake switch

D023140 40-63
 4.16 TRAILER BRAKES

4.16 TRAILER BRAKES

6
5 7
P

p
2 1 2 1

0443.7356.4
X73 X72 X71
4
2

ITA TRAILER BRAKE

0441.9533
RL1
(40A)

GND
GND
+30
+15
1 + G 0.012.8894.4 85 86

0443.7875
9 2 12 3 23 1 3 4 2
X39

0.012.8672.4
ST1 ST2 G17 30 87

1
3

F27

F16

F28
0 1 2

7.5A

15A
3A
1 3 4 2 4 3 1 5 9 21 2 30 28 5 29 50 15 X 30 +30 9 -31 7 6 21

0.012.8732.4
AS5 X6 AS3 AS1 TKAB2 X17 P1 J2 P4 J3 P3

TKAB3
1

FU100
0443.7846

100A
+30A GND4

+ - 7
BATTERY
p

0.012.8672.4 0443.7355.4
X71
4
2

ITA TRAILER BRAKE

0441.9533
RL1
(40A)

GND
GND
+30
+15
1 + G 0.012.8894.4 85 86

0443.7875
9 2 12 3 23 1 3 4 2
X39 30 87

ST1 ST2 G17

1
3

F27

F16

F28
0 1 2

7.5A

15A
3A
1 3 4 2 4 3 1 5 9 21 2 30 28 5 29 50 15 X 30 +30 9 -31 7 6 21

0.012.8732.4
AS5 X6 AS3 AS1 TKAB2 X17 P1 J2 P4 J3 P3

TKAB3
1
FU100
0443.7846

100A

+30A GND4

+ -

BATTERY
1 Starter switch
2 Compressed air pressure gauge
3 Handbrake switch
4 Instrument panel
5 Trailer braking low pressure switch
6 Trailer parking brake solenoid valve coil
7 Trailer braking air pressure sensor

D023150 40-64
 4.17 FRONT AXLE SUSPENSION

4.17 FRONT AXLE SUSPENSION

RL1 RL8 RL9

0441.9533
(40A) (STOP) (D/T BRAKE)

1 2 1 2

30 85 86 87
4 5 3 4 5 3
D6 D7
1N4007 1N4007

F11
20A
9 10
1

F1
11

F34

F17
0 1 2

100A

7.5A

7.5A
2 3 4 1 2 3 4 1 8 20 4 5 50 15 X 30 +30 -31 7 5 4 20 24 17 19 8 7 5 2
JX2 JX1 X17
0.012.8894.4

X35 X32 P1 P4 J3 P5 J1 P5 P3 J2

AS3 GND 4
11
3

0443.7849
AS1
3
12 10
21 9 FE2
8 7
7 6
6 5 X68
5 4 1
4 3 2 2
3 2
2 1
1
S
FE1
1
2 3
H
1
2 4

5 TKAB3 X18 JX4 JX3 X69

1 10 9 5 1 14 13 12 8 19 13 11 2 15 22 9 14 17 5 4 20 2 1 1 2 3
0.012.8732.4 0443.7850 U
S
0443.7846

FU100

7
6 5
100A

8
+30A

+ -

BATTERY

1 Starter switch
2 Front axle suspension load sensing solenoid valve coil
3 Axle Down control solenoid valve coil
4 Axle Up control solenoid valve coil
5 Front axle suspension position sensor
6 Front axle suspension control unit
7 Diagnostics connector
8 Front suspension pushbutton
9 Brake pedal switch (Left)
10 Brake pedal switch (Right)
11 Rear lift control unit

D016960 40-65
 4.18 TRANSMISSION

4.18 TRANSMISSION

20 1
0 1 2
ECU PS
0443.8656 0.012.8732.4 65 63 20 30 1 2 8 50 33 34 11 57 29 5 14 39 15 16 3 40 17 55 32 21 45 36 13 56 62 4 44 24 37 38 67 22 66 68 23 31 15 X 30
0441.9533
RL1 RL13 RL12
AS4 X17 (40A) (EV F/S) (SWITCH F/S)
3 21
3.9 Ohm
1 18
19 3.9 Ohm
4 19
30 85 86 87
1 2 1 2

3.9 Ohm
2 22 4 5 3 4 5 3
D11 D10
20
FW
X37

F16

F28
F35

F27
N 1N4007 1N4007
RV

15A
3A
7.5A

7.5A
0443.7875

3 1 3 6 9
P4 +30 -31 7 6 22 7 18 19 15
P5 J2 P1 P4 J3 P3 P5

+12V 1 AS5
18 M 5 3
M 6 1
Sig 2 5
X40

0.012.8894.4
GND 4
X33 AS6
1 8
17 2
3
4
3
2
1
X34 6
4 5
1 Starter switch 16 1
2
2 Armrest
3 Gearbox control lever
+15
ST1 AS3
2 9
4 Diagnostics connector GEAR BOX PRESSURE 7
+30 9
5

5 Field/road sensor GND 3 21

15
GND 12
AS1

F/S LEVER
6 Field/road selection solenoid valve
ST2
7 Speed sensor for odometer WHEEL INPUT 22
ROAD LAMP 6 16

8 Proportional valve solenoid FIELD LAMP 5 17

AS2 TKAB1
TKAB2 X18 X12 TKAB3 G3
9 Engine speed sensor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 15 6 7 8 8 2 1 2 1 2 3 1 3 4 5

TKAB1
10 Gearbox output shaft speed sensor

0443.7534.4
0443.7846
11 Transmission speed sensor

FU100
12 Transmission oil temperature sensor 4 3

100A
13 Transmission oil low pressure switch
+30A X21
14 Gearshift solenoid valves (Y1, Y2, Y3, Y4) 10 12 9 11

15 Instrument panel GND2 + - 2

16 Clutch pedal position sensor
0.012.8672.4

PRESS SWITCH

BATTERY

17 Clutch pedal depressed proximity sensor

F/S SWITCH
EV GROUP

PS 1
18 Transmission display
LS/PS

EV F/S
1
19
TEMP

NLSA

EV PROP
NLSE

Shuttle control lever

NAB
NHK

20 Transmission ECU
E F C D A B 2 1 2 1 3 2 1 3 2 1 3 2 1 2 1 3 2 1 1 2 1 2
Freq Freq Freq U Freq
P
HK
Y2
Y3
Y4

Y1

Prop

14 13 12 11 10 9 8 7 6 5

D023160 40-66
 4.19 ASM - 4WD - DIFFERENTIAL

4.19 ASM - 4WD - DIFFERENTIAL

0441.9533
RL9 RL8
RL1 (DT/BRAKE) (STOP)
(40A)

F10

F13
F11
1 2 1 2

30 85 86 87 4 5 3 4 5 3

7.5A
20A

15A
10 11 D7

1N4007
D7

1N4007

F27
0 1 2

7.9A
0.012.8894.4 2 3 4 1 2 3 4 1
0.012.8732.4 50 15 X 30 +30 9 6 7 8 19 17 -31 24 20 18 1 4

DF 1
ST2 X35 X32 X17 P1 J2 J3 J2 P3 P4 P5
9 DT 14
+15 2
+30 9 AS3
GND 3 11
GND 12 9
5
10
8
1

8
1

10
9 AS2
5 5

7
1

7
1

10
9
6
5
AS1
6 21 GND4
1 11
7 9
2 10
8 8
1

6
0

10
9 5
6 6
5 7 MS1 JX2 TKAB3 TKAB2
1 2 3 30 18 23 10 16 20 11 2 13 8 1 13 14

FU100
0.013.5915.4

0.012.8672.4
0443.7896
4 100A

X82 +30A EVDF EVDT

1 2 3 4 1 2 1 2
GND2

+ -

BATTERY
3 2

1 Starter switch
2 Four wheel drive (4WD) clutch solenoid valve
3 Differential lock solenoid valve
4 Rear lift control unit
5 Steering angle sensor
6 ASM switch
7 Differential lock switch
8 4WD switch
9 Instrument panel
10 Brake pedal switch (Left)
11 Brake pedal switch (Right)

D023170 40-67
 4.20 REAR LIFTER

4.20 REAR LIFTER

0442.9835 0443.7846
UPDX
1
17 2 G14
7
1 8
16 2 9
DWDX +30A
0441.9533
1
UPSX + - RL1
15 2 G15
(40A)

FU100
7 BATTERY 85 86

1 8
14 2 9
30 87

100A
DWSX
1

F27

F16
0442.9835

7.5A
0 1 2

3A
F34
7.5A

13 12 11 1 50 15 X 30 3 5 2 9 1 +30 -31 7 6
TKAB3 X17 P5 J2 P1 P4 J3

ST1 AS1
GND 3 21 GND4
GND 12
+30 9 5
AS3
3
+15 2 9
RADAR OUTPUT 5 7 2 2

1
WHEEL RPM OUTPUT 11 4
13 1

0
RADAR INPUT 21 2
AS2 X13
ST2

X18
9
10
3
0.012.8894.4

1 Starter switch
2 Radar control switch
3 Diagnostics connector
4 Lift and hand throttle console
5 Rear lift control unit
6 Lift control panel 3
2
4
7 Lift draft sensor (Right) 1

EHR
8 Lift draft sensor (Left) 10 1 21 22 24 25 23 17 19 20
TKAB2 X14
11 3 9 7 8 4 1 6 10 5 12
JX1
1 2 3 21 15 23 10 17 14 22 8 18 13 7 19 16 9 4 20 5 6 3 12 15 22 19
JX2
9 Rear lift position sensor 0.012.8732.4

