DEUTZ-FAHR AGROTRON 106 MK3 Workshop Manual Download Page 7 | Manualshive

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00-5

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 a guide to the use of the necessary software for machine and en-
gine configuration and for diagnostic.

Section 30

Contains the methods, checks and adjustments regarding the external
components; the operations dealt with in this section do not require 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:

Engine DEUTZ 1012 - 1013

0297 9771

Italian
English
French
German

Transmission ZF 7100L

0298 6837

German

0298 6838

English

0298 6839

French

0298 6840

Spanish

Transmission ZF 7100S

0298 6871

German

0298 6872

English

0298 6873

French

0298 6874

Spanish

Rear axle 7100

0298 6877

German

0298 6878

English

0298 9879

French

0298 9880

Spanish

Trasmission/rear axle 7200 L-S-H

0298 6831

German

0298 6832

English

0298 6833

French

0298 6834

Spanish

Front axle ZF 2025-2035-2045 AS

0298 6803

German

0298 6856

English

0298 6857

French

0298 6858

Spanish

HOW THE MANUAL IS STRUCTURED

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Summary of Contents for AGROTRON 106 MK3

Page 1: ...WORKSHOP MANUAL AGROTRON 106 MK3 AGROTRON 110 MK3 AGROTRON 115 MK3 AGROTRON 120 MK3 AGROTRON 135 MK3 AGROTRON 150 MK3 AGROTRON 165 MK3 SAME DEUTZ FAHR DEUTSCHLAND GmbH ...

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Page 3: ... 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 ...

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Page 5: ...d repairs wear close fitting clothing safety goggles and protective gloves that are suitable for the task cleaning draining flu ids repairs When working near moving parts long hair should be gathered up and secured safely under a cap to prevent the risk of entanglement and sever injury 6 Do not allow anyone who is not directly involved in the work to come near the machine ensure that they remain a...

Page 6: ...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 theweightofthecomponentstoberemoved Ensure lifting equipment is attached correctly 26 When lifting or supporting an assembly or compo nent manoeuvre the parts slowly...

Page 7: ...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 Engine DEUTZ 1012 1013 0297 9771 Italian English French German Transmissi...

Page 8: ...ion regar ding refitting of the component in question Recover oil liquid or fuel and the quantity to be recov ered E g REFITTING UNIT Operation heading Refitting is the reverse of removal Technique to be applied during refitting Technique or important information regarding the refit ting operation Filling with oil or liquid with quantity 2 During removal and refitting operations in addition to the...

Page 9: ...h 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 Safety rules to be applied during operation Coating Partsmustbecoatedwithadhesive lubricant etc Ope...

Page 10: ...op rings ensure that cotter pins are bent over so that they cannot work loose Ensure that circlips are correctly installed in their seatings When applying threadlocking compound first clean the part removing all oil and grease then cover the thread evenly applying a few drops of the compound When applying sealant first clean the surface removing all traces of oil and grease and check for dirt or i...

Page 11: ...ymmetrically 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 Thepermittedload kg decreasesininverseproportiontotheangleofsuspension thetablebelowindicates howthe permittedl...

Page 12: ...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 104...

Page 13: ...e anaer obic threadlockers series 5 and 6 Can also be used toincreasecurespeed at low temperatures or in applications where thereis large gaps between the parts SEALANTS for faces and flanges Loctite 510 Colour red Super rapid anaerobic sealant for sealing between rigid metal faces can eliminate the need for conventional gaskets as it can fill gaps up to 0 4 mm Does not shrink and therefore fasten...

Page 14: ...OMPOUNDS Loctite 601 Colour fluorescent green Anaerobic fast curing high strength adhesive Suitable for sealing and retaining cylindrical assemblies with gap clearances of up to 0 10 mm used for retaining rotors gears bearings pulleys bushes etc on shafts Loctite 638 Colour fluorescent green Anaerobic structural adhesive quick curing very high strength suitable for bonding cylin drical parts in no...

Page 15: ... for mounting of steering unit inner gasket T4 00239499 Tool for mounting of steering unit dust seal T5 5 9030 743 1 Test lead for checking sensors with multimeter T6 5 9030 743 0 Test lead for checking sensors with multimeter T7 5 9030 740 0 SERDIA installation disc T8 5 9030 741 0 Adapter cable T9 5 9030 740 2 Interface level III T10 5 9030 742 0 EDS software pack SPECIAL TOOLS ...

