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Same Explorer 75 85 95 workshop service repair manual

It is workshop manual for Same tractors. Models included:
75
85
95

language:english
number of pages: 872 (full digital version)

Main sections:
Introduction
Safety sections
1. TRANSMISSION....................................................................... 1
INTRODUCTION....................................................................... 1
DESCRIPTION.......................................................................... 2
1.1 CLUTCH HOUSING
(for versions without hydraulic shuttle)........................... 3
1.2 CLUTCH HOUSING AND HYDRAULIC
SHUTTLE ASSEMBLY.................................................... 4
1.3 HML UNIT....................................................................... 5
1.4 GEARBOX AND SHUTTLE ASSEMBLY......................... 6
1.4.1 5 -SPEED GEARBOX WITH MECHANICAL
SHUTTLE AND UNDERDRIVE ............................. 6
1.4.2 5-SPEED GEARBOX WITH MECHANICAL
SHUTTLE AND HML UNIT ................................... 7
1.4.3 5-SPEED GEARBOX WITH HYDRAULIC
SHUTTLE AND HML UNIT ................................... 8
1.5 BEVEL PINION AND RANGE GEARBOX ....................... 9
1.5.1 VERSIONS WITH 3 RANGE GEARS .................... 9
1.5.2 VERSIONS WITH 4 RANGE GEARS .................. 10
1.6 4WD ENGAGEMENT AND PARKING
BRAKE ASSEMBLY...................................................... 11
1.7 DIFFERENTIAL UNIT.................................................... 12
1.7.1 VERSION WITHOUT SBA................................... 12
1.7.2 VERSION WITH SBA.......................................... 13
1.8 BRAKES AND REAR AXLE ASSEMBLY....................... 14
2. REAR PTO ............................................................................. 15
DESCRIPTION........................................................................ 15
2.1 PTO CONTROL CLUTCH ASSEMBLY......................... 16
2.2 2-SPEED PTO AND GROUNDSPEED PTO.................. 19
2.3 2-SPEED PTO AND GROUNDSPEED PTO.................. 20
3. FRONT AXLE......................................................................... 21
3.1 FINAL DRIVE ................................................................ 22
3.2 PINION, DIFFERENTIAL AND DIFFERENTIAL
LOCK (version without SBA) ........................................ 23
3.3 PINION, DIFFERENTIAL AND DIFFERENTIAL
LOCK (version with SBA).............................................. 24
4. HYDRAULIC SYSTEM .......................................................... 25
DESCRIPTION........................................................................ 25
4.1 STEERING AND SERVICES HYDRAULIC CIRCUIT
(basic version)............................................................... 26
4.2 STEERING AND SERVICES HYDRAULIC CIRCUIT
(version with HML)........................................................ 27
4.3 STEERING AND SERVICES HYDRAULIC CIRCUIT
(version with hydraulic shuttle) ..................................... 28
4.4 STEERING AND SERVICES HYDRAULIC CIRCUIT
(version with HML and hydraulic shuttle) ..................... 29
4.5 LIFT AND AUXILIARY SERVICES HYDRAULIC
DIAGRAM (basic version)..............................................30
4.6 LIFT AND AUXILIARY SERVICES HYDRAULIC
DIAGRAM (full optional version)....................................31
4.7 STEERING CIRCUIT GEAR PUMP................................32
4.8 LIFT CIRCUIT GEAR PUMP..........................................33
4.9 POWER STEERING.......................................................34
4.10 HML SOLENOID VALVES (version without
hydraulic shuttle............................................................35
4.11 HML SOLENOID VALVES (version with
hydraulic shuttle) ...........................................................36
4.12 HYDRAULIC SHUTTLE SOLENOID VALVES
(version without HML) ...................................................37
4.13 HYDRAULIC SHUTTLE SOLENOID VALVES
(version with HML) ........................................................38
4.14 SERVICES SOLENOID VALVES (version without SBA) 39
4.15 SERVICES SOLENOID VALVES (version with SBA)......40
4.16 Pressure control valves.................................................41
4.17 AUXILIARY SERVICES CONTROL VALVE....................42
4.18 HYDRAULIC LIFT CONTROL VALVE............................43
4.18.1 FUNCTION ........................................................44
4.18.2 OPERATION ......................................................45
4.19 ELECTRONIC LIFT CONTROL VALVE..........................49
5. BRAKING SYSTEM...............................................................51
DESCRIPTION.........................................................................51
5.1 SEPARATE-BRAKES VALVE....................................52
5.1.1 FUNCTION ..........................................................52
5.1.2 OPERATION ........................................................54
5.2 TRAILER BRAKING VALVE .........................................57
5.2.1 HYDRAULIC TRAILER BRAKING
(ITALY VERSION)................................................57
5.2.2 HYDRAULIC TRAILER BRAKING
(EXPORT VERSION) ..........................................59
5.2.3 AIR TRAILER BRAKING (ITALY VERSION) ......61
5.2.4 AIR TRAILER BRAKING (EXPORT VERSION) .62
5.2.5 PRESSURE LIMITING VALVE ...........................63
5.2.6 TRAILER BRAKING VALVE (2-WAY).................64
5.2.7 TRAILER BRAKING VALVE (1-WAY).................65
1. DIAGNOSIS TOOLS .......................................................... 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 CONFIGURING THE SERIAL PORTS........................ 5
2. CONNECTION OF THE TESTER TO THE ELECTRONIC
CONTROL UNITS .............................................................. 7
2.1 CONNECTING ART® TO THE HYDRAULIC LIFT AND
ENGINE CONTROL UNITS7
3. INTRODUCTION TO THE ELECTRONIC SYSTEM
OF THE TRACTOR............................................................ 9
3.1 ENGINE ECU ...................................................................... 9
3.2 PREHEATING ECU ........................................................... 10
3.3 LIFT ECU .......................................................................... 10
3.3.1 HYDRAULIC LIFT SYSTEM..................................... 10
3.3.2 SBA TRACTION CONTROL SYSTEM ..................... 12
3.4 SBA ECU .......................................................................... 13
3.5 SHUTTLE ECU ................................................................. 14
3.5.1 SHUTTLE ELECTRONIC CONTROL SYSTEM........ 14
3.5.2 HML UNIT ELECTRONIC CONTROL SYSTEM....... 15
3.6 HML ECU ......................................................................... 16
4. PUTTING THE TRACTOR INTO SERVICE .................... 17
4.1 INTRODUCTION ............................................................... 17
4.2 RENEWAL OF THE ENGINE ECU ..................................... 17
4.2.1 SETTING THE TYPE OF ENGINE............................ 17
4.2.2 CALIBRATION OF THE HAND THROTTLE ............. 19
4.2.3 CURRENT CALIBRATION AT 1400 rpm.................. 21
4.2.4 CONFIGURATION OF THE WHEELS PARAMETER 22
4.3 RENEWAL OF THE LIFT ECU .......................................... 24
4.3.1 CONFIGURATION FOR PRESENCE OF
THE RADAR............................................................. 24
4.3.2 CONFIGURATION OF THE WHEELS PARAMETER 26
4.3.3 CALIBRATION OF THE MINIMUM LIFT HEIGHT.... 27
4.3.4 CALIBRATION OF THE MAXIMUM LIFT HEIGHT... 29
4.3.5 CALIBRATION OF THE STEERING
SENSOR (for versions with SBA only) ..................... 30
4.3.6 CANCELLING ALARMS........................................... 31
4.4 RENEWAL OF THE SHUTTLE ECU .................................. 33
4.4.1 INITIALIZATION OF THE ECU ................................. 33
4.4.2 CALIBRATION OF THE CLUTCH PEDAL................ 35
4.4.3 CONFIGURATION OF OPTIONAL EQUIPMENT ..... 36
4.4.4 CANCELLING ALARMS........................................... 38
4.4.5 NOTES REGARDING THE CLUTCH
CALIBRATION PROCEDURE................................... 39
4.4.6 NOTES ON THE CLUTCH CALIBRATION
PARAMETERS.......................................................... 40
4.4.7 NOTES ON HOW TO CHANGE PARAMETER
SETTINGS DURING MANUAL CALIBRATION ........ 41
4.4.8 AUTOMATIC CALIBRATION OF THE SHUTTLE
CLUTCHES............................................................... 41
4.4.9 MANUAL CALIBRATION OF THE SHUTTLE
CLUTCHES............................................................... 44
4.5 RENEWAL OF THE INSTRUMENT PANEL ........................47
5. ALARMS .......................................................................... 49
5.1 ENGINE ECU ALARMS
(CODE 2.8519.052.0 - Sw Ver. https://www.tradebit.com) .....................49
5.1.1 LIST OF ALARMS SIGNALLED ON THE
HOLD LIGHT 49
5.1.2 LIST OF ALARMS SIGNALLED ON THE ART .......... 49
5.2 LIFT CONTROL UNIT ELC2 ALARMS
(code 2.8519.006.0) 5 ..........................................................9
5.2.1 LIST OF ALARMS FLASHED ON LIFT CONTROL
BUTTON 59
5.2.2 LIST OF ALARMS DISPLAYED ON ART .................. 62
5.3 SHUTTLE ECU ALARMS
(code 2.8519.017.0 Sw Ver. V3.7J0) ...............................103
5.3.1 LIST OF ALARMS SIGNALLED ON THE
ALARM LIGHT 103
5.3.2 LIST OF ALARMS DISPLAYED ON THE ART ........ 107
6. ENGINE ECU TESTER .................................................. 157
PRESENTATION SCREEN ....................................................157
ENGINE TESTS ......................................................................157
1. ENGINE PARAM. .............................................................158
2. AUTOPROGRAM .............................................................158
ENGINE LIST................................................................... 160
3. CHECK.............................................................................161
3.1 HAND THROTTLE .................................................. 161
3.2 PEDAL SENSOR .................................................... 162
3.3 ACTUATOR ............................................................ 162
4. MANUAL PROG. ..............................................................163
4.1 LOW IDLE RPM PROGRAMM................................ 163
4.2 DROOP................................................................... 164
4.3 MINIMUM CURRENT............................................. 164
4.4 ADJ. https://www.tradebit.comRRENT.............................................. 165
4.5 THROTTLE PEDAL SENSIBILITY........................... 165
4.6 ADJUSTMENT HANDGAS ..................................... 166
5. PEDAL SENSOR ..............................................................167
6. ACTUATOR .....................................................................167
7. ENGINE RPM CHECK .....................................................168
8. AUTODIAGNOSIS............................................................168
7. LIFT ECU TESTER.......................................................... 169
PRESENTATION SCREEN .....................................................169
MAIN MENU...........................................................................169
1. MONITORS MENU...........................................................170
1.1 LIFT ........................................................................ 170
1.2 CONSOLLE ............................................................ 171
1.3 SBA ........................................................................ 172
1.4 ALIMENTATION ..................................................... 172
2. PARAMETERS MENU......................................................173
2.1 SPEED CONSTANT ............................................... 173
3. SETTING MENU...............................................................174
3.1 MINIMUM HEIGHT................................................. 174
3.2 MAXIMUM HEIGHT................................................ 175
3.3 STEERING.............................................................. 175
3.4 LOCK SPEED......................................................... 176
4. ALARM LIST.....................................................................176
8. SHUTTLE ECU TESTER ............................................... 177
PRESENTATION SCREEN ....................................................177
MAIN MENU...........................................................................177
1. CALIBRATIONS ..............................................................178
1.1 CLUTCH PEDAL .................................................... 178
1.2 OPTIONAL EQUIPMENT........................................ 179
2. TEST MENU.....................................................................179
2.1 SOLENOID TESTS ................................................. 180
2.2 AUTOMATIC SOLENOID TESTS ........................... 180
2.3 HARDWARE TEST ................................................. 181
3. MONITOR .......................................................................181
3.0 MISCELLANEOUS ................................................. 182
3.1 CONTROLS............................................................ 183
3.2 DIAGNOSTICS....................................................... 183
4. CALIBRATION..................................................................184
4.1 MANUAL CALIBRATION........................................ 184
4.2 AUTOMATIC CALIBRATION.................................. 186
5. ALARM LIST ....................................................................187
ENGINE HOOD AND SIDE PANELS............. 1
Removal...................................................................... 1
Refitting ...................................................................... 2
RADIATOR..................................................... 3
Removal...................................................................... 3
Refitting ...................................................................... 7
STARTER MOTOR......................................... 8
Removal...................................................................... 8
Refitting ...................................................................... 9
FENDERS..................................................... 10
Removal.................................................................... 10
Refitting .................................................................... 10
WHEELS....................................................... 11
FRONT WHEELS...........................................................11
Removal.................................................................... 11
Refitting .................................................................... 11
REAR WHEELS.............................................................12
Removal.................................................................... 12
Refitting .................................................................... 12
FRONT LIFT ................................................. 13
LIFT CYLINDERS..........................................................13
Removal.................................................................... 13
Refitting .................................................................... 14
Disassembly ............................................................. 15
Assembly .................................................................. 17
FRONT PTO................................................. 19
COMPLETE ASSEMBLY ..............................................19
Removal.................................................................... 19
Refitting .................................................................... 23
Disassembly ............................................................. 24
Assembly .................................................................. 29
PUMP ASSEMBLY........................................................36
Disassembly ............................................................. 36
Assembly .................................................................. 37
CLUTCH - BRAKE ASSEMBLY ...................................38
Disassembly ............................................................. 38
Assembly .................................................................. 43
SOLENOID VALVE ASSEMBLY...................................44
Disassembly ............................................................. 44
Assembly .................................................................. 44
FRONT AXLE DRIVE SHAFT....................... 45
Removal.................................................................... 45
Refitting .................................................................... 45
FRONT SUPPORT........................................46
Removal.................................................................... 46
Refitting .................................................................... 52
FRONT AXLE................................................53
COMPLETE AXLE ASSEMBLY....................................53
Removal.................................................................... 53