470R

470R

4K7

4K7

4K7

4K7
10 Lift Up solenoid valve

0.012.8672.4

220R

220R

220R

220R
11 Lift Down solenoid valve Versione con bracciolo
1 2 3
12 6

0443.7354.4
Radar EHR
POS SEN
RADAR

13
DRAFT

DRAFT

Instrument panel
EV DW

RIGHT
EV UP

LEFT

5
14 Rear lift Down Lx pushbutton 2 3 1 2 1 2 1 1 2 3 1 2 3 1 2 3
GND2
15 Rear lift Up Lx pushbutton U U U
X21
16 Rear lift Down Rx pushbutton 11 10
S F F 3 4 5

17 Rear lift Up Rx pushbutton 12 8 7

18 Armrest 9
18

D023180 40-68
 4.21 FRONT AND REAR PTO

4.21 FRONT AND REAR PTO

0442.9835
PTO DX G14

0443.7846
3 12
12 2 11 0441.9533
1 10
RL1(40A)

PTO SX G15

F29
3 12
30 85 86 87
2 11

7.5A
1 10

0442.9835 - PTO MODULE

+30A
+

D12

FU100
BATTERY 6A100R

F34

F10

F16
F27

F16
F1

7.5A

7.5A
100A

3A
9 1 IC1
+
3

4
IC2
+
3

100A

7.5A
10 11
DIA DIA

3A
5 5
OUT H OUT V
2 2
IN IN
0 1 2 GND GND 6V 2 6H 5 7V 3V7H 3H 1 10W 2V 2H
1 1

1 10 9 5 3 2 1 3 2 1 1 8 9 10 50 15 X 30 -31 +30 9 7 6 24 12 13 8 10 11 23 25 9 3 18 1 2 5

PTO X9 X10 TKAB3 X17 P4 P1 J2 J3 P3 P5 J2

AUTO

0.012.8894.4

GND4
ST1 AS1 9
+15 2
+30 9 5
GND 3
GND 12 21
5 2
ISO7
8
PTO RPM INPUT 20
ST2 AS2 3
REAR PTO 11 11
12
MS1 TKAB2
FRONT PTO 10
JX1
11 4 5 20 13 23 12 9 1
0.012.8732.4

0.013.5915.4

0.012.8672.4
7

PTO SENS
EV PTO
HZW D+ B+
1 2 1 2 1 2 3
GND2 + GND2
G

4 3
6 5

1 Starter switch 7 Rear lift control unit

2 ISO7 socket (implement connection) 8 Instrument panel
3 Rear PTO speed sensor 9 PTO AUTO switch
4 Rear PTO solenoid valve 10 Front PTO pushbutton (in cab)
5 Alternator (D+) 11 Rear PTO pushbutton (in cab)
6 Front PTO solenoid valve 12 Rear PTO Rx pushbutton

D023190 40-69
PAGE INTENTIONALLY
LEFT BLANK
ENGINE WIRING (4 CYLINDERS) (1/2) 0421.3182

5. WIRING
ENGINE WIRING (4 CYLINDERS) (1/2)

1 B6
2
3 B48
4

B43
3 2 1

1 2

3
2 F30
1

2
G18 1
B1

Y3

1
2 B37
2
B40
1

B1 Not utilised
B6 Not utilised
B37 Fuel temperature sensor
B40 Camshaft speed sensor (Pickup)
B43 Coolant temperature sensor
B48 Engine boost pressure sensor
F30 Not utilised
G18 To engine wiring
Y3 Actuator

0421.3182

D023200 40-71
ENGINE WIRING (4 CYLINDERS) (2/2) 0421.3182

ENGINE WIRING (4 CYLINDERS) (2/2)

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
G18

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

2 3 4 1 2 1 2 3 1 2 1 2 1 2 1 2 3 4 5 6 7 1 2 3 R Rosso/Red H Grigio/Gray
1

B48 B37 F30 B43 B1 B40 Y3 B6

0421.3182

D0023220 40-72
ENGINE WIRING (6 CYLINDERS) (1/2) 0421.3172

ENGINE WIRING (6 CYLINDERS) (1/2)

1
2
B48 3
4
B6

B43
3 2 1

1 2

3
2 F30
1

2
G18 1
B1

Y3

1
2 B37
2
B40
1

B1 Not utilised
B6 Not utilised
B37 Fuel temperature sensor
B40 Camshaft speed sensor (Pickup)
B43 Coolant temperature sensor
B48 Engine boost pressure sensor
F30 Not utilised
G18 To engine wiring
Y3 Actuator

0421.3172

D0023210 40-73
ENGINE WIRING (6 CYLINDERS) (2/2) 0421.3172

ENGINE WIRING (6 CYLINDERS) (2/2)

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
G18

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

2 3 4 1 2 1 2 3 1 2 1 2 1 2 1 2 3 4 5 6 7 1 2 3 R Rosso/Red H Grigio/Gray
1

B48 B37 F30 B43 B1 B40 Y3 B6

0421.3172

D0023220 40-74
CONNECTORS LOCATION ENGINE

CONNECTORS LOCATION

1 G18

B43

F0077580

2
B48

F0077590

3
F30

F0077600

40-75
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION ENGINE WIRING

ENGINE WIRING

4
B6

2
F0077610

1 3

5
Y3

4
5

F0077620

6
B40 F0077570

B37

B1
F0077630
0421.3182
0421.3172

40-77
PAGE INTENTIONALLY
LEFT BLANK
ENGINE WIRING (1/2) 0.013.5915.4/10

ENGINE WIRING (1/2)

+30C Starter motor (+30)
+50 Battery (+50)

7
5

8
B+ Alternator (B+)

12 11 10 9
3
G18 D+ Alternator (D+)

2
1
FU101 Preheating relay power fuse
RL40
G18 To engine wiring (Deutz)
X74 P RL42 HZW Front PTO solenoid valve
2 1
2 1 K Air conditioning compressor
2 1

L Air cleaner clogged sensor

T X79 MS2 MS1 To side console wiring

P
X86 MS2 To front console wiring

1
2
2

P To fuses
1
3

T
RL40 Engine starter relay
RL42A Preheating relay
RL42B Preheating relay
1

MS1
2

X88 RL42 Preheating relay

3

T Coolant temperature sensor (for Infocenter)

ZW
H X74 Compressor and condenser fan pressure
switch
2
1
X81 X78 Preheating device

S
GND2
X79 Not utilised
HZW X80 Start enable switch (Green)
1 2

X81 Brake fluid level sensor

X80
X82 Steering angle sensor
X86 Left headlamp
X87 Horn
X88 Right headlamp

L +50
+30C
L
X87

D+

B+

1 2 3 4
X82

RL42A FU101 +30B

RL42B X78
FUSE

0.013.5915.4/10

D023290 40-79
ENGINE WIRING (2/2) 0.013.5915.4/10

ENGINE WIRING (2/2)

RL40

HZW P G18 X86 X88 +30C B+ D+ X80

+50

D+
1 2 2 1 5 3 2 8 9 12 13 14 15 17 18 19 23 24 25 1 2 3 1 2 3 3 2 1 5 2 1
MN1.5

M1.5
M1.5

M1.5

ZB1
M1
B+
30

50

RN4
ZB1
R4
RL42B X78

R10

RN4
N 25

RL42A FU100 +30B

200 A
X74 1 2 1 K

H1.5

S.U.1
M1.5

X81 T L
1 2 2 1

M1

M1

M1
RL42
2 1
X87
2 1 1 2 3 4
X82
M1.5

X79
1

C1
TABELLA COLORI / COLOURS TABLE
M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue
GR1.5

GN1.5

BR1.5

CB1.5
HR1.5

HV1.5
RV1.5

ZB1.5

GH 1
RN 1
G1.5

NZ 1
B1.5
MN1

V1.5

MB1
RG1

AG1

BN1

CB1

CN1

SN1
GH1
HN1
RV1

Z Viola/Violet B Bianco/White
VN1
LR1

HL1
M1
B1

C1
H1
M1
H1
V1

A1
Z1
L1

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11
R Rosso/Red H Grigio/Gray

MS1 MS2 GND2

0.013.5915.4/10

D0023310 40-80
CONNECTORS LOCATION ENGINE

CONNECTORS LOCATION

1
MS2
MS1

F0038880

X80

F0043321

3 G18

F0077640

40-81
CONNECTORS LOCATION ENGINE

4 GND2

F0077560

X78

F0077760

6 X87

F0077650

40-82
CONNECTORS LOCATION ENGINE

7 P

HZW

F0077660

8
K

X82

F0077670

9
X74

X88

F0077770

40-83
CONNECTORS LOCATION ENGINE

10

X86

F0043401

11
D+

B+

F0077680

12 X79

F0078590

40-84
CONNECTORS LOCATION ENGINE

13
+30B

F0075390

14 L

F0077780

15 RL42B RL42A

RL40
RL42

F0078560

40-85
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION ENGINE WIRING

CONNECTORS LOCATION
16
16 14
X81

17
11 A

18
F0077690

6
17 8

+30C
F0077700

1
5
3
12
F0078570

18 2
15 4

13 7
9
+50

10

F0077710
F0078580

0.013.5915.4/20

40-87
PAGE INTENTIONALLY
LEFT BLANK
TRANSMISSION WIRING (1/2) 0.012.8672.4

TRANSMISSION WIRING (1/2)

EV PTO

POS SEN 2 1

1
2
3

PO
S
RIGHT PTOSEN
G17 DRAFT
3 2 1
EVUP

4
3
1
32

2
1

2
TKAB2

1
1
TO 0.012.8732.4 EVDF EVDW

P
U

2
1
DW

TKAB1 X70
TO 0.012.8732.4

LEFT

3 2 1
DRAFT LEFT
DRAFT
F.P.

1 2
FP

R.P.
NEUTRAL

1 2
LS RP
2 1 EVPROP LS/PS EVGROUP
EVDT NHK

1
2 1

2
3 2 1
FUEL NLSE

LS/PS
NEUTRAL

2
NHK

1
LS

3
2
1
E
LS
N
GND2

N
LS
A
EV
F/

SWITCH
S

PRESS.
AB
N

3
2
1
RADAR

TEMP

LS
2
1
1

NLSA
2
3

EVF/S 1 2

PS
NAB 1 2 3
1 2 LS
PRESS
SWITCH
TEMP F/S SWITCH PS
RADAR

EVDF Differential lock solenoid valve G17 To trailer brake wiring PS Configuration connector (Powershuttle)
EVDTFour-wheel drive control solenoid valve (4WD) LEFT DRAFT Lift draft sensor (left) PTO SEN Rear PTO speed sensor
EVDW Lift Down solenoid valve LS Not utilised RADAR Radar
EVGROUP Gear change solenoid valves (Y1, Y2, Y3, Y4) LS/PS Configuration connector RIGHT DRAFT Rear lift draft sensor (Right)
EVPROP Proportional solenoid valve NAB Speed sensor for odometer RP Rear screen washer pump
EVPTO Rear PTO solenoid valve NEUTRAL LS Not utilised TEMP Transmission oil temperature sensor
EVUP Lift Up solenoid valve NHK Transmission speed sensor TKAB1 To side console wiring
EV F/S Field/road selection solenoid valve NLSA Gearbox output shaft speed sensor TKAB2 To side console wiring
F/S SWITCH Field/road sensor NLSE Engine speed sensor X70 Trailer socket (for lights and auxiliary power)
FP Windscreen washer pump POS SEN Lift position sensor switch
FUEL Fuel level sensor PRESS SWITCH Transmission oil sensor
0.012.8672.4

D023230 40-89
 AN 1.5

1
HN 1.5

2
G17 HV 1.5

D0023240
Z1

4
MB1.5

2
R.P. M 1.5

1
GND2
M 1.5

2
F.P. Z 1.5

1
M1
EVUP NZ 1.5
GN 1

3
RIGHT HV 1

2
M1
DRAFT HR 1 MB 1.5

1
EVDW
TRANSMISSION WIRING (2/2)

GN 1 AN 1.5

3
LEFT HN 1 HN 1.5

2
DRAFT HV 1.5
HR 1

1
V 1.5

RV 1 Z 1.5

3
POS ZG 1.5 HV 1

2
SEN HR 1 HN 1

1
RV 1
TRANSMISSION WIRING (2/2)

ZG 1.5
M1 HR 1.5

1
MN 1.5 NZ 1.5

2
EVDT
MB 1.5
M1

1
ZB 1.5 GN 1.5

2
RADAR GH 1 MN 1

3
1

F/S
MN 1
TKAB 2

M1
SWITCH

1
MN 1.5
FUEL ZB 1

2
CA 1.5
L 1.5
M1

1
GN 1

2
PTO SEN ZB 1.5
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10

GH 1

3
GN 1
9

ZB 1
8

M 1.5

1
7

VB 1

2
NHK N 1.5
6

GH 1

3
Z1
5

NEUTRAL
4

M1 LS

1
CA 1.5 AG 1
3

2
EVDF
VB 1
2

M1 HG 1.5

1
1

EVPTO L 1.5

2
AG 1

1
MN 1
2

EVF/S

GN 1

3
RG 1

2
NLSE M 2.5
1

MB 1

1
R 1.5
2

GN 1 R 1.5

3
CN 1 M 1.5 R 1.5

2
X70

NLSA MB 1 VN 1.5
31 R

1
VN 1.5
BN 1.5 BN 1.5
GN 1 HR 1.5 HR 1.5
3
2 V1 HN 1.5 HN 1.5
NAB
MB 1 RN 1.5 RN 1.5
1

G 1.5 G 1.5
L 58R 58L 54 54A

CN 1.5
2

EVPROP LR 1.5 LR 1.5

1

CN 1.5

VG 1 VG 1.5
1

40-90
RN 1 GN 1.5
2

TEMP
ZB 1.5
Z 1.5
RG 1
TKAB 1

CN 1

NB 1.5
Z

S
V

R
N
M

GN 1 V 1.5
1

PS
GN 1.5
BN 1.5 RN 1
1
31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10

LS/PS
Rosa/Pink
Nero/Black

Rosso/Red
Viola/Violet

CN 1
9

Verde/Green
Marrone/Brown

MN 1 M 1.5 N 1.5
1
8

PRESS
LS

BN 1.5 MN 1
2
7

SWITCH
AN 1.5 AN 1.5
6

L
B
A

H
C

L 1.5 L 1.5
E
5

Z 1.5
4

EV
ZB 1.5
3

GROUP
TABELLA COLORI / COLOURS TABLE

CN 1.5
Grigio/Gray
2

Giallo/Yellow
Azzurro/Blue

Bianco/White

Blu/Dark Blue
Arancio/Orange

C 1.5 C 1.5
F
1

MB 1
1

NEUTRAL
CM 1
2

LS
0.012.8672.4
0.012.8672.4
CONNECTORS LOCATION TRANSMISSION

CONNECTORS LOCATION

TKAB1
TKAB2

F0039320

POS SEN

F0043490

3
EVPTO

EVDF

F0043500

40-91
CONNECTORS LOCATION TRANSMISSION

PTO SEN

F0043510

5
TEMP

F0043520

6
EVDT

F0043540

40-92
CONNECTORS LOCATION TRANSMISSION

7
NAB

F0043530

8
EVF/S

F0043550

9
NHK

F0043560

40-93
CONNECTORS LOCATION TRANSMISSION

10
NLSE
NLSA

F0043570

11

GND2

F0043590

12
PRESS
SWITCH EVGROUP

F0043580

40-94
CONNECTORS LOCATION TRANSMISSION

13
FUEL

F0025110

14

EVPROP

F0043600

15
P/S SWITCH

F0043610

40-95
CONNECTORS LOCATION TRANSMISSION

16 LS

LS/PS

PS

F0043620

17 RADAR
NEUTRAL LS

F0043630

18
RP
FP

F0043640

40-96
CONNECTORS LOCATION TRANSMISSION WIRING

TRANSMISSION WIRING

19 20
LEFT RIGHT
G17 DRAFT DRAFT
21

1 EVDW
18

19
17
16
2
F0043651

6 15

20 13
X70 3
4
5 8
14

7 9 12

10

F0043671
11

21
F0077740

EVUP

F0043661

0.012.8672.4

40-97
PAGE INTENTIONALLY
LEFT BLANK
TRAILER BRAKE WIRING (ITALY) 0443.7356.4

TRAILER BRAKE WIRING (ITALY)

X71

1
2

2
G17 3
X72
3
4

G17

1 2 3 4

AN 1

HN 1.5

Z 1.5
HV 1.5
X73
AN 1

HN 1 HN 1.5
Z 1.5
HN 1.5

HV 1.5

X73
X71
1 2

X72

G17 To transmission wiring

X71 Compressed air pressure sensor trailer braking system
X72 Solenoid valve for trailer parking brake
X73 Trailer braking low pressure switch

0443.7356.4

D0003993 40-99
TRAILER BRAKE WIRING 0443.7355.4

TRAILER BRAKE WIRING

1
2
G17 X71

3
4

Z1
4 X71

G17
2

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

G17 To transmission wiring

X71 Compressed air pressure sensor trailer braking system

0443.7355.4

D0003853 40-100
CONNECTORS LOCATION CABLAGGIO LINEA FRENATURA RIMORCHIO

TRAILER BRAKE WIRING

1
1
G17

F0043681

2
F0077720

X71

ITALY VERSION

F0043301

3
X9
2

F0077730

X10
F0043310
0443.7356.4
0443.7355.4

40-101
PAGE INTENTIONALLY
LEFT BLANK
FRONT AXLE SUSPENSION WIRING (CAB) 0443.7849

FRONT AXLE SUSPENSION WIRING (CAB)

2
S

1
H
FE2
DEUTSCH

DT06-12S
IPD-USA

2
H

1
2
X68

1
FE2

3 2 1
1 2 3 4 5 6 7

GN 1.5

B1
CN 1.5

VN 1.5

Z1
L1

M 1.5
X69

GN 1.5
CN 1.5

VN 1.5

B1

Z1
L1
2 2 2 1 2 3

H S X68
1 1 1

M1

M1

M1
X69

FE2 To front axle suspension wiring (cab)

H Axle Up control solenoid
S Front axle Down solenoid
X68 Front axle suspension load sensing solenoid
X69 Front axle suspension position sensor
0443.7849

D0004172 40-103
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION FRONT AXLE SUSPENSION WIRING

FRONT AXLE SUSPENSION WIRING

1 FE2

F0039410

X68
H
2
F0025011

3
3
F0077750

X69
X6

F0043261

0443.7849

40-105
PAGE INTENTIONALLY
LEFT BLANK
CAB POWER SUPPLY WIRING 0443.7846/20

CAB POWER SUPPLY WIRING

G14 G15

GND3

FU100

TKAB3 +30A

GND4 GND2

FU100
H 16
1 100 A +30A
GV 2.5
2
BN 1.5
3
HN 1
4
VN 1.5
5
HR 1
6
RN 1.5
7
BL 1
8
LR 1
9
RG 1
10
L1
11
H1
GND2
12
BR 1
13

14
M5

TKAB3 GND3
M5

+30A Battery
TABELLA COLORI / COLOURS TABLE FU100 Main power supply fuse
M5 M Marrone/Brown C Arancio/Orange

GND4 V Verde/Green A Azzurro/Blue G14 To fender wiring - narrow

RG 0.5

RG 0.5
GV 1.5

BN 1.5

RN 1.5

BR 0.5

GV 1.5

BN 1.5

RN 1.5

BR 0.5
LR 0.5

LR 0.5
BL 0.5

BL 0.5
M 1.5

M 1.5

M 1.5

M 1.5
H 0.5

H 0.5

Z Viola/Violet B Bianco/White
HN 1

HR 1
L 0.5

L 0.5

N Nero/Black L Blu/Dark Blue

G15 To fender wiring - narrow
S Rosa/Pink G Giallo/Yellow
TKAB3 To side console wiring
12 12 R Rosso/Red H Grigio/Gray
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11

G15 G14

0443.7846/20

D0011492 40-107
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION CAB POWER SUPPLY

CONNECTORS LOCATION

G14
F0024261

2
GND4

TKAB3

F0024271

G15
F0024302

40-109
PAGE INTENTIONALLY
LEFT BLANK
 CAB POWER SUPPLY WIRING

CAB POWER SUPPLY WIRING

GND3

1 2

F0024281

6 5
5 GND2
4
3

F0077560

F0043220

6
+30A

F0076051

0443.7846/20

40-111
PAGE INTENTIONALLY
LEFT BLANK
FRONT AXLE SUSPENSION WIRING 0443.7850/10

FRONT AXLE SUSPENSION WIRING

FE1

FE2

JX3 JX4
4 5 20 1 2 11 13 22 15 2 17 14 9 19 8 12

GN 1.5

MN 1.5
M 1.5

G 1.5
CN 1.5
V 1.5
V 1.5

BL 1
AG 1

L1
VN 1.5

B1
Z1
HV 1.5
H1
R 1.5
JX3 JX4

G 1.5
1
MN 1.5 2
V 1.5
3

4
HV 1.5
5
AG 1 FE1
6
TABELLA COLORI / COLOURS TABLE BL 1 7
M Marrone/Brown C Arancio/Orange
M 1.5
V Verde/Green A Azzurro/Blue
8
H1

GN 1.5
CN 1.5

VN 1.5
Z Viola/Violet B Bianco/White 9

M 1.5
L1
B1
Z1
N Nero/Black L Blu/Dark Blue R 1.5
10
S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
1 2 3 4 5 6 7

FE2

FE1 To side console wiring

FE2 To front axle suspension wiring
JX3 Front axle suspension control unit
JX4 Front axle suspension control unit

0443.7850/10

D0004193 40-113
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION FRONT AXLE SUSPENSION WIRING

FRONT AXLE SUSPENSION WIRING

1
FE2

F0024400

3
2
1
2

JX3

JX4

F0058131

3
FE1

F0024380

0.012.4027.4

40-115
PAGE INTENTIONALLY
LEFT BLANK
FENDER WIRING - NARROW 0442.9835

FENDER WIRING - NARROW

X65

X66

1
PTOSX

2
PTODX

3
G16 PTOSX UPSX DWSX
2
SEN X66 X65 G16 PTODX UPDX DWDX

1
1

DWSX 1 2 1 2 3 1 2 1 2

2
DWDX

VG 1

H1
LR 1
BL 1

L1

L1
M1
HN 1

HN 1
BN 1.5

RG 1

BR 1
RN 1.5
M 1.5

M1
HEB

1
UPSX

2
UPDX

3
G14-G15
M 1.5
1
M1
G14-G15 2
VG 1
3
BN 1.5
4
HN 1
5
RN 1.5
6
L1
7
H1
8
BR 1
9
BL 1
10
LR 1
11
RG 1
12

DWDXRH lift Down pushbutton UPDXRH rear lift Up pushbutton

DWSXLH lift Down pushbutton UPSXLH rear lift Up pushbutton
G14 To cab power supply wiring X65 Rear right lower worklights
G15 To cab power supply wiring X66SXRear left sidelight and direction indicator
G16 To number plate light wiring X66DXRear right sidelight and direction indicator
PTODXRH rear PTO control button (on fender)
PTOSXNot utilised

0442.9835

D003761 40-117
NUMBER PLATE LIGHT WIRING 0441.4114

NUMBER PLATE LIGHT WIRING

X67 G16

1
M1

X67 2
G16
HN 1

G16 To fender wiring - narrow

X67 Number plate light

0441.4114

D0003801 40-118
CONNECTORS LOCATION FENDER AND NUMBER PLATE LIGHT

CONNECTORS LOCATION

1 X65

F0024333

2 UPSX
DWSX

G16

PTOSX
F0024363

3 DWDX UPDX
G16
PTODX

F0024353

40-119
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION FENDER NARROW WIRING - PLATE LIGHT WIRING

FENDER NARROW WIRING - PLATE LIGHT WIRING

4 1 1

G14-G15

3
F0024342

5 X66
6

4
5

4 2

F0024323

6
X67

FENDER PLATE LIGHT

0442.9835 0441.4114

F0024201

40-121
PAGE INTENTIONALLY
LEFT BLANK
FRONT CONSOLE WIRING (1/2) 0.012.8894.4/30

FRONT CONSOLE WIRING (1/2)

ST1

ST2

X34

X30 X31 X33 4

AS3

1
X32

2
3
AS6

3A

3
MS2
G4

X35
1
AS1

AS2
8

7
5

6
1 Sidelights switch AS1 To side console wiring X30 Not utilised
3 Cab headlights low beam switch AS2 To side console wiring X31 Accelerator pedal position sensor
3A Lower front worklights switch (on cab) AS3 To side console wiring X32 Right brake pedal switch
4 50S lights switch AS6 To side console wiring X33 Clutch pedal depressed proximity sensor
5 Front suspension pushbutton G4 To lights selector switch wiring X34 Clutch pedal position sensor
6 ASM switch MS2 To engine wiring X35 Left brake pedal switch
7 Differential lock switch ST1 Instrument panel
8 4WD switch ST2 Instrument panel 0.012.8894.4/30

D0016681 40-123
FRONT CONSOLE WIRING (2/2) 0.012.8894.4/30

FRONT CONSOLE WIRING (2/2)

X35 X32 X34 X33 X31 X30
M1 2 2 1 Z1 2 1 1
3 3 4 NZ 1 3 4 4
2 1 4 1 2 3
2 1 4 1 2 3 1 2 4 1 2 4

AR 0.5
LB 0.5

H 0.5

N 0.5

GH 1

GH 1
LR 1

LR 1
MN 1
HR 1

HL 1

HL 1
MB 1

GV 0.5

LN 0.5
HG 0.5
12
RN 1.5
7
HL 1 11
LR 1
10
GH 1 9
AR 0.5

AS6
8
G 0.5
6
AB 0.5
5
LN 0.5 4
H 0.5 3
GV 0.5 2
LB 0.5 1
14
GV 0.5
13
V1
12
MN 1
11
TX V1 MB 1
1 10
N 0.5 N 0.5
15 2 9
M 0.5
GND 3
58 4
H 0.5 H 0.5 8
HR 0.5 HR 0.5 7
RADAR OUTPUT 5
SG 0.5 SG 0.5
ST1 RPM PTO OUTPUT
GEAR BOX PRESSURE
6
7
G 0.5
6

HAND BRAKE-OIL LEVEL 8

RN 0.5
R 0.5 R 0.5
30 9 5
RX 10
GV 0.5
WHEEL RPM OUTPUT 11 HV 1 HV 1 4
GND 12 M 0.5

AS3
RN 1
1
M1
2
MB 0.5
3
4
HG 0.5
5
A 0.5
ZB 1
MS2 6
7
RV 1
GH 1
8
LR1
9
10
HL1
RN1.5
11
12

A1 3
DF
LN 0.5
1
TRAILER 2 VN 0.5 VN 0.5
2 2
TRAILER 1
LB 0.5 LB 0.5
3 1
HV 0.5 HV 0.5
DIRECTIONS LIGHT 4 18
HN 0.5 HN 0.5
HML DOWN 5 17
HB 0.5 HB 0.5 16
HML UP 6
L 0.5 L 0.5
GENARATORE 7 15
MB 0.5 B1
AIR FILTER 8 14
AG 0.5 AG 0.5
ENGINE PRESSURE 9 13
V 0.5 V 0.5 12
FRONT PTO 10
REAR PTO
LR 0.5 LR 0.5 11
11
CB 0.5 CB 0.5 10
ENGINE RPM 12

AS2
FUEL 13
ZB 0.5 ZB 0.5 9
ST2 DT 14
A 0.5
RV 0.5
SN 1 8
ENGINE TEMPERATURE 15
B 0.5 B 0.5 7
HIGH BEAM 16
HyHYDRAULIC FILTER 17
MV1 MV1 6
SPARE 18
NZ 1 5
HG 0.5 4
PRE HEATING 19
PTO RPM INPUT 20
GN 0.5 GN 0.5 3
RADAR INPUT 21
Z 0.5 Z 0.5 2
WHEEL INPUT 22
AB 0.5 1
ITA TRAILER BRAKE 23
AN 0.5
C 0.5 CN 0.5
STEERING PRESSURE CIRCUIT 24 4
CN 0.5 V 1.5 3
EMR ALARM 25
26 AN 0.5 2
SPARE
RN 0.5 1
MV 1 22
M 2.5 21
VN 1 20
HN 1 19
N1 18
GH 1 17
BN 1 16
V 2.5

AS1
15
VN 2.5 14
ZB 1 13
R 1.5 12
VG 1 11
GN 1
10
LN 1 9
RV 1
8
VB 1 7
HR 1 6
RG 1 5
M1

M1

M1
RG 1

M1
M1

RG 1
M1
RG 1

RG 1

M1
RG 1

RG 1
RG 1

RG1

M1
10 F 9 10 F 9 10 F 9 10 F 9 10 F 9 10 F 9 10 F 9
VN 2.5

S
V 1.5

S S S 10 9 S S S
BN 1 8
RV 1

R 1.5

3 HN 1 5 5 8 7 5 RV 1 6 6 NZ 1 5 NZ 1
BN 1 GH 1 1 V 2.5 1 1 GN 1 2 HR 1 2 HR 1 1
1
6 5
MV 1
2 8 N1 LN 1 7 5 5
4 3 VG 1 1 VB 1 1 NZ 1
ZB 1

2 1
H 0.5

1 3 3a RG 1
5 6 7 8
4
G4

0.012.8894.4/30

D0016690 40-124
CONNECTORS LOCATION FRONT CONSOLE

CONNECTORS LOCATION

X33

X34
F0025431

2 3
4

G4

1
F0058140

ST2

ST1
F0025020

40-125
CONNECTORS LOCATION FRONT CONSOLE

4 5
8

6
7

A0025060

MS2

A0025080

AS1
AS3

AS6 AS2

A0025090

40-126
CONNECTORS LOCATION FRONT CONSOLE WIRING

FRONT CONSOLE WIRING

7
4
3
X31

F0079190

8 X35

X32

X30
6
8 5
7
D0023320

A0025071

0.012.8894.4/30

40-127
PAGE INTENTIONALLY
LEFT BLANK
 SIDE CONSOLE WIRING (1/2) 0.012.8732.4/40

SIDE CONSOLE WIRING (1/2)

P2 MS1 To engine wiring
MX1 Engine control unit
GND6 X2 MX2 Engine control unit
BLACK
P6 FE1 P1 To fuses
TKAB2 TKAB3 TKAB1
P2 To fuses
DS1 X5 X6 P3 To fuses
R
ED
X4 P4 To fuses
X1 1 2 P5 To fuses
P6 To fuses
PTO AUTO PTO AUTO switch
REAR WIPER Rear screen wiper switch
GND4 RL41 Preheating warning light ON relay
TKAB1 To transmission wiring
X7
X19 TKAB2 To transmission wiring
G1 TKAB3 To cab power supply wiring
MS1
X18 X20
WORK LIGHT Rear worklights switch
6
5
4

X1 Direction indicators flasher unit (Red)

3
2

AS6 G2
1

AS1 X8 X2 Direction indicators flasher unit (black)

X4 Not utilised
X5 Driver seat air suspension compressor
YELLOW

P5 X6 Handbrake switch
J1 AS5 X7 Cigar lighter
X8 Engine ECU circuit board

LEVER
FU131 X9 Front PTO button (in cab)

F/S
AS3 X10 Rear PTO button (in cab)
X11 Not utilised
BLACK

P1 X9 X10 MX2 MX1

P3 AS4 AS2 X12 Gearshift lever
RL41 1 2 3 1 2 3
X13 Radar control switch
X14 Lift control panel
X15 Auxiliary power socket
X17 X16 Not utilised
X17 Starter switch

3 2 1
EHR
X18 Diagnostics connector
WHITE

JX1 APS G3

1
X19 Auxiliary power supply connector (in cab)

32
EMR X20 To armrest wiring
X11 X12
X20 Engine speed keypad
WOR
KLIGHT
BLACK

JX2
FLASHING
LIGHT X13
E.C.U. (PS)
X14
P4
CLEANFIX
FU121
X15 ISO7
ISO4
X16 REAR PTO
J3 J2 WIPER AUTO

0.012.8732.4/40

D0023260 40-129
SIDE CONSOLE WIRING (2/2) 0.012.8732.4/40

SIDE CONSOLE WIRING (2/2)

F/S LEVER

FU121
GND4
PTO REAR FLASHING WORK P6
AUTO CLEANFIX P2 DS1
X1 X3 X2 WIPER LIGHT LIGHT X9 X10

P4
10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
1 5 9 10 1 5 9 10 X17 1 2 3 4 5 6 7 8 9 10 1 2 3 X5 X7 X15

21
20
19
18
17
16
15
14
13
12

10
1 2 3 4 5 6 7 8 9 10 1 5 9 10 1 2 3

11
VF 49b RE LE 31 P1 P2 49 LA RA 49a
TKAB1 TKAB3

9
8
7
6
5
4
3
2
1
1 2 1 2 3 - +

RG 1
VB 1

GR 1.5

BR 1

AG 1.5
C 0.5

BL 1

BL 1

HN 1.5

HR 1.5
B 1.5
RG 1

RG 1

RG 1
B1

B 2.5

VN 1.5

ZB 1

V 1.5

Z1

ZB 1

BR 1
RG 0.5

RG 0.5

BN 1.5
14 13 12 11 10 9 8 7 6 5 4 3 2 1

M 1.5

H 2.5
24 25 26 27 28 29 30 31

RN 1.5
RN 2.5
RN 4
M4

M4

M6

M1
LN 1
N 2.5

H 2.5

B 1.5

V 2.5

G 1.5

HN 2.5

H1
HR 2.5

HN 1.5

HR 1.5

GV 1.5

VN 1.5

HV 1.5
50 15 X 30

RN 1.5

HR 1.5

R 1.5
VN 1.5

BR 1.5

L 1.5

RN 1.5

BN 1.5
LR 1.5

R 16
VN 1.5
LR 1.5
V1

HR 2.5
MB 1.5
R 1.5

N 2.5

H 2.5
M 0.5
P3 - 23 R 0.5

RG 1
BN 1.5
HN 1

GN 1.5
VN 1.5

A 2.5

HV 1.5

M1

M1

M 1.5
M 0.5

M1
See sheet 2

BR 1

R 1.5

MB 1.5

GV 1.5

Z1

BN 1.5

GN 1.5

P3 - 05 RV 1.5

M 2.5
GR 1.5

AG 1.5

R4
NZ 1

RN 2.5

H 1.5

GR 1.5

BL 1

HR 1.5

HN 1.5

GV 2.5
R 1.5
HN 1.5

BN 1.5

P3 - 07
P3 - 25
P3 - 08
CN 1

R 2.5
A
R 16 P1
RN 2.5
04-J1

P3 - 06
P5 - 11
B HN 1.5
J3 - 07
P5 - 03

09-J1
HR 1.5
08-J1
GV 1.5
GV 1.5
05-J1
6 GV 1.5
See sheet 2 GV 1.5
5 06-J1
AS 5

4 CB 1.5
N1
3
H1 BL 1
2 24-P3
M1 RN 1.5 01-P3
1
RN 1.5 02-P3
See sheet 2 B 1.5
22 03-J1
See sheet 2 L 1.5
21 05-J2
See sheet 2 C 1.5
20 14-P3
See sheet 2 C 1.5 15-P3
19
18 See sheet 2 RG 1
GN 1.5 RG 1 18-P5
17
MB 1.5 16-P5 R 2.5
16 03-P3
G 1.5 R 2.5
15 04-P3
RN 1.5 05-J3
14 Z1
H1
13 Z1 08-J3 07-P5
AS4

N 2.5 17-P5 GND

12 B1
B1 GND
11 12-P5
G1 22-P5
10
BN 1 GND
9 N1
N1 GND
8
M1
7
H 2.5 RG 1
6
L 1.5 03-J3 RG 1
5 10-P3
R 2.5 06-P5 LR 1.5
4
BN 1.5 LR 1.5
3 09-P3
VN 1.5 L1
2
B 2.5 L1
1 11-P3
H 2. 5
8-P5
V1
V1
Pin 1 13-P3
See sheet 2 N1
bis 8 13-P5
LR 1.5
AS6

LR 1.5
Pin 9 12-P3
See sheet 2 HN 2.5
bis 11 21-P3
RV 1
02-J2
RV 1
See sheet 2
13 CB 1 M1
V1 RV 1
12 1
MN 1 20-P3 VN 1.5
11
MB 1.5 M1 2 X13
10 3
N1
N1 06-J3 M1
9 1
H1 See sheet 2
2
AS3

8 HR 1 See sheet 2
3
HR 1 See sheet 2
7 4
SG 1
6 5
R1 09-J2
5 6
HV 1
4 7
See sheet 2
8 X18
See sheet 2 BN 1
3 9
VN 1 02-J3 S1
2 10
BL 1 01-J3 V1
1 11
HV 1 04-J3 CB 1
18 12
HN 1 19-P5
17 13
HB 1 15-P5 14
16
L1
15 BL 1
14
B1 1
VN 1
13
AG 1.5 2
12
V1
B1
3 ISO4
11
LR 1 4
See sheet 2
10 M1
9
ZB 1.5 1
X19
AS2

RG 1
2
8
B 0.5
7 20-J2
MV 1
6
NZ 1 01-P5
5
M1
4 1
GN 1 HR 1
3 2
2 Z 1.5 HV 1
3 ISO7
SG 1
1 4
C1
5
6
See sheet 2
See sheet 2

MV 1 23-P5
22 H 1.5
M 2.5 4
21
VN 1 10-P5 M1
20
HN 1 09-P5 3
19
18
N1 RN 1
2 X6
GH 1 25-P5
17 M1
BN 1 1
16
V 2.5
15
VN 2.5 14-P5
14
ZB 1 21-P5
AS1

13
See sheet 2
12 C 2.5
VG 1 C
11
GN 1 M4
10
B
9
LN 1
24-P5
G1
RV 1 R4
8 A
7
6
RG 1 R4
5
See sheet 2
4
See sheet 2 R4 FU131
3
AN 1
2
RN 1
1 H1
4
HR 1.5
3
G2
22-P3
01-J2

N 0.5
2
18-P3
02-J1
01-J1

07-J1

08-J2
N 0.5
1
See sheet 2

See sheet 2

See sheet 2

See sheet 2
See sheet 2

See sheet 2

See sheet 2
See sheet 2

See sheet 2
See sheet 2
See sheet 2

See sheet 2
See sheet 2
See sheet 2

See sheet 2
See sheet 2
See sheet 2
MN 1.5

MN 0.5

GR 0.5
MN 0.5

AR 0.5

MN 1.5

MB 1.5
GR 0.5
HN 1.5

BR 1.5

LB 0.5

VN 1.5
HN 1.5

LR 0.5

ZB 1.5
ZG 1.5
NZ 1.5
MV 1

GN 1
V 1.5
G 1.5

L 1.5

TABELLA COLORI / COLOURS TABLE

M 1.5

R 0.5
G 0.5

V 0.5
MB 1

L 1.5
V 0.5
H 1.5

L 1.5

VN 1

RV 1
AN 1

HL 1

S1
Z1

M Marrone/Brown C Arancio/Orange
HG 1.5

GN 1.5
CB 1.5

AB 1.5

HR 1.5

HN 1.5
ZB 1.5

HV 1.5

MB 0.5
RV 1.5
GN 1.5

AG 1.5

GN 1.5

AR 0.5
BR 1.5
GR 1.5

HR 1.5
HR 1.5

ZG 1.5

HV 1.5

RV 1.5

RV 1.5
LR 1.5

NZ 1.5

LB 0.5

NZ 0.5

LR 0.5
RV 1.5

M 1.5
G 1.5

MB 1
Z 1.5

V 1.5

R 0.5

G 0.5
B 1.5

H 1.5
B 1.5

GN 1
Z 0.5

Z 0.5

HR 1

VG 1

BN 1
L 0.5

L 0.5

HV 1
L 1.5

RV 1
NZ 1

HL 1
RV 1

BL 1
V Verde/Green A Azzurro/Blue
C1

B1

1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 Z Viola/Violet B Bianco/White
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
N Nero/Black L Blu/Dark Blue
MS1 TKAB2 JX1
BLACK
EHR
X14
JX2
WHITE
S

R
Rosa/Pink

Rosso/Red
G

H
Giallo/Yellow

Grigio/Gray
0.012.8732.4/40

D0023270 40-130
CONNECTORS LOCATION SIDE CONSOLE

CONNECTORS LOCATION

1
MX2 X8

MX1

F0022191

2
X7

F0022202

3
X6

F0022211

40-131
CONNECTORS LOCATION SIDE CONSOLE

X5

F0022221

5
G2

G1

F0022231

6
TKAB2
TKAB1
TKAB3

GND4

F0022240

40-132
CONNECTORS LOCATION SIDE CONSOLE

7
X4

F0022251

8 X1

X2

GND6

X19

FE1
F121
X121

F0058120

9
E.C.U. (PS)

F0022271

40-133
CONNECTORS LOCATION SIDE CONSOLE

10 11

X20

X15
X17

ISO7

ISO4

F0022281 F0022291

12 13

MS1
DS1

F0022300 F0022310

40-134
CONNECTORS LOCATION SIDE CONSOLE

14 FLASHING WORK
LIGHT LIGHT CLEANFIX

REAR PTO
WIPER AUTO

F0039461

15 P2 P6
FU131

P1

J1
P3
J2

X18
P4

P5 J3

F0058110

16
JX1

JX2

F0022341

40-135
CONNECTORS LOCATION SIDE CONSOLE

17 X9

X10

F0022351

18 X14

F0022361

19
AS5
AS4
AS6 AS2
AS1 AS3

F0022390

40-136
CONNECTORS LOCATION SIDE CONSOLE WIRING

SIDE CONSOLE WIRING

20 12

X12 11
17
16
18 15
EMR
X13
✽X11 13
20

19 14
X16
1 2 9
X11: NOT UTILISED F0022381

10

G3 6

5
EHR
4 D0016620

0.012.8732.4/40

40-137
PAGE INTENTIONALLY
LEFT BLANK
AIR CONDITIONING WIRING (CAB) 0.010.2562.2

AIR CONDITIONING WIRING (CAB)

M
87b 87 86 85 30 RL31 87b 87 86 85 30 RL30
X23

AR
S
R

R
N

A
BR

N
GL
X22
G1
BR

BR

GL

V
N

LR
3 2 1

R
N

C
G2
6

GN
4

CB
3

V
2

B
1

VN

LN

B
AR

CB

VN
LR
LR

GN
X25
A

S
N

V
C

C
V

N
R

N
C
C B A
2 3 4 5 1
X26
X29 X27 1 2 3 4 5
X24
X28 RL32 30 85 86 87 87b
4 3 2 1

1 2 3 4 C TABELLA COLORI / COLOURS TABLE

1 2
M Marrone/Brown C Arancio/Orange

M V

Z
Verde/Green

Viola/Violet
A

B
Azzurro/Blue

Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

G1 To side console wiring X24 Air conditioning control panel illumination connector
G2 To side console wiring X25 Air conditioning thermostat
RL303rd heater fan speed relay X26 Air conditioning on/off switch
RL314th heater fan speed relay X27 Fan speed selector switch
RL321st heater fan speed relay X28 Rh heater fan resistor
X22 Lh heater fan X29 Rh heater fan
X23 Lh heater fan resistor

0.010.2562.2

D0009353 40-139
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION AIR CONDITIONING

CONNECTORS LOCATION

X28

X29
F0024243

2
G2

RL
G1

F0024213

X22

X23
F0024253

40-141
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION AIR CONDITIONING WIRING

AIR CONDITIONING WIRING

X25

F0024233

5 X27

1
X26
2
4 3 D0016670

X24

F0024223

0.010.2562.2

40-143
PAGE INTENTIONALLY
LEFT BLANK
DISPLAY WIRING 0443.7875

DISPLAY WIRING

X38

AS5 X39

X38 X39 X40

Light

Light

+ G 12V Sig Light M M

01 02 03 04 05 06
M1

M1

M 0.5

M 0.5
H1

N1

N 0.5
H 0.5

N 0.5
CB 1

B 0.5

H 0.5

X40

06

B 0.5 05 TABELLA COLORI / COLOURS TABLE

CB 1 04 M Marrone/Brown C Arancio/Orange

N1
03 AS5 V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White
H1 02 N Nero/Black L Blu/Dark Blue
M1 S Rosa/Pink G Giallo/Yellow
01
R Rosso/Red H Grigio/Gray

AS5 To side console wiring

X38 Compressed air pressure gauge light
X39 Compressed air pressure gauge
X40 Transmission display

0443.7875

D0016641 40-145
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION DISPLAY WIRING

DISPLAY WIRING

1 1 2

X38

X39

F0024461

2
X40

D0016660

F0024471

3
AS5

F0024450

0443.7875

40-147
PAGE INTENTIONALLY
LEFT BLANK
ROOF WIRING (1/2) 0443.7851/10

ROOF WIRING (1/2)

X42
X41

DS1
TO 0.012.8732.4
X43

G5 GND5

G6
X45

2 1 X44

M
AR
4 3
X52

RO

I T 85 8
6 5

NE

AL 7
AM
8 7

EC 8 7 a
12

86
V
X46

36
RL21
2 1

G
4 3
X51

RI
G
IO
6 5
8 7

X53
X47 X48

1
2
3 X49 GND
4
5
X50

G8

G10

G11
GND

GND G9
G7

DS1 To side console wiring RL21 Front upper worklights on cab relay (50S) X48 Right front loudspeaker
G5 To cab roof front worklights wiring X41 Left rear loudspeaker X49 Clock
G6 To cab roof front worklights wiring X42 Rear screen wiper motor X50 Left front loudspeaker
G7 Front left sidelights connector X43 Right rear loudspeaker X51 Radio (grey)
G8 To cab roof front worklights wiring X44 CB power connector X52 Radio (brown)
G9 Front right sidelights connector X45 Door open warning signal switch X53 Side console courtesy light
G10 To windscreen wiper motor wiring X46 Interior roof light
G11 To cab roof front worklights wiring X47 Rotating beacon 0443.7851/10

D0004253 40-149
ROOF WIRING (2/2) 0443.7851/10

ROOF WIRING (2/2)

X52-X51
X45 X46 X53 X49 X44 X42 G10
G6 G51 X47

+ right

- right
+ left

- left

31b
53a
31b
53a
X48 X43 X41

58
G8 G11

30
15

53
53

31
31
-
1 2 1 2 1 2
G7 G9 - 30 58 15 30 - - 15 30

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 1 2 1 2 2 3 6 7 12 14 15 16 1 2 3 4 1 2 3 4
1 2 3 4 1 2 3 4
GND GND GND GND

MB 1

MB 1
Z1

HN 1

HR 1

BR 1

BR 1

BR 1
M1

HN 1

M1

M1
M1

HG 1.5
GR 1.5

M 2.5

GR 1.5
M1.5

M1.5

MB 1.5
BN 1.5

HR 2.5
HN 1.5

MB 1.5

G 1.5
M 1.5

M 1.5
N1
GV 1.5

GV 1.5

HG 1.5
AG 1.5

HN 1

N 2.5

AG 1.5

HR 1

GN 1.5

HV 1.5

B 1.5
R 1.5
RV 1.5
NV 1.5

H 2.5
M 1.5

M 1.5
M 2.5

M 2.5
M 1.5

M 1.5
GND5
M 1.5

M 1.5

M 1.5

R 1.5
DS 14
B 1.5
DS 15

MB 2.5
DS 12
AG 1.5
DS 16
H 2.5
DS 17
GR 1.5
DS 20
HR 2.5
DS 19
HN 1
DS 13
N 2.5
DS 21
BR 1
DS 18
HR 1
DS 11
DS1

G 1.5
DS 01
RV 1.5
DS 02
HV 1.5
DS 03
GN 1.5
DS 04
Low work light

VN 1.5
DS 05
BN 1.5
DS 06
V 2.5
DS 07
Z1
DS 08
GV 1.5
DS 09
GV 1.5
DS 10

4
MB 2.5
HG 2.5 3
3 V1
5 5

2 4 1
M1 V 2.5
1 2

HIGH BEAM LIGHTS/LOW WORK LIGHTS SWITCH OVER (AS)

RL21

0443.7851/10

D0004201 40-150
CONNECTORS LOCATION ROOF

CONNECTORS LOCATION

1
G8

F0024502

2 X50-X48

X46

F0024562

3 X45

X41-X43
F0024542

40-151
CONNECTORS LOCATION ROOF

4 X44

G5-G6

F0024572

5 G11

G10

F0024552

X53
F0024582

40-152
CONNECTORS LOCATION ROOF

7 X51
X52

RL21

F0024513

8 GND5

F0024530

X49

F0024491

40-153
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION ROOF WIRING

ROOF WIRING

5 2 5
10 1
2
3 4 3 6
7
3
4
X42 X47

10
12 11

F0024522

11 DS1

4
D0016800

F0024480

12
GND

G7 - G9

F0055552

0443.7851/10

40-155
PAGE INTENTIONALLY
LEFT BLANK
CAB LOWER HEADLIGHTS WIRING 0441.1923.4
WINDSCREEN WIPER MOTOR WIRING 0441.2045

CAB LOWER HEADLIGHTS WIRING WINDSCREEN WIPER MOTOR WIRING

G12-G13
G7- G9
G10 X58
X59-X60

1
G1.5 1
BG1.5 HIGH BEAM-WORKING LIGHT BG1.5
2 M1.5 2
X58
1 1
2
G1.5 LOW BEAM G1.5
2 G10 3
N1.5 3
3
M1.5 DIRECTION LIGHT M1.5
3 G12-G13 4
VN1.5 4
HR0.75 POSITION LIGHT HR0.75
G7- G9 4 4

M1.5
GND M1.5

N1
HR0.75 X59-X60
HR0.75

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
TABELLA COLORI / COLOURS TABLE
V Verde/Green A Azzurro/Blue
M Marrone/Brown C Arancio/Orange Z Viola/Violet B Bianco/White
V Verde/Green A Azzurro/Blue N Nero/Black L Blu/Dark Blue
Z Viola/Violet B Bianco/White S Rosa/Pink G Giallo/Yellow
N Nero/Black L Blu/Dark Blue R Rosso/Red H Grigio/Gray
S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

G7 To roof wiring G10 To roof wiring

G9 To roof wiring X58 Windscreen wiper motor
G12 To cab lower front worklights wiring (machine without front lift)
G12 To cab lower front worklights wiring (machine with front lift)
G13 To cab lower front worklights wiring (machine without front lift)
G13 To cab lower front worklights wiring (machine with front lift)
X59 Front left sidelight and direction indicator
X60 Front right sidelight and direction indicator

0441.1923.4 0441.2045

D0015573 D0016840 40-157

CAB LOWER FRONT WORKLIGHTS WIRING (MACHINE WITHOUT FRONT LIFT) 0442.5602
CAB LOWER FRONT WORKLIGHTS WIRING (WITH FRONT LIFT) 0441.6727

CAB LOWER FRONT WORKLIGHTS WIRING CAB LOWER FRONT WORKLIGHTS WIRING
(MACHINE WITHOUT FRONT LIFT) (WITH FRONT LIFT)

G12- G13 X61-X62

G12- G13
X63-X64

31

56b
56a
R0.75 H0.75
1 4
N0.75 3 M1.5
G12-G13
2
3
X61-X62 G12- G13 2
G1.5 X63-X64
1 B1.5
4

31
56b
56a

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue TABELLA COLORI / COLOURS TABLE

Z Viola/Violet B Bianco/White
M Marrone/Brown C Arancio/Orange
N Nero/Black L Blu/Dark Blue
V Verde/Green A Azzurro/Blue
S Rosa/Pink G Giallo/Yellow
Z Viola/Violet B Bianco/White
R Rosso/Red H Grigio/Gray
N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

G12 To cab lower headlights wiring G12 To cab lower headlights wiring
G13 To cab lower headlights wiring G13 To cab lower headlights wiring
X61 Front left worklight on cab X63 Front left worklight on cab
X62 Front right worklight on cab (without front lift) X64 Front right worklight on cab (with front lift)

0442.5602 0441.6727

D0015582 40-158 D0016830

CAB ROOF FRONT AND REAR WORKLIGHTS WIRING 0443.4993

CAB ROOF FRONT AND REAR WORKLIGHTS WIRING

G8- G11 G5- G6

X56-X57 X54-X55

1 2

1 2
1
2 HB1.5
H1.5 1 1
3 1
X56-X57 G5- G6 2
M1.5
2 X54-X55
G8- G11 4 2

M1.5

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

G5 To roof wiring
G6 To roof wiring
G8 To roof wiring
G11 To roof wiring
X54 Upper rear right worklights
X55 Upper rear left worklights
X56 Upper front left worklight
X57Upper front right worklight

0443.4993

D0016812 40-159
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION WORKLIGHTS AND WINDSCREEN

CONNECTORS LOCATION

1
X59-X60

G12-G13

F0055531

2
X61-X62

X61-X62

F0055541

X63 - X64

F0058330

40-161
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION CAB WORKLIGHTS AND WINDSCREEN WIRING

CAB WORKLIGHTS AND WINDSCREEN WIRING

X54
3 G5
X55

G6
G7 - G9

X57 X56 5
F0055551

4 G11
3

2
G10
3

1 X58 2

F0058310
1

5 D0016850

G8

0441.1923.4 0441.2045
F0058320 0442.5602 0443.4993
0441.6727

40-163
PAGE INTENTIONALLY
LEFT BLANK
LIGHTS SELECTOR SWITCH 0443.8656

LIGHTS SELECTOR SWITCH

AS4

X120

DIRECTION LOW BEAM

X119 LIGHT HIGH BEAM
CONTROL CONTROL
L
Flash FRONT WIPER
X118 CONTROL Z
0
Abb
R 0 1

Int.
0

X120
NVB1
1
R1
2
NV1 FRONT WASHER
3 PUMP CONTROL
4
NB1
5
H1
6

7
L1
8 HORN
9
CONTROL
M0.75
10 X118
1

3
TABELLA COLORI / COLOURS TABLE
X119 4
M Marrone/Brown C Arancio/Orange

N0,75/1 15/1
1

56b

56a
49a

MB0,75 31b
MB0,75 53c
-31

56
5

53
30

15

49
L
R

NG0,75 H
NR0,75 J
V Verde/Green A Azzurro/Blue

NGL0,75
BV0,75

RV0,75
6

LNB1

G0,75
M0,75
NBV1
Z Viola/Violet B Bianco/White

C0,75
V0,75
BN1
NV1

G1

B1
R1

H1
L1
N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 AS4

AS4 To side console wiring

G4 To side console wiring
X36 Hazard warning lights on/off switch
X37 Shuttle control lever

0443.8656

D0015103 40-165
PAGE INTENTIONALLY
LEFT BLANK
CONNECTORS LOCATION LIGHTS SELECTOR SWITCH WIRING

LIGHTS SELECTOR SWITCH WIRING

1 G4
1
2

X36
F0025481

D0016650
X37
3

F0024421

3
AS4

F0024430

0443.8656

40-167
PAGE INTENTIONALLY
LEFT BLANK
ARMREST WIRING 0443.7354.4

ARMREST WIRING

X21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 bis 42

AR 1

R1

BN 1

RV 1
LR 1
V1

B1

VB 1
HL 1

HR 1

RG 1
G1
LR 1

LN 1

BR 1
L1
H1
GH 1 / HG 1
1
2
X20

3
4
5
6
G3
1

EHR
2

X21
3

GH 1 / HG 1

VB 1
BN 1
RV 1

LR 1
LN 1
AR 1

HR 1

RG 1
G1
HL 1

BR 1
L1
R1

H1
V1

B1
1

EMR
2
3

1 2 3 1 2 3 6 5 4 3 2 1 1 2 3 4 5 6

EHR EMR G3 X20

EHR To side console wiring

EMR To side console wiring
G3 To side console wiring
X20 To side console wiring
X21 Armrest

0443.7354.4

D0003872 40-169
PAGE INTENTIONALLY
LEFT BLANK
FUSES AND RELAYS CONTROL UNIT (1/2) 0441.9533.4/10

FUSES AND RELAYS CONTROL UNIT (1/2)

FUSES
F2 Rotating beacon - Rear screen wiper (30A) F21 Upper left high light (see F23 - F9 too) (7.5A)
P1 F3 Fan - Air conditioning system (30A) F22 Upper right high light (see F23 - F9 too) (7.5A)
RL1 RL2 RL3
+ F4 Rear worklights (see F10 too) (30A) F23 High lights (15A)
F5 Not used F24 Left lower beam - light - Rear left side lights -
P2
P6 F6 Front worklights (see F10 too) (30A) Trailer socket terminal 58L - Left number plate light
F7 Radio - CB - terminal +15 (20A) (7.5A)
F8 Radio - clock - CB - courtesy light - terminal +15 (5A) F25 Right lower beam - Right number plate light - Rear ri-
F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 ght side lights - railer socket terminal 58 right
F9 Lower beam - lower beam including lights switch
F26 Emergency lights (15A)
30A

30A

30A

30A

20A

5A

7.5A

10A

20A

15A

15A

15A

15A

3A

7.5A
(see F21 - F22 - F23 too) (7.5A)
R LAP F10 Computer - lights switch lighting (7.5A) F27 Power Shift - Infocenter (7.5A)
CB F
TOP
HPSA
RADIO
CLOCK STOP
CHECK
F11 Stop lights - 4WD (15A) F28 Operator’s seat(15A)
SENSOR

F12 Front screen wiper - Horn (15A) F29 PTO control - PTO keypad (7.5A)
F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
F13 4WD - diff. locking (15A) F30 Electronic control engine speed (7A)
30A

30A

30A

RL4

7.5A

7.5A

7.5A

7.5A

15A

7.5A

7.5A

7.5A

7.5A
F14 Front worklights on the flashing pilot lamp (15A) F31 Left lower beam (see F23 too) (7.5A)
+12 F32 Right lower beam (see F23 too) (7.5A)
DIN F15 Direction indicators lights (15A)
J1 PTO
F33 Lower and upper lower beam (15A)
RIGHT LEFT CHECK F F16 INFOCENTER - Transmission speed sensor - Rear
F18 F19 F20
TOP PTO - Transmission display - air compressed gene- F34 Agronotric h - hD (7.5A)
F31 F32 F33 F34 F35 rator - Radar sensor - Switchs pilot lamp (3A) F35 Power Shift terminal 15 (7.5A)
F17 Front axle suspension (see F11 too) (7.5A)

15A

7.5A

7.5A

7.5A

7.5A
RL5 RL6 RL7 F18 Cigar lighter - Connection socket (30A)
J2 F19 Electric socket (30A)
F20 Lower beam including lights switch - High lights
TOP
(see F24 - F25 too) (30A)
RL8 RL9
STOP
P3
STOP

RL10 RL11
TOP
RL12 P4 RELAYS
GND
LIGHT RL1 Terminal 15 (40A) RL9 4WD solenoid valve (10A)
RL14 RL2 Rear worklights (40A) RL10 High lights
RL13
RL3 Front worklights (40A) RL11 High lights(10A)
RL4 Front screen wiper (10A) RL12 Field/road indicator (10A)
RL15
PTO EV J3 RL5 Lights (10A) RL13 4WD solenoid valve (10A)
E.C.U. RL6 Upper and lower lower beacon (10A) RL14 Direction indicators - emergency lights (10A)
RL7 Lower beacon (10A) RL15 High lights commutator (10A)
RL8 Stop lights - 4WD (10A)
P5
CONNECTORS
J1 To side console wiring P3 To side console wiring
J2 To side console wiring P4 To side console wiring
J3 To side console wiring P5 To side console wiring
P1 To side console wiring P6 To side console wiring
P2 To side console wiring

0441.9533.4/10

D0016750 40-171
D0016760
P4 (-31)

P5 - 7 SWITCH LIGHT (LF)

P6 - 3 ROOF POSITION F24

7.5A

2
J1 - 9 SOCKET/FENDER POSITION

5
3

4
P6 - 1 ROOF POSITION (RH) F25

1
7.5A
J1 - 8 SOCKET/FENDER POSITION

4
5
1

D8
FULL BEAM

1N4007
RL10
P1 (+30)

2
FULL BEAM LIGHT COMAND P5 - 12

3
P2 - 3 30 ROOF(clock-cb-radio-light) F8
5A
D2
1N4007

4
P5 - 6 HAZARD/LIGHTS COMAND F26

5
15A

D3
POSITION
1N4007 J2 - 9 INSTRUMENT CLUSTER

1N4007
SWITCH LIGHT FR.CONSOLE

RL5
P5 - 10
D1 J2 - 6 30 TRANSMISSION F27

2
POS.SWITCH LIGHT P5 - 23 7.5A
FUSES AND RELAYS CONTROL UNIT (2/2)

3
POSITION P5 - 13
REAR WORK LIGHT POSITION LIGHT F20
J1 - 5 30A

87
85
REAR WORK LIGHT J1 - 6
P3 - 4 LIGHER

REAR WORK L.
P3 - 3 TRAILER SOCKET POWER SUPPLY F18

RL2(40A)
30A
WORK LIGHT COMAND J3 - 9

86

30
P3 - 1 25A SOCKET

ROOF FRONT WORK LIGHT P2 - 2 P3 - 2 25A SOCKET F19

30A

87
85
ROOF FRONT WORK LIGHT P2 - 4

REAR WORK LIGHT F4

RL3(40A)
30A

FRONT WORK L.
FRONT WORK LIGHT COMAND P5 - 21

86

30
ROFF FRONT WORK LIGHT F6
30A

EV F/S P3 - 22
FUSES AND RELAYS CONTROL UNIT (2/2)

4
5
P3 - 7 HALF-BEAM F23

EV F/S
F/S LEVER SWITCH 15A

D11

1N4007
30

RL13
85

3
CLEAN FIX/LIGHTER P3 - 21
RL1(40A)

J3 - 7 STARTING SWITCH (15)

86

FIELD LIGHT P5 - 19
87

4
STREET LIGHT P5 - 15

5
F/S GEAR BOX SWITCH P3 - 18

D10
SWITCH S/F

1N4007
P5 - 9 HALH/FULL BEAM SWITCH F9

RL12
7.5A

3
STREET/FIELD/CLEAN FIX
F28
15A

4
STOP LIGHT (15A EXT.FUSE) J1 - 4

5
P5 - 20 STOP
F11
STOP COMAND (PEDAL) 20A

D6

1N4007
RL8
STOP

2
FRONT GLASS WIPER/HORN
F12
15A

3
P3 - 5 REAR WINDSCREEN (53a)
EV DT P3 - 17

4
P3 - 6 FLASHER/REAR WINDSCREEN F2
30A

5
1

D7
P3 - 15 HEATING GROUP

1N4007
DT x ASM P5 - 24
RL9

P3 - 14 HEATING GROUP F3
30A
DT/BRAKE

DT LIFT INPUT J2 - 8
3

TRAILER BRAKE EV/FRONT AXLE P3 - 19

NOT USED P6 - 9 F10
P5 - 18 COMPUTER/LIGHT SWITCH CONSOLE
ZERO SETTING 7.5A
P5 - 16
2

31b FRONT WINDSCREEN P6 - 10

5

J1 - 7 ENGINE/COLD START E.C.U.

F30
7.5A
RL4

INTERMITTANCE
J3 - 5
FRONT GLASS W.

P5 - 14 LOW FRONT LIGHT

F14
FRONT WIPER POUMP
4 1 6

J3 - 8 15A
HORN/FRONT GLASS WIPER P5 - 17
P5 - 4 NOT USED
53a WINDSCREEN P6 - 4
P5 - 1 DT SWITCH/DISTRIBUTOR
F13
NOT USED P6 - 6 15A

P3 - 12
5

BACK EV PTO J3 - 3 15 HAZARD/LIGHTS COMAND F15

15A
IC1

OUT
+

1
3

GND
PTO MODULE

J2 - 7 FRONT AXLE F17

7.5A

40-172
DIA

IN

INFOCENTER/DISPLAY/ON-OFF CLUTCH SENSOR

2
4

J3 - 6
J2 - 4 NOT USED F16
3A
J2 - 1 REAR PTO/RADAR/WHEEL SENSOR/ARMREST
P3 - 13
5

FRONT EV PTO
P3 - 16 HPSA F7
20A
IC2

OUT

6A100R P2 - 6 15 ROOF(CLOCK-CB-RADIO)
V
+

1
3

GND

D12 F29
7.5A
DIA

IN

P3 - 24 REAR/FRONT PTO E.C.U.

2
4

P5 - 2

FRONT PTO LED P3 - 8 6V

P3 - 20 NOT USED
2
REAR PTO LED P3 - 10 6H
D+ P3 - 11 5
7V
3V
7H
3H
J2 - 2 NOT USED
1
PTO AUTO P3 - 23 IOW LIFT CONTROL/RADAR F34
P3 - 25 J2 - 5
FRONT PTO COMAND 2V 7.5A
REAR PTO COMAND P3 - 9 2H

J2 - 3 15 TRANSMISSION F35 P5 - 3
7.5A

FULL BEAM
J1 - 3
4

FULL BEAM TOP P6 - 2

5
1

D9

1N4007
FULL-BEAM TOP
RL11

TOP SWITCH P5 - 25
3

FULL-BEAM F33
15A
4
5
1

D4

1N4007
RL6
HALF-BEAM TOP

J1 - 2 HALF-BEAM F31
4

7.5A
5
1

D5

1N4007

F32
RL7

J1 - 1 HALF BEAM
7.5A
2

LIGHT COMAND P5 - 22
HALF-BEAM

P2 - 1 HALF-BEAM F22
7.5A
J3 - 2
2 TRAILER
C3

J3 - 1
1 TRAILER F21
P2 - 5 HALF-BEAM
C2

7.5A
J3 - 4
DIR.LIGHT
C1

P5 - 11
TEMP HAZARD ECU 49a
RL14(HAZARD)

49A

TEMP HAZARD ECU 49 P5 - 8

49
G

31

0441.9533.4/10
0441.9533.4/10