Page 16: ...x 17 87 kg cm psi x 0 070 kg lb Imp gall x 0 100 lb US gall x 0 120 kg m lb cu ft x 16 21 Nm lb ft x 1 356 bar psi x 0 07 CONVERSIONFROMMETRICTOBRITISHUNITS inch mm x 0 0394 foot m x 3 281 yard m x 1 094 Eng miles km x 0 622 Sq in cm x 0 155 Sq ft m x 10 77 Sq yard m x 1 197 Cu in cm x 0 061 Cu ft m x 0 035 Cu yard m x 1 311 Imp gall litres x 0 220 US gall litres x 0 264 pint litres x 1 762 quart ...

Page 17: ... 2 3 4 AIR TRAILER BRAKING EXPORT VERSION 42 COMPRESSOR 43 PRESSURE LIMITING VALVE 44 CAB SUSPENSION FEED VALVE 45 TRAILER BRAKING VALVE 2 WAY 46 TRAILER BRAKING VALVE 1 WAY 47 3 HYDRAULIC FRONT AXLE SUSPENSION 48 3 1 FRONT SUSPENSION CONTROL VALVE 49 4 FRONT AXLE 53 4 1 HUB CARRIER AND FINAL REDUCTION UNIT 54 4 2 DIFFERENTIAL 56 5 HYDRAULIC SYSTEM 58 HYDRAULIC SYSTEM 106 115 CV models CCLS versio...

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Page 19: ... to change the direction of travel the command is actually only implemented when the speed of the tractor falls below 10 km h and when the operator depresses the clutch pedal In the POWER SHUTTLE version the reversal of the direction of travel is managed entirely by the electronic control unit without the operator having to depress the clutch pedal This type of control is achieved by way of a prop...

Page 20: ...ssion 5 Hydraulic gearbox control distribution valve 6 Pilot line fitting for main clutch 7 Main clutch control pump Booster 8 Transmission oil low pressure sensor 9 Gearbox output shaft speed sensor nLsa 10 Creeper engagement shaft 11 Transmission oil temperature sensor 12 Four wheel drive control solenoid valve 13 Transmission oil suction line filter 14 Speed sensor for odometer nAb 15 Rear powe...

Page 21: ...ANSMISSION MAIN COMPONENTS Power Shift version 18 Left brake cylinder 19 30 km h speed limiting pin 20 Mechanical gearbox shift lever 21 Right brake cylinder 22 Differential lock control valve 23 Differential lock control solenoid valve ...

Page 22: ...e casing 25 Lift shaft 26 Right axle casing 27 Rear PTO speed sensor 28 Gearbox oil level indicator 29 Rear reduction unit oil level indicator 24 27 25 26 28 D0004390 29 TRANSMISSION MAIN COMPONENTS Power Shift version ...

Page 23: ...ential lock control solenoid valve lubrication of the gearbox rear differential and rear PTO clutch control shaft D0004411 PTO control solenoid valve Lubrication circuit pressure relief valve Four wheel drive control solenoid valve Gearbox lubrication Gearbox control distribution valve Lubrication of rear differential Lubrication of rear PTO drive shaft Cooler not part of the transmission Temperat...

Page 24: ...rive to the front axle The POWER SHIFT transmission is equipped with a double output power take off 9 to drive the hydraulic system pumps COMPONENTS 1 Engine 2 Hydraulically controlled 8 speed gearbox 4 forward and 4 reverse 3 Creeper unit 4 Main clutch 5 6 speed mechanical gearbox 6 Pinion 7 4WD engagement clutch 8 Power take off for front axle drive 9 Power take off for hydraulic pumps D0004400 ...

Page 25: ...ly controlled gearbox 5 Clutch C 6 Clutch A 7 Creeper unit 8 Creeper unit synchronizer 9 Main clutch 10 Mechanical gearbox 11 Hydraulic pumps PTO drive gear 12 3rd and 4th speed synchronizer 13 5th and 6th speed synchronizer 14 1st and 2nd speed drive shaft 15 Rear PTO drive shaft 16 1st and 2nd speed synchronizer 17 Pinion 18 4WD control clutch 19 Creeper unit driven shaft 20 Clutch F 21 Clutch G...

Page 26: ... is entirely manual by way of the clutch pedal The system is equipped with a clutch cylinder Booster that directs fluid under pressure to the main clutch in accordance with the travel of the clutch pedal 1 Clutch pedal 2 Clutch pilot cylinder 3 Transmission gear pump 4 Clutch control cylinder Booster 5 Main clutch D0004420 3 2 1 4 5 ECU GEARBOX MAIN CLUTCH Power Shift version ...

Page 27: ...lect S H M and L ratios B the shuttle control valve 2 to select FORWARD and REVERSE gears This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox the rear differential and the rear PTO control shaft D0004430 2 1 2 1 PILOT PRESSURE VALVE 10 bar PILOT PRESSURE VALVE 18 bar P2 B1 S2 Y7 Y6 Y5 Y1 Y4 Y3 Y2 A B F G H1 G1 S1 W G2 H2 D C VR U R1 P1 CONTROL AND LU...

Page 28: ...e Pg to relief valve M10x1 e Pressure Pr from relief valve 18 bar M10x1 f Engagement pressure of clutch C or D M10x1 g General pressure 18 bar M10x1 h Engagement pressure of clutch A B or F G M10x1 l Pilot pressure 10 bar M10x1 m D clutch pressure M10x1 n C clutch pressure M10x1 p Modulated pressure M10x1 D0004440 a b c d e f g h l m n p GEARBOX GEARBOX CONTROL VALVE Power Shift version ...

Page 29: ...ilot solenoid valve for clutch selection valve G1 Y5 Pilot solenoid valve for road field selection valve Y2 Pilot solenoid valve for C or D clutch selection valve G2 P3 Pilot pressure regulating valve G2 Clutch selection valve for C or D clutches P4 General pressure regulating valve U Road field operating mode selection valve P1 Pressure modulating valve P2 2 stage valve R1 Null shift valve D00053...

Page 30: ...NENTS Y6 Pilot solenoid valve for FORWARD gear Y7 Pilot solenoid valve for REVERSE gear VR FORWARD REVERSE control spool valve S2 Relief valve 1 Neutral return device D0005330 1 1 VR Y6 Y7 S2 GEARBOX SHUTTLE CONTROL VALVE Power Shift version ...

Page 31: ...gear change L M H S L M H S Y6 Y7 Y1 Y2 Y3 Y4 Solenoid valve Forward Reverse Solenoid valve energised Solenoid valve briefly energised during gear change S H M L S H M L Y6 Y7 Y1 Y2 Y3 Y4 D0004501 L gear M gear H gear S gear Reverse Forward Neutral Output shaft Input shaft L gear M gear H gear S gear A B D F G C B D F G A C A B D F G C A B D F G C A B D F G C B D F G A C A B D F G C A B D F G C A ...

Page 32: ...al sensor S6 Transmission oil low pressure sensor 18 bar Y2 GV2 26 A13 1 V A11 B3 ED1 ED2 ED3 V ED4 R ED6 EAM3 EDM2 EAM1 EAM2 EF1 EF2 EF3 18 45 37 9 6 7 13 35 22 42 16 19 71 47 EDM1 67 17 25 27 33 5 29 51 50 30 10 SD2 AD1 AD6 AD7 AD9 SD1 SDD1 AD5 AD2 A1 E8G B2 B4 S3 A14 H4 A6 A8 A7 A5 A2 S6 A10 39 PWM1 A3 A4 S4 32 49 2 24 26 AD3 AD4 AD8 ENGINE 16 47 71 P H X 1 F1 2 KL 30 PERMANENT PLUS 1 F2 2 KL 1...

Page 33: ...l solenoid valve 5 Hydraulic pump for transmission 6 Hydraulic gearbox distribution valve 7 Transmission oil low pressure sensor 8 Gearbox output shaft speed sensor nLsa 9 Creeper engagement shaft 10 Transmission oil temperature sensor 11 Four wheel drive control solenoid valve 12 Transmission oil suction line filter 13 Speed sensor for odometer nAb 14 Clutch speed sensor nHk 15 Rear power take of...

Page 34: ...NSMISSION MAIN COMPONENTS Power Shuttle version 18 Left brake cylinder 19 30 km h speed limiting pin 20 Mechanical gearbox shift lever 21 Right brake cylinder 22 Differential lock control valve 23 Differential lock control solenoid valve ...

Page 35: ... casing 25 Lift shaft 26 Right axle casing 27 Rear PTO speed sensor 28 Gearbox oil level indicator 29 Rear reduction unit oil level indicator 24 27 25 26 28 D0004390 29 TRANSMISSION MAIN COMPONENTS Power Shuttle version ...

Page 36: ...ifferential lock control solenoid valve lubrication of the gearbox rear differential and rear PTO clutch control shaft D0005181 Main clutch Proportional solenoid valve PTO control solenoid valve Lubrication circuit pressure relief valve Four wheel drive control solenoid valve Gearbox lubrication Gearbox control distribution valve Lubrication of rear differential Lubrication of rear PTO drive shaft...

Page 37: ...e drive to the front axle The POWER SHUTTLE transmission is also equipped with a double output power take off 9 to drive the hydraulic system pumps COMPONENTS 1 Engine 2 Hydraulically controlled 8 speed gearbox 4 forward and 4 reverse 3 Creeper unit 4 Main clutch 5 6 speed mechanical gearbox 6 Pinion 7 4WD engagement clutch 8 Power take off for front axle drive 9 Power take off for hydraulic pumps...

Page 38: ...lly controlled gearbox 5 Clutch C 6 Clutch A 7 Creeper unit 8 Creeper unit synchronizer 9 Main clutch 10 Mechanical gearbox 11 Hydraulic pumps PTO drive gear 12 3rd and 4th speed synchronizer 13 5th and 6th speed synchronizer 14 1st and 2nd speed drive shaft 15 Rear PTO drive shaft 16 1st and 2nd speed synchronizer 17 Pinion 18 4WD control clutch 19 Creeper unit driven shaft 20 Clutch F 21 Clutch ...

Page 39: ... 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 position 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 D0005200 4 1 5 6 3 ECU 2 GEARBOX MAIN CLUTCH ...

Page 40: ...ct S H M and L ratios B the shuttle control valve 2 to select FORWARD and REVERSE gears This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox the rear differential and the rear PTO control shaft PILOT PRESSURE VALVE 10 bar PILOT PRESSURE VALVE 18 bar P2 B1 S2 Y7 Y6 Y5 Y1 Y4 Y3 Y2 A B F G H1 G1 S1 W G2 H2 D C VR U R1 P1 P4 P4 VR1 VR2 Y8 CONTROL AND LUBR...

Page 41: ... Pg to relief valve M10x1 e Pressure Pr from relief valve 18 bar M10x1 f Engagement pressure of clutch C or D M10x1 g General pressure 18 bar M10x1 h Engagement pressure of clutch A B or F G M10x1 l Pilot pressure 10 bar M10x1 m D clutch pressure M10x1 n C clutch pressure M10x1 p Modulated pressure M10x1 D0004440 a b c d e f g h l m n p GEARBOX GEARBOX CONTROL VALVE Power Shuttle version ...

Page 42: ...ilot solenoid valve for clutch selection valve G1 Y5 Pilot solenoid valve for road field selection valve Y2 Pilot solenoid valve for C or D clutch selection valve G2 P3 Pilot pressure regulating valve G2 Clutch selection valve forC or D clutches P4 General pressure regulating valve U Road field operating mode selection valve P1 Pressure modulating valve P2 2 stage valve R1 Null shift valve D000532...

Page 43: ...ENTS Y6 Pilot solenoid valve for FORWARD gear Y7 Pilot solenoid valve for REVERSE gear VR FORWARD REVERSE control spool valve S2 Relief valve 1 Neutral return device D0005330 1 1 VR Y6 Y7 S2 GEARBOX SHUTTLE CONTROL VALVE Power Shuttle version ...

Page 44: ...ng gear change L M H S L M H S Y6 Y7 Y1 Y2 Y3 Y4 Solenoid valve Forward Reverse Solenoid valve energised Solenoid valve briefly energised during gear change S H M L S H M L Y6 Y7 Y1 Y2 Y3 Y4 D0004501 L gear M gear H gear S gear Reverse Forward Neutral Output shaft Input shaft L gear M gear H gear S gear A B D F G C B D F G A C A B D F G C A B D F G C A B D F G C B D F G A C A B D F G C A B D F G C...

Page 45: ... B3 ED 11 ED 8 EU 1 ED 6 ED 7 ED 2 ED 3 ED 12 EDM 1 ER 1 EF 7 59 44 38 67 22 65 20 30 31 39 17 SD 2 57 11 56 5 55 29 ADM 5 ADM 4 AIP 4 ADM 6 EST 45 B4 B1 A5 H3 A9 A2 1 S7 S6 A10 40 EF 6 S4 32 AIP 3 ENGINE B9 63 16 62 ED 1 EF 5 EF 4 A1 A11 36 14 SD 1 AIP 1 SD 4 15 SDDK A6 CLUTCH PEDAL CLUTCH 6 SPEED TRANSMISSION B13 A4 A3 ADM 7 34 ADM 8 33 AIP 7 50 P 1 F1 2 KL 30 1 F2 2 KL 15 B9 S6 H3 A9 A6 H5 1 2 ...

Page 46: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 47: ...tial 5 and epicyclic reduction units 2 to the rear wheels 1 Therearaxleisequippedwithanelectro hydraulicallycontrolