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Same Diamond 210 235 265 service repair workshop manual

It is workshop manual for Same tractors. Models included:
210
235
265

language:english
number of pages: 902 (full digital version)

Main sections:
Introduction
Safety sections
1. TRANSMISSION ................................................................ 1
1.1 ENGINE-TRANSMISSION CONNECTION........................ 2
1.1.1 FLEXIBLE COUPLING............................................... 2
1.1.2 FLUID COUPLING..................................................... 3
1.2 TRANSMISSION ............................................................... 5
1.2.1 MAIN COMPONENTS
(1-SPEED PTO VERSION) ......................................... 5
1.2.2 MAIN COMPONENTS
(2-SPEED PTO VERSION) ......................................... 8
1.2.3 TRANSMISSION HYDRAULIC SYSTEM................. 11
1.2.4 GEARBOX ............................................................... 12
1.2.5 MAIN CLUTCH........................................................ 15
1.2.6 HYDRAULIC GEARBOX AND SHUTTLE
DISTRIBUTION VALVE............................................ 16
1.2.7 CLUTCH ENGAGEMENT AND SOLENOID
VALVE OPERATION SCHEMATIC .......................... 20
1.2.8 TRANSMISSION ELECTRONIC SYSTEM
SCHEMATIC............................................................ 21
1.3 REAR AXLE..................................................................... 22
1.4 PREAR PRO.................................................................... 24
1.4.1 1-SPEED REAR PTO............................................... 25
1.4.2 2-SPEED REAR PTO............................................... 26
2. BRAKING SYSTEM.......................................................... 27
2.1 BRAKE MASTER CYLINDER......................................... 28
2.2 BRAKE 29
2.3 TRAILER BRAKING SYSTEM 30
2.3.1 HYDRAULIC TRAILER BRAKING
(ITALY VERSION ..................................................... 30
2.3.2 HYDRAULIC TRAILER BRAKING
(EXPORT VERSION) ............................................... 32
2.3.3 AIR TRAILER BRAKING (ITALY VERSION) ............ 34
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION) ......... 35
3. HYDRAULIC FRONT AXLE SUSPENSION..................... 42
3.1 FRONT SUSPENSION CONTROL VALVE.......................43
4. FRONT AXLE.................................................................... 47
4.1 HUB CARRIER AND FINAL REDUCTION UNIT ..............48
4.2 DIFFERENTIAL ................................................................49
4.3 STEERING ANGLE SENSOR...........................................50
5. HYDRAULIC SYSTEM ..................................................... 51
5.1 VARIABLE DISPLACEMENT PUMP ................................53
5.1.1 HYDRAULIC PUMP..................................................56
5.1.2 LOAD SENSING VALVE, PRESSURE
CUT-OFF VALVE......................................................58
5.2 POWER STEERING .........................................................66
5.3 PRESSURE RELIEF VALVE .............................................67
5.4 PRIORITY VALVE.............................................................68
5.5 AUXILIARY SERVICES CONTROL VALVE ......................69
5.5.1 TYPES OF SPOOL VALVE (LS)................................70
5.5.2 LIFT CONTROL VALVE SECTION............................71
1. DIAGNOSIS TOOLS ALL ROUND TESTER................... 1
1.1 ALL ROUND TESTER ......................................................... 1
1.1.1 DESCRIPTION OF THE KIT ....................................... 1
1.1.2 NOTES ON CORRECT USE ...................................... 2
1.1.3 DESCRIPTION OF THE TESTER ............................... 2
1.1.4 GENERAL NOTES ON CONNECTING AND
POWERING UP THE TESTER ................................... 3
1.1.5 SELECTION OF THE DISPLAY LANGUAGE ............. 3
1.1.6 SETTING THE SERIAL PORTS................................... 5
1.2 SERDIA 3.5 LEVEL III SOFTWARE 7
1.2.1 DESCRIPTION OF THE KIT ....................................... 7
1.3 EDS EST45 SOFTWARE .................................................. 8
1.3.1 DESCRIPTION OF THE KIT ....................................... 8
2. CONNECTING THE TESTER TO THE ELECTRONIC
CONTROL UNITS............................................................... 9
2.1 CONNECTION OF THE ART® TO THE HPSA AND
ARMREST CONTROL UNITS .............................................. 9
2.2 CONNECTING THE PORTABLE COMPUTER
WITH SERDIA 3.5 SOFTWARE TO THE ENGINE
CONTROL UNIT ............................................................... 10
2.3 CONNECTION OF THE PORTABLE COMPUTER WITH
EDS SOFTWARE TO THE TRANSMISSION CONTROL
UNIT ................................................................................... 11
2.3.1 CONNECTION TO THE TRANSMISSION
CONTROL UNIT ...................................................... 11
3. INTRODUCTION TO THE ELECTRONIC SYSTEM
OF THE TRACTOR .......................................................... 13
3.1 ELECTRONIC SYSTEM 13
3.2 CANBUS SYSTEM ........................................................... 14
3.2.1 ARMREST ................................................................ 15
3.2.2 ENGINE CONTROL UNIT (DEUTZ EMR2) ............... 16
3.2.3 HPSA CONTROL UNIT ............................................ 17
3.2.3.1 REAR LIFT SYSTEM ........................................ 18
3.2.3.2 SISTEMA PTO POSTERIORE ........................... 19
3.2.3.3 SISTEMA PTO ANTERIORE ............................. 19
3.2.3.4 FRONT AXLE SUSPENSION SYSTEM ............ 20
3.2.3.5 ASM SYSTEM 21
3.2.3.6 BOSCH ELECTRONIC CONTROL
VALVE SYSTEM ............................................... 22
3.3 TRANSMISSION CONTROL UNIT ........................... 23
3.4 INFOCENTER ........................................................... 24
4. PUTTING THE TRACTOR INTO SERVICE ..................... 25
4.1 INTRODUCTION 25
4.2 RENEWAL OF THE ENGINE CONTROL UNIT ................. 25
4.2.1 READING AND SAVING DATA ................................ 25
4.2.2 PROGRAMMING THE CONTROL UNIT .................. 26
4.2.3 CALIBRATION OF THE ACCELERATOR PEDAL .... 27
4.3 RENEWAL OF THE TRANSMISSION
CONTROL UNIT ................................................................28
4.3.1 SETTING THE TRACTOR VERSION AND
SERIAL NUMBER .....................................................28
4.3.2 CALIBRATION OF THE CLUTCH PEDAL
POSITION SENSOR ..................................................30
4.3.3 CALIBRATION OF THE MAIN CLUTCH
PROPORTIONAL SOLENOID VALVE........................32
4.4 RENEWAL OF THE HPSA CONTROL UNIT.......................34
4.4.1 INITIALISATION OF THE HPSA CONTROL UNIT .....34
4.4.2 SETTING THE WHEEL TYPE.....................................35
4.4.3 SETTING THE PTO MANAGEMENT
(FOR USA ONLY) ......................................................37
4.4.4 SETTING THE TYPE OF LIFT POSITION
SENSOR (for versions with AB sensor only) .............39
4.4.5 SETTING THE TYPE OF PTO
(for 1-speed PTO version only.................................. 41
4.4.6 CALIBRATION OF THE LOW AND HIGH
POSITIONS OF THE LIFT.........................................43
4.4.7 CALIBRATION OF THE ACCELERATOR PEDAL.....45
4.4.8 SETTING THE TYRE CIRCUMFERENCE.................47
4.4.9 SETTING THE TYPE OF PTO OUTPUT
SHAFT .......................................................................48
4.4.10 SETTING THE INFOCENTER LANGUAGE............50
4.4.11 CONFIGURING THE SYSTEM FOR
PRESENCEOR ABSENCE OF THE
FRONT PTO...........................................................51
4.4.12 CONFIGURING THE SYSTEM FOR
PRESENCE OR ABSENCE OF
FRONT AXLE SUSPENSION ................................52
4.4.13 CONFIGURING THE SYSTEM FOR
PRESENCE OR ABSENCE OF THE RADAR .........53
4.5 RENEWAL OF THE ARMREST CONTROL UNIT ...............54
4.5.1 CALIBRATION OF THE HAND THROTTLE 54
4.5.2 CALIBRATION OF THE JOYSTICK FOR
CONTROL VALVES N°3 & N°4................................. 56
5. ALARMS ........................................................................... 61
5.1 ALARMS DISPLAYED ON THE
INSTRUMENT PANEL .......................................................62
5.2 ALLARMI CENTRALINA HPSA .........................................73
5.3 ENGINE CONTROL UNIT ALARMS ................................129
5.4 TRANSMISSION CONTROL UNIT
ALARMS ..........................................................................153
5.4.1 DEFINITION OF TRANSMISSION OPERATING
MODES ...................................................................153
5.4.2 ABNORMALITIES NOT DETECTED BY
THE TRANSMISSION CONTROL UNIT ..................154
5.4.3 ELENCO ALLARMI CENTRALINA
TRASMISSIONE .....................................................155
5.4.4 THE MESSAGE EE APPEARS ON DISPLAY........224
5.4.5 EDS SOFTWARE UNABLE TO CONNECT TO
THE TRANSMISSION CONTROL UNIT. ................224
5.4.6 TRANSMISSION SLIPS UNEXPECTEDLY
FROM FORWARD OR REVERSE DRIVE INTO
NEUTRAL. ...............................................................225
5.4.7 THE TRANSMISSION CONTINUES TO SHIFT
RANGE AUTOMATICALLY EVERY 1 OR
2 SECONDS ..........................................................225
5.4.8 MOMENTARY LOSS OF TRACTION WITH
THE TRACTOR IN MOTION ...................................226
5.4.9 THE TRANSMISSION STAYS IN NEUTRAL ..........227
5.5 ARMREST ALARMS ........................................................229
5.6 LIST OF ALARMS FOR THE BOSCH
ELECTROHYDRAULIC CONTROL VALVE ......................241
5.6.1 MINOR ALARMS ....................................................241
5.6.2 ALARMS OF MEDIUM SEVERITY ..........................242
5.6.3 MAJOR ALARMS ...................................................242
5.7 CANBUS ALARMS ..........................................................243
5.7.1 TABELLA ALLARMI ................................................244
6. HPSA CONTROL UNIT TESTER MANUAL .................. 255
STRUCTURE OF THE SYSTEM .............................................255
OPENING SCREEN................................................................256
MAIN MENU...........................................................................256
1. MONITOR MENU ...................................................257
1.1 TRANSMISSION .....................................................257
1.2 PTO ........................................................................259
1.3 ASM 259........................................................................
1.4 LIFT ........................................................................ 260
1.5 SUSPENSION ........................................................261
1.6 CAN STATUS .........................................................262
1.7 DISTRIBUTORS .....................................................262
2. CALIBRATION MENU .....................................................263
2.1 CALIBRATION SUSPENSION ................................263
2.2 CALIBRATION OF TRANSMISSION SYSTEM
SENSORS ......................................................................264
2.3 CONFIGURATION OF SPEED SETTING ................264
2.4 MENU CONFIGURATION ......................................265
2.5 CALIBRATION OF DISTRIBUTORS .......................265
3. TEST MENU ....................................................................266
3.1 TESTS ON TRANSMISSION ANALOG SENSORS .266
3.2 TESTS ON TRANSMISSION DIGITAL BUTTONS ..267
3.3 TESTS ON ASM SENSORS ...................................267
3.4 TESTS ON LIFT SYSTEM ANALOG SIGNALS .......268
3.5 TESTS ON LIFT SYSTEM DIGITAL LIFHT .............268
3.6 TESTS ON SUSPENSION ......................................269
3.7 TESTS ON PTO ......................................................269
3.8 MISCHELLANEOUS ...............................................270
3.9 TEST ON EEPROM MEMORY BLOCK 1 ..................270
3.10 TEST ON EEPROM MEMORY BLOCK 2 ................271
4. ALARM MENU ................................................................272
4.1 HPSA CONTROL UNIT ACTIVE AND PASSIVE
ALARMS...........................................................................272
4.2 ENGINE CONTROL UNIT ACTIVE AND PASSIVE
ALARMS ...........................................................................273
4.3 TRANSMISSION CONTROL UNIT ACTIVE
AND PASSIVE ALARMS.................................................. 273
4.4 ARMREST ACTIVE AND PASSIVE ALARMS .........274
4.5 CLEAR PASSIVE ALARMS ....................................274
7. ARMREST TESTER MANUAL ...................................... 275
PRESENTATION SCREEN ....................................................275
MAIN MENU ..........................................................................275
1. MONITOR .......................................................................276
2. TESTS MENU ..................................................................277
2.1 JOYSTICK ..............................................................277
2.2 EXTERNAL CONSOLE ...........................................278
2.3 INT. CONSOLE ......................................................278
2.4 HOIST .....................................................................279
2.5 POWER SUPPLIES 2 ................................................79
2.6 LEDS TEST ............................................................280
3. CALIBRATIONS MENU ...................................................280
3.1. CALIBRATION OF THE HAND THROTTLE LEVER 281
3.2 CALIBRATION OF JOYSTICK
FOR CONTROL VALVES N° 3 & N°4 .............................281
4. ALARM LIST ...................................................................282
8. OPERATORS MANUAL EDS
(Electronic Diagnosis System) .................................... 283
1. GENERAL INTRODUCTION ............................................283
1.1 FUNCTIONAL SCOPE ...........................................283
1.2 HARDWARE REQUIREMENTS ..............................284
1.2.1 INTERFACE CABLE (SERIAL) ........................ 284
1.2.2 ADAPTER CABLE FOR CENTRAL
DIAGNOSIS INTERFACE................................ 285
1.2.3 SYSTEM REQUIREMENTS ............................285
1.2.4 SOFTWARE INSTALLATION ..........................286
1.3 STARTING AND TERMINATING OF THE
EDS PROGRAM .....................................................286
1.3.1 STARTING OF THE EDS PROGRAM .............286
1.3.2 Terminating of the EDS program ....................287
2. TRANSMISSION DIAGNOSIS .........................................288
2.1 THE MAIN MENU ......................................................288
2.1.1 SCREEN AND MENU STRUCTURE ...............288
2.1.2 FILE ................................................................288
2.1.3 CONTROL ......................................................289
2.1.4 OPTIONS ........................................................289
2.2 ONLINE HELP 2........................................................90
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45 .291
3.1 PREPARATIONS FOR TRANSMISSION DIAGNOSIS
WITH DEST 45 ......................................................291
3.2 DEST 45 PROGRAM DESCRIPTION ...................292
3.2.1 FILE >MAIN MENU .........................................292
3.2.2 MENU DIAGNOSIS .........................................293
3.2.3 CONTROL ......................................................300
3.2.4 OPTIONS ........................................................305
3.3 ERROR CODES POWER-SHUTTLE /DEST 45.......307
3.4 DISPLAY POWERSHUTTLE ...................................308
3.5 ERROR CODE LIST WITH DESCRIPTION .............309
3.6 OTHER INFORMATIONS ........................................320
3.7 SENSORS AND SOLENOID VALVES AT
THE TRANSMISSION T-7100 ................................321
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100 .......322
3.9 SENSORS AND SOLENOID VALVES AT THE
TRANSMISSION T-7200 ........................................323
3.10 ELECTRO-HYDRAULIC GEAR SHIFT
T-7200 / T-7300 ..................................................... 324
3.11 ERROR ANALYSIS ................................................ 325
3.11.1 VA SOLENOID VALVE AND TEMPERATURE
SENSOR T-7100 L AND T-7200 L ................. 325
3.11.2 SV DIFFERENTIAL LOCK AND SV POWER
TAKE OFF CLUTCH T-7100 L AND T-7200 L 325
3.11.3 SPEED SENSORS INPUT/OUTPUT
WITH T-7100 L ............................................... 325
3.11.4 LOCKING MAGNET FIELD/STREET AND
TEMPERATURE SENSOR T-7100 L .............. 326
3.11.5 PLUG DRIVING CLUTCH NHK ON
OUTPUT/GROUND SPEED NAB AND
VICE VERSA WITH T-7200 L
(both plugs are connected) ............................ 326
4. PREPARATIONS FOR DIAGNOSIS OF THE
INFOCENTER ................................................................. 327
4.1 PROGRAM DESCRIPTION .................................... 328
4.1.1 MAIN MENU ................................................... 328
4.1.2 F1 CONSTANTS CHANGE .......................... 329
4.1.3 F2 DIAGNOSIS PRINT ................................ 330
4.1.4 F3 TEST MODE ........................................... 331
4.1.5 END =QUIT THE INFOCENTER PROGRAM .. 337
4.2 CONSTANT VALUES FOR INFOCENTER ...................... 338
9. SERDIA (LEVEL III) ....................................................... 343
1. SETUP AND COMMUNICATIONS .................................... 343
1. 1 MINIMUM EQUIPMENT REQUIRED ...................... 343
1.1.1 CONTROL UNITS .......................................... 343
1.1.2 DIAGNOSTIC CONNECTOR .......................... 343
1.1.3 INTERFACE .................................................... 343
1.1.4 PC/ NOTEBOOK ............................................ 343
1.2 ORDERING ............................................................ 344
1.2.1FIRST-TIME USERS .............................................. 344
1.2.2 ORDERING SINGLE PARTS .......................... 344
1.2.3 ADAPTER ....................................................... 344
1.2.4 SERDIA UPDATES.......................................... 344
1.3 SWITCHING ON AND INSTALLING THE
SOFTWARE ........................................................... 345
1.3.1 INSTALLING MS WINDOWS ......................... 345
1.3.2 INSTALLING SERDIA FROM DISKETTES ..... 345
1.3.3 INSTALLING SERDIA FROM
THE SERPIC CD ............................................. 346
1.3.4 USER LEVEL, ACCESS RIGHTS ................... 346
1.3.5 SETTING UP THE LINK BETWEEN
CONTROL MODULE (ENGINE)
AND NOTEBOOK ........................................... 347
1.3.6 STARTING THE PROGRAM ........................... 347
1.3.7 SETTING UP COMMUNICATIONS
WITH THE CONTROL UNIT (ECU).................. 348
1.3.8 OFF-LINE MODE ............................................ 348
1.3.9 PASSWORD-PROTECTED MODE ................. 349
1.3.10 DEMO MODE
(TRAINING WITH NO CONTROL UNIT) ......... 349
1.4 USING THE PROGRAM ......................................... 349
1.4.1 MAIN SCREEN, MENU SELECTION .............. 350
1.4.2 "ECU SELECTION MENU.............................. 351
1.4.3 MEASURED VALUES" ("ACTUAL
MEASURED VALUES) MENU ...................... 351
1.4.4 "PARAMETERS" MENU ................................. 351
1.4.5 "ERROR MEMORY" MENU ........................... 351
1.4.6 "FUNCTION TEST" MENU ............................. 352
1.4.7 "EXTRAS" MENU ........................................... 352
1.4.8 HELP .............................................................. 352
1.5 CLOSING THE PROGRAM ............................................. 352
2. ECU SELECTION ............................................................353
2.1 SELECTING TWO CONTROL UNITS ..............................353
2.2 PRINTING ........................................................................354
2.3 PROTOCOL .....................................................................355
2.4 IDENTIFICATION AND MEASUREMENT DATA ..............355
2.4.1 EMR1 ..............................................................355
2.4.2 EMR2 ..............................................................356
3. MEASURED VALUES 3......................................................57
3.1 ACTUAL MEASURED VALUES (GENERAL) ...........357
3.1.1 MEASURED VALUE SELECTION ...................358
3.1.2 GRAPHICS ......................................................361
3.2 RAM-VALUES .........................................................362
3.3 DATA LOGGER (ONLY EMS2) ...............................366
3.4 INPUT/OUTPUT ASSIGNMENT ............................366
3.5 CAN STATUS .........................................................366
4. PARAMETERS .................................................................369
4.1 CONFIGURATION (GENERAL) ...............................369
4.2 OVERALL PROGRAMMING ...................................370
4.3 CALIBRATION ........................................................371
5. ERROR MEMORY .............................................................372
5.1 GENERAL ...............................................................372
5.2 ERROR TABLE .......................................................373
5.2.1 EMR1 ERROR TABLE .....................................373
5.1.2 EMR2 ERROR TABLE .....................................377
5.1.3 ERROR MEMORY 2 ........................................382
6. EXTRAS .............................................................................383
6.1 MAXIMUM SPEED .................................................383
6.2 LOGISTIC DATA ....................................................383
6.3 LOAD SPECTRUM .................................................384
6.4 MAINTENANCE INTERVAL EXCEEDED .................384
6.5 OVERRIDE MEMORY .............................................384
6.6 MAINTENANCE DATA ..............................................84
7. TASKS ...............................................................................385
7.1 EMR1 ......................................................................385
7.1.1 EXAMPLE GOVERNOR SETTING .....................85
7.1.2 EXAMPLE SPEED DROOP SETTING .............387
7.1.3 DEFINE INPUTS AND OUTPUTS ...................388
8. WHAT TO DO IF...? 389
8.1 SERDIA GENERAL .................................................389
8.1.1 ERROR WHILESETTING UP
COMMUNICATIONS .......................................389
8.1.2 INTERFACE CONFIGURATION WITH
ISETUP ............................................................390
8.1.3 ACCESS CONFLICTS IN WINDOWS 3.1 .......390
8.1.4 ERROR MESSAGE IN WINDOWS
3.11 WHEN STARTING SERDIA .....................390
8.2 EMR1 ......................................................................391
8.2.1 ENGINE SURGES ..........................................391
8.2.2 ACCELERATOR PEDAL CALIBRATION .........393
8.2.3 MANUAL THROTTLE CALIBRATION .............394
8.2.4 EXAMPLE OF FAULT FINDING ......................395
8.2.5 ENGINE DOES NOT START ...........................396
8.2.6 ENGINE STOPS FOR NO KNOWN REASON .397
8.2.7 REPLACING THE EMR1 ACTUATOR .............397
8.2.8 CONTROL UNIT REPLACEMENT ..................399
8.2.9 ERROR READING THE CONFIGURATION
DATA ...............................................................401
ACCESSORIES
TOWING HITCH REMOTE CONTROL AND RENEWAL
OF THE CONTROL CABLE
Removal.................................................................. 132
Refitting .................................................................. 133
AIR COMPRESSOR
Removal.................................................................... 22
Refitting .................................................................... 23
FLEXIBLE COUPLING OF THE FRONT PTO
(Models with front PTO only)
Removal and refitting ............................................... 59
FRONT PTO ASSEMBLY
Removal.................................................................... 96
Refitting .................................................................... 97
RENEWAL OF THE TRAILER AIR BRAKES
COUPLING VALVES
Removal and refitting ............................................... 33
TRAILER BRAKING VALVES AND AIR RESERVOIR
(Version with air trailer braking)
Removal.................................................................... 27
Refitting .................................................................... 32
AIR CONDITIONING
COMPRESSOR DRIVEBELT
Adjusting................................................................... 36
Discharging, flushing and recharging....................... 37
CONDENSER
Removal.................................................................... 43
Refitting .................................................................... 44
AIR CONDITIONING COMPRESSOR
Removal.................................................................... 38
Refitting .................................................................... 39
AIR CONDITIONING EVAPORATOR
Removal.................................................................. 178
Refitting .................................................................. 179
RECEIVER-DRIER
Removal and refitting ............................................... 40
AIR CONDITIONING SYSTEM
Operation.................................................................. 35
Maintenance............................................................. 36
CLIMATE CONTROL PANEL
Removal and refitting ............................................. 172
HEATER MATRIX
Removal.................................................................. 175
Refitting .................................................................. 177
HEATER VALVE
Renewal .................................................................. 173
CONDENSER FAN
Removal and refitting................................................ 41
RIGHT-HAND AIR CONDITIONING FAN
Removal and refitting.............................................. 180
COMPRESSOR FAN - RENEWAL AND
TENSIONING OF THE DRIVEBELTS
Removal.................................................................... 19
Refitting ................................................................... 21
LEFT-HAND AIR CONDITIONING FAN
Removal and refitting.............................................. 181
CAB
CAB
Removal.................................................................. 194
Refitting ................................................................. 202
GEARSHIFT CONTROL CABLES
Renewal .................................................................. 136
CAB DOOR CABLE
Renewal .................................................................. 182
RIGHT-HAND CONSOLE CONTROLS
Removal and refitting.............................................. 166
RIGHT-HAND CONSOLE
Removal.................................................................. 150
Refitting .................................................................. 156
LEFT-HAND CONSOLE
Removal.................................................................. 157
Refitting .................................................................. 158
CENTRE CONSOLE AND SHROUD
Removal.................................................................. 146
Refitting .................................................................. 149
STEERING COLUMN SWITCH UNIT AND THE
SHUTTLE CONTROL LEVER
Removal and refitting.............................................. 144
TRANSMISSION STATUS DISPLAY
Removal and refitting.............................................. 185
GEARSHIFT LEVER
Removal and refitting.............................................. 134
TRAILER BRAKING AIR PRESSURE GAUGE
Removal and refitting.............................................. 184
ARMREST CONTROL PANELS
Removal.................................................................. 139
Refitting .................................................................. 141
CAB ACCESS STEPS
Removal and refitting ................................................13
DRIVER'S SEAT AND MULTIFUNCTION ARMREST
Removal and refitting ..............................................138
RENEWAL OF THE CAB AIR SPRINGS AND
HYDRAULIC DAMPERS ............................................ 203
STEERING WHEEL, STEERING COLUMN
SWITCH UNIT AND INSTRUMENT PANEL
Removal ..................................................................142
Removal and refitting ..............................................143
CHASSIS
BATTERY
Removal and refitting ................................................12
4WD PROPELLER SHAFT
Removal ....................................................................66
Refitting .....................................................................67
FRONT BEARING OF THE 4WD PROPELLER SHAFT
Removal ....................................................................68
Refitting .....................................................................69
FRONT FENDERS
Removal and refitting ................................................87
FRONT WHEELS
Removal and refitting ................................................86
REAR WHEELS
Removal and refitting ................................................88
FUEL TANKS
Removal ..................................................................112
Refitting ...................................................................113
BATTERY SUPPORT
Removal and refitting ................................................14
TOWING HITCH AND SUPPORT
Removal ..................................................................219
Refitting ...................................................................220
CREEPER CABLE
CREEPER CONTROL CABLE
Removal ..................................................................170
Refitting ...................................................................171
ELECTRICAL AND ELECTRONIC
SIDE PANELS
ENGINE ECU
Removal ..................................................................163
Refitting ...................................................................163
ELECTRONIC CONTROL UNITS
Removal ..................................................................159
Refitting ...................................................................160
FUSE AND RELAY BOARD
Removal ..................................................................161
Refitting ...................................................................162
PEDAL AND RELATED DEVICES ............................. 164
ACCELERATOR POTENTIOMETER
Refitting ...................................................................111
ENGINE
ALTERNATOR
Removal ....................................................................17
Refitting .....................................................................18
COMPLETE AIR CLEANER ASSEMBLY
Removal and refitting ............................................... 62
FLUID COUPLING AND THE FLYWHEEL
(only for models 235-265)
Removal ................................................................. 210
Refitting .................................................................. 216
FLEXIBLE COUPLING
Removal and refitting ............................................. 209
SILENCER
Removal ................................................................... 64
Refitting .................................................................... 65
ENGINE
Removal ................................................................. 205
Refitting .................................................................. 208
STARTER MOTOR
Removal ................................................................... 15
Refitting .................................................................... 16
AIR INTAKE PIPE
Removal and refitting ............................................... 61
EXHAUST PIPE 6
Removal and refitting ............................................... 63
TURBOCHARGER
Refitting .................................................................... 60
ENGINE HOOD AND SIDE PANELS
ENGINE HOOD AND SIDE PANELS
Removal ..................................................................... 9
Refitting .................................................................... 11
FRONT AXLE
FRONT AXLE AND SWINGING SUPPORT
Removal ................................................................. 103
Refitting .................................................................. 106
FRONT SUSPENSION CYLINDERS
Removal ................................................................... 98
Refitting .................................................................. 100
Renewal and checking ........................................... 101
FRONT SUSPENSION SOLENOID VALVES
Removal ................................................................. 108
Refitting .................................................................. 109
CALIBRATION OF THE FRONT SUSPENSION
POSITION SENSOR
Removal end calibration......................................... 110
FRONT CARRIER
Removal and refitting ............................................. 107
FRONT LIFT
REMOVAL OF THE FRONT LIFT VALVE BLOCK
Removal and refitting ............................................... 89
FRONT LIFT CYLINDERS
Removal ................................................................... 90
Refitting .................................................................... 92
FRONT LIFT ASSEMBLY
Removal ................................................................... 93
Refitting .................................................................... 95
HYDRAULIC BRAKES
BRAKE MASTER CYLINDERS
Removal ................................................................... 70
Refitting .................................................................... 72
ADJUSTMENT OF THE PARKING BRAKES.............168
ADJUSTMENT OF THE BRAKE LIGHT SWITCHES...75
ADJUSTMENT OF THE PARKING BRAKE SWITCH167
RENEWAL OF THE PARKING BRAKE CABLE.........169
BLEEDING THE BRAKING SYSTEM...........................73
HYDRAULIC SYSTEM
AUXILIARY SPOOL VALVE STACK
Disassembly ........................................................... 192
Assembly ................................................................ 193
TESTING THE AUXILIARY SERVICES PUMPS ........114
HYDRAULIC SERVICES CONTROL VALVE
Removal.................................................................. 186
Refitting .................................................................. 191
PISTON PUMP
Removal.................................................................. 118
Refitting .................................................................. 120
HYDRAULIC SERVICES OIL RESERVOIR
Removal.................................................................. 115
Refitting .................................................................. 117
PRIORITY VALVE
Removal.................................................................. 121
Refitting .................................................................. 122
LIFT
LOWER LINKS OF THE HYDRAULIC LINKAGE
Removal.................................................................. 217
Refitting .................................................................. 218
LIFT CYLINDERS
Removal.................................................................. 123
Refitting .................................................................. 124
Disassembly and assembly.................................... 125
LIFT DRAFT SENSOR
Removal and refitting ............................................. 131
TESTING THE LIFT POSITION SENSOR
Testing.................................................................... 126
Removal and refitting ............................................. 127
RADIATORS - COOLERS
COMPLETE RADIATOR-COOLERS ASSEMBLY
Removal.................................................................... 53
Refitting .................................................................... 57
INTERCOOLER
Removal.................................................................... 45
Refitting ................................................................... 47
RADIATOR
Removal.................................................................... 50
Refitting .................................................................... 52
FUEL COOLER
Removal and refitting ............................................... 42
GEARBOX OIL AND HYDRAULIC SERVICES
OIL COOLERS
Removal.................................................................... 48
Refitting .................................................................... 49
EXPANSION TANK
Removal and refitting ............................................... 58
STEERING SYSTEM
STEERING UNIT
Removal.................................................................... 76
Refitting .................................................................... 77
Disassembly and assembly ...................................... 78
POWER STEERING PUMP
Removal.................................................................... 24
Refitting .................................................................... 26
THE STRUCTURE OF THE UNIT........................................... 1
HOW TO CONSULT THE UNIT .............................................. 2
1. INTRODUCTION
1.1 List of wiring harnesses................................................. 3
1.2 Definition of components and symbols......................... 4
1.3 General rules ................................................................. 4
1.4 Diagnostic instruments.................................................. 6
1.5 Wire colour codes ......................................................... 6
2. INDICES
2.1 Component description index....................................... 7
2.2 Component code index............................................... 12
2.3 Connector index.......................................................... 17
3. COMPONENTS
3.1 Connector layouts ....................................................... 25
3.2 Component technical data.......................................... 29
3.3 Pinouts and descriptions of electronic control units... 38
4. SYSTEMS
4.1 Earthing points.......................................................... 45
4.2 Starting ..................................................................... 46
4.3 Preheating................................................................. 47
4.4 Electrical engine control ........................................... 48
4.5 Lights - steering column switch unit
(without front lift) ....................................................... 49
4.6 Lights - steering column switch unit (with front lift) .. 50
4.7 Cab accessories ....................................................... 51
4.8 Worklights (without front lift) ..................................... 52
4.9 Worklights (with front lift) .......................................... 53
4.10 Windscreen wipers ................................................... 54
4.11 Infocenter .................................................................. 55
4.12 Power outlet sockets ................................................ 56
4.13 Radio - cb ................................................................. 57
4.14 Diagnostics sockets canbus .................................. 58
4.15 Air conditioning - heater fans.................................... 59
4.16 Braking system ......................................................... 60
4.17 Trailer brakes ............................................................ 61
4.18 Front axle suspension............................................... 62
4.19 Transmission............................................................. 63
4.20 Asm - 4wd differential ............................................ 64
4.21 Electronic lift (with ab position sensor) ..................... 65
4.22 Front and rear ptos ................................................... 66
4.23 Solenoid-operated valves ......................................... 67
4.24 Electronic lift (with bosch position sensor) ............... 68
5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS,
CONNECTOR POSITIONS
0.010.2562.2 Air conditioning wiring (cab) ............... 143
0.012.2010.4 Fender wiring ...................................... 113
0.012.2018.4/10 Number plate light wiring.................... 114
0.012.3654.4/10 Wiring for air trailer braking ................ 110
0.012.3655.4/10 Wiring for hydraulic and air trailer
braking (ITALY) ................................... 109
0.012.4027.4/20 Front axle suspension wiring.............. 105
0.013.1007.4 Side console wiring
(with ab lift position sensor)................ 125
0.013.1007.4/10 Side console wiring
(with bosch lift position sensor) .......... 128
0.013.1201.4/10 Front console wiring ........................... 119
0.013.1211.4/10 Transmission wiring
(with ab lift position sensor).................. 89
0.013.1211.4/20 Transmission wiring
(with bosch lift position sensor) ............ 91
0.013.1320.4/10 Engine wiring ........................................ 75
0.013.1324.4/10 Engine hood wiring............................... 85
0.013.2588.4 Optional control valves wiring .............. 93
0.013.4085.4 Extension wiring for front lights ............ 86
0419.9869 Engine wiring (KHD).............................. 69
0441.2045 Windscreen wiper motor wiring.......... 156
0441.6727 Wiring for front lower worklights
(on cab) (with front lift) ........................ 164
0442.5602 Wiring for front lower worklights
(on cab) (without front lift)................... 164
0443.4993 Front and rear wiring for upper
worklights ........................................... 165
0443.6707 EXtension rotating beacon ................. 155
0443.7851/10 Roof wiring.......................................... 153
0443.8656 Lights selector switch ........................ 171
0441.1923.4 Cab lower headlights wiring ............... 163
0443.7875.01 Display wiring ..................................... 149

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