Refitting .................................................................... 54
End float adjustment................................................. 55
STEERING CYLINDERS...............................................58
Removal.................................................................... 58
Refitting .................................................................... 59
Disassembly ............................................................. 60
Assembly .................................................................. 60
PLANETARY GEAR UNIT.............................................61
Removal.................................................................... 61
Refitting .................................................................... 62
Disassembly ............................................................. 63
Assembly .................................................................. 66
STEERING ANGLE SENSOR .......................................69
Removal.................................................................... 69
Refitting .................................................................... 69
STEERING KNUCKLE HOUSING AND AXLE SHAFT 70
Removal.................................................................... 70
Refitting .................................................................... 75
Adjusting the bearings preload................................. 77
BEVEL PINION-DIFFERENTIAL ASSEMBLY..............80
Removal.................................................................... 80
Refitting .................................................................... 82
DIFFERENTIAL LOCK (Versions without SBA) ..........83
Removal.................................................................... 83
Refitting .................................................................... 85
Adjustment ............................................................... 86
DIFFERENTIAL LOCK (Version with SBA) .................90
Disassembly ............................................................. 90
Assembly .................................................................. 92
BEVEL GEAR PAIR.......................................................94
Disassembly (Version without SBA).......................... 94
Disassembly (Version with SBA)............................... 99
Adjustment of the differential preload
(versions without SBA)........................................... 109
Adjustment of the pinion and crown wheel
(versions without SBA)........................................... 113
Completion of assembly......................................... 113
Adjustment of the differential preload and pinioncrown
wheel backlash (versions with SBA) ............ 115
DIFFERENTIAL ...........................................................120
Disassembly ........................................................... 120
Assembly.................................................................121
EXHAUST PIPE (versions with cab) ........ 122
Removal ..................................................................122
Refitting...................................................................122
ENGINE...................................................... 123
Preparation before separating the engine
from the transmission.............................................123
Preparation for removal...........................................123
Separation or removal .............................................124
Refitting...................................................................129
FUEL TANK................................................ 131
Removal ..................................................................131
Refitting...................................................................132
CAB............................................................ 133
Removal ..................................................................133
Refitting...................................................................140
HYDRAULIC SHUTTLE............................. 141
COMPLETE ASSEMBLY............................................ 141
Removal ..................................................................141
Refitting...................................................................145
Disassembly............................................................146
Assembly.................................................................148
Endfloat adjustment ................................................149
CLUTCH UNITS.......................................................... 150
Disassembly............................................................150
Assembly.................................................................158
INTERMEDIATE GEAR .............................................. 166
Disassembly............................................................166
Assembly.................................................................166
INTERMEDIATE SHAFT............................................. 167
Disassembly............................................................167
Assembly.................................................................168
CLUTCH HOUSING................................... 169
COMPLETE ASSEMBLY............................................ 169
Separating clutch housing from the transmission...169
Reassembly clutch housing from the transmission 176
HML UNIT AND GEARBOX ...................... 178
COMPLETE ASSEMBLY............................................ 178
Removal ..................................................................178
Refitting...................................................................179
HML UNIT .................................................. 180
COMPLETE ASSEMBLY............................................ 180
Removal ..................................................................180
Refitting...................................................................183
Adjustment of the planet carrier assembly
end float ..................................................................184
L AND M GEAR CLUTCH UNIT.......................... 187
Assembly.................................................................189
H GEAR CLUTCH UNIT.......................................... 191
Assembly.................................................................194
PLANETARY GEAR UNIT .......................................... 195
Disassembly............................................................195
Assembly.................................................................197
GEARBOX ASSEMBLY..............................199
COMPLETE ASSEMBLY ........................................... 199
Removal ................................................................. 199
Refitting .................................................................. 200
COMPLETE ASSEMBLY (versions with HML) ........ 201
Disassembly ........................................................... 201
Assembly................................................................ 203
Adjustment of the HML output shaft end float....... 204
GEARBOX SUPPORT PLATE AND GEAR
SELECTOR RODS (versions with HML).................. 206
Disassembly ........................................................... 206
Assembly................................................................ 207
Adjustment of the secondary shaft bearing play.... 209
GEARBOX INPUT SHAFT (versions with
hydraulic shuttle)...................................................... 211
Disassembly ........................................................... 211
Assembly................................................................ 212
SHUTTLE AND UNDERDRIVE SHAFT ..................... 213
Disassembly ........................................................... 213
Assembly................................................................ 217
MAIN SHAFT.............................................................. 219
Disassembly ........................................................... 219
Assembly................................................................ 220
SECONDARY SHAFT (versions with HML).............. 221
Disassembly ........................................................... 221
Assembly................................................................ 224
SECONDARY SHAFT (versions without HML) ........ 225
Disassembly ........................................................... 225
Assembly................................................................ 228
HML UNIT OUTPUT SHAFT...................................... 230
Disassembly ........................................................... 230
Assembly................................................................ 231
REMOTE CONTROL VALVE......................232
COMPLETE ASSEMBLY ........................................... 232
Removal ................................................................. 232
Refitting .................................................................. 235
REMOTE VALVE COUPLERS ................................... 236
Removal ................................................................. 236
Refitting .................................................................. 236
REMOTE VALVES ASSEMBLY ................................. 237
Disassembly ........................................................... 237
Assembly................................................................ 238
TOWING HITCH .........................................239
Removal ................................................................. 239
Refitting .................................................................. 239
HYDRAULIC LIFT.......................................240
COMPLETE ASSEMBLY ........................................... 240
Removal ................................................................. 240
Refitting .................................................................. 242
Disassembly ........................................................... 243
Assembly ............................................................... 246
LIFT CYLINDER ......................................................... 248
Disassembly ........................................................... 248
Assembly................................................................ 248
BUSHINGS ................................................................. 250
Renewal.................................................................. 250
LIFT CONTROL VALVE ............................................. 251
Disassembly ........................................................... 251
Assembly................................................................ 254
ELECTRONIC LIFT CONTROL VALVE......................257
Removal.................................................................. 257
Refitting .................................................................. 257
MECHANICAL DRAFT SENSOR................................258
Removal.................................................................. 258
Refitting .................................................................. 258
Disassembly ........................................................... 259
Assembly................................................................ 260
3-POINT LINKAGE (versions with
mechanical lift control)............................ 261
Removal.................................................................. 261
Refitting .................................................................. 262
REAR AXLE ............................................... 263
COMPLETE ASSEMBLY ............................................263
Preparation for removal of the right axle................ 263
Preparation for removal of the left axle .................. 265
Removal of the complete rear axle......................... 268
Refitting .................................................................. 269
Disassembly ........................................................... 270
Assembly................................................................ 273
PLANETARY GEAR UNIT...........................................276
Disassembly ........................................................... 276
Assembly................................................................ 276
REAR PTO ................................................. 277
PTO INPUT SHAFT (4-speed) ....................................277
Removal.................................................................. 277
Refitting .................................................................. 278
Disassembly ........................................................... 279
Assembly................................................................ 281
PTO CLUTCH...................................................282
Removal.................................................................. 282
Refitting .................................................................. 286
Disassembly ........................................................... 288
Assembly................................................................ 292
PTO OUTPUT SHAFT (4-speed version) ..................293
Disassembly ........................................................... 293
Assembly................................................................ 296
GROUNDSPEED PTO OUTPUT SHAFT....................297
Disassembly ........................................................... 297
Assembly................................................................ 299
GROUNDSPEED PTO SELECTOR............................300
Disassembly ........................................................... 300
Assembly................................................................ 300
SERVICES SOLENOID VALVE
ASSEMBLY ............................................... 301
Removal.................................................................. 301
Refitting .................................................................. 302
HYDRAULIC PUMPS ................................ 303
HYDRAULIC PUMP FOR HYDRAULIC LIFT
AND AUXILIARY SERVICES .....................................303
Removal.................................................................. 303
Refitting .................................................................. 304
Removal.................................................................. 305
Refitting .................................................................. 305
RANGE GEARBOX AND REAR
DIFFERENTIAL ASSEMBLY .....................306
COMPLETE ASSEMBLY............................................306
Removal.................................................................. 306
Refitting .................................................................. 306
DIFFERENTIAL (versions with mechanical
engagement) .............................................................307
Removal.................................................................. 307
Refitting .................................................................. 309
Disassembly ........................................................... 310
Assembly ................................................................ 312
DIFFERENTIAL (version with SBA) ...........................313
Removal.................................................................. 313
Refitting .................................................................. 314
Disassembly of differential lock side ...................... 315
Assembly ................................................................ 318
Disassembly of crown wheel side .......................... 319
Assembly ................................................................ 321
BEVEL PINION............................................................322
Disassembly ........................................................... 322
Assembly ................................................................ 326
RANGE SELECTOR ASSEMBLY...............................328
Disassembly ........................................................... 328
Assembly ................................................................ 329
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL
(versions without SBA)330
Disassembly ........................................................... 330
Assembly ................................................................ 331
FOUR-WHEEL DRIVE ENGAGEMENT CONTROL
(versions with SBA)332
Removal.................................................................. 332
Refitting .................................................................. 333
Disassembly ........................................................... 334
Assembly ................................................................ 336
4WD OUTPUT SHAFT AND PARKING BRAKE ........337
Disassembly ........................................................... 337
Disassembly ........................................................... 338
Assembly ................................................................ 340
BEVEL GEAR PAIR.....................................................341
Preparation for adjustments ................................... 342
Adjustment of the differential bearings preload ..... 344
Adjustment of the pinion position........................... 346
Adjustment of the pinion and crown wheel ............ 350
PUMP DRIVE PTO .....................................352
OUTER GEAR .............................................................352
Disassembly ........................................................... 352
Assembly ................................................................ 353
INTERNAL GEAR........................................................354
Disassembly ........................................................... 354
Assembly ................................................................ 355
CLUTCH ASSEMBLY AND TORSIONAL
SPRING PLATE .........................................356
Removal.................................................................. 356
Refitting .................................................................. 356
BRAKES......................................................357
REAR AXLE BRAKE DISCS.......................................357
REAR AXLE BRAKE PISTON.................................... 358
Disassembly............................................................358
Assembly.................................................................358
FRONT AXLE BRAKE DISCS .................................... 360
Removal ..................................................................360
Refitting...................................................................360
FRONT AXLE BRAKE PISTON.................................. 361
Disassembly............................................................361
Assembly.................................................................361
PARKING BRAKE ...................................................... 362
Disassembly............................................................362
Assembly.................................................................363
BRAKE CYLINDERS.................................................. 364
Removal ..................................................................364
Refitting...................................................................365
BRAKING SYSTEM.................................................... 366
Brake bleeding procedure.......................................366
Bleeding the rear brakes circuit ..............................366
Bleeding the front brakes circuit .............................367
DASHBOARD............................................. 369
Removal ..................................................................369
Refitting...................................................................372
HYDROSTATIC STEERING VALVE........... 373
Removal ..................................................................373
Refitting...................................................................374
Testing the maximum operating pressure ..............374
PRESSURE RELIEF VALVE SETTING.....................374
Disassembly............................................................375
Assembly.................................................................381
SIDE CONSOLE .........................................392
Removal ................................................................. 392
Refitting .................................................................. 396
REMOTE VALVE CONTROL LEVERS.......397
Removal ................................................................. 397
Refitting .................................................................. 399
AIR CONDITIONING SYSTEM ..................400
SPECIFICATIONS................................................... 400
Operation................................................................ 401
Flushing and recharging the system ...................... 402
COMPRESSOR.......................................................... 403
Removal ................................................................. 403
Refitting .................................................................. 404
Tensioning the drivebelt ......................................... 405
HYDRAULIC TRAILER BRAKING VALVE.406
Removal ................................................................. 406
Refitting .................................................................. 406
THE STRUCTURE OF THE UNIT................................. 1
HOW TO CONSULT THE UNIT ................................... 2
1. INTRODUCTION....................................................... 3
1.1 LIST OF WIRING HARNESSES ........................................ 3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS....... 4
1.3 GENERAL RULES............................................................ 5
1.3.1 MODIFICATION OF THE TRACTOR'S
ELECTRICAL/ELECTRONIC CIRCUITS............ 5
1.3.2 MAIN WIRING FAULTS ...................................... 5
1.3.3 REMOVAL, REFITTING AND DRYING
OF CONNECTORS AND WIRING...................... 6
1.4 DIAGNOSTIC INSTRUMENTS.......................................... 7
1.5 WIRE COLOUR CODES.................................................. 7
2. INDICES.................................................................... 8
2.1 PART DESCRIPTION INDEX............................................. 8
2.2 COMPONENT CODE INDEX .......................................... 13
2.3 CONNECTOR INDEX ...................................................... 18
3. COMPONENTS ..................................................... 26
3.1 CONNECTOR LAYOUTS............................................. 26
3.2 COMPONENT TECHNICAL DATA .................................. 28
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC
CONTROL UNITS38
3.3.1 ENGINE ECU (COD. 2.8519.052/50)........................ 38
3.3.2 SBA ECU (COD. 0.011.5547.4) ................................ 38
3.3.3 PTO ECU (COD. 0.010.7749.4/30) ........................... 39
3.3.4 PREHEATING ECU (COD. 2.8519.023.0/30) ............ 39
3.3.5 HML ECU (COD. 0.010.8869.4/20) .......................... 39
3.3.6 LIFT ECU (COD. 2.8519.006.0)................................. 40
3.3.7 SHUTTLE ECU (COD. 2.8519.017.0/10) .................. 41
4. SYSTEMS ............................................................... 43
4.1 EARTHING POINTS ........................................................ 43
4.2 STARTING AND PREHEATING ........................................ 44
4.3 ELECTRONIC ENGINE CONTROL .................................. 45
4.4 LIGHTS - STEERING COLUMN SWITCH UNIT (CAB) .... 46
4.5 LIGHTS - STEERING COLUMN SWITCH UNIT
(PLATFORM) ................................................................... 47
4.6 DIAGNOSTIC ACCESSORIES (WITH SBA
WITHOUT SHUTTLE)...................................................... 48
4.7 DIAGNOSTIC ACCESSORIES (WITH LIFT
WITHOUT SHUTTLE)...................................................... 49
4.8 DIAGNOSTIC ACCESSORIES (WITH SHUTTLE) ............ 50
4.9 DIAGNOSTIC ACCESSORIES (WITH LIFT AND
SHUTTLE) ....................................................................... 51
4.10 INSTRUMENT PANEL...................................................... 52
4.11 WORKLIGHTS (CAB) ....................................................... 53
4.12 WINDSCREEN WIPERS................................................... 54
4.13 HEATING.......................................................................... 55
4.14 AIR CONDITIONING ........................................................ 56
4.15 BRAKES - HYDRAULIC TRAILER BRAKING...................57
4.16 BRAKES - AIR TRAILER BRAKING..................................58
4.17 SHUTTLE AND HML (VERSION WITH MECHANICAL
GOVERNOR) ...................................................................59
4.18 SHUTTLE AND HML (VERSION WITH ELECTRONIC
GOVERNOR) ...................................................................60
4.19 SHUTTLE (VERSION WITH MECHANICAL GOVERNOR) 61
4.20 SHUTTLE (VERSION WITH ELECTRONIC GOVERNOR).62
4.21 HML (VERSION WITH ELECTRONIC GOVERNOR).........63
4.22 HML (VERSION WITH MECHANICAL GOVERNOR) ........64
4.23 SBA (WITH LIFT)...............................................................65
4.24 SBA (WITHOUT LIFT) .......................................................66
4.25 ELECTRONIC LIFT CONTROL .........................................67
4.26 FRONT AND REAR PTO ..................................................68
5. WIRING .................................................................. 69
BATTERY WIRING....................................................................69
FRONT WIRING (1/2)................................................................75
FRONT WIRING (2/2)................................................................76
LINK BOX WIRING ...................................................................77
FRONT PTO SOLENOID VALVE WIRING................................78
CENTRAL WIRING (1/2) ...........................................................87
CENTRAL WIRING (2/2) ...........................................................88
LIGHTS WIRING (CAB).............................................................95
LOWER LIGHTS WIRING (CAB)...............................................96
UNDERBODY WIRING (WITH HYDRAULIC SHUTTLE) (1/2) 101
UNDERBODY WIRING (WITH HYDRAULIC SHUTTLE) (2/2) 102
UNDERBODY WIRING (1/2) ...................................................103
UNDERBODY WIRING (2/2) ...................................................104
CAB POWER WIRING............................................................105
AIR SPRUNG SEAT WIRING..................................................106
SCREENWASH PUMP WIRING........................................... 106
SBA PUSHBUTTON WIRING.................................................119
SBA WIRING ........................................................................ 119
ELECTRONIC GOVERNOR ENGINE WIRING.......................123
ELECTRONIC LIFT WIRING (1/2)........................................... 129
ELECTRONIC LIFT WIRING (2/2)........................................... 130
REAR WIRING (1/2) ................................................................135
REAR WIRING (2/2) ................................................................136
REAR WIRING (WITH SHUTTLE) (1/2)....................................137
REAR WIRING (WITH SHUTTLE) (2/2)....................................138
HYDRAULIC BRAKE WIRING................................................139
PNEUMATIC BRAKE WIRING.............................................. 139
ROOF WIRING (1/2)................................................................147
ROOF WIRING (2/2)................................................................148
HEATERING WIRING (1/2) .....................................................153
HEATERING WIRING (2/2) .....................................................154
AIR CONDITIONING WIRING (1/2) ........................................ 159
AIR CONDITIONING WIRING (2/2) ........................................ 160
AIR CONDITIONING FAN WIRING (1/2) ................................ 165
AIR CONDITIONING FAN WIRING (2/2) ................................ 166
LOUDSPEAKER WIRING - RADIO - REAR WIPER
- ROTATING BEACON - CLOCK.......................................... 169
FRONT WIPER WIRING......................................................... 175
WORKLIGHT WIRING............................................................ 179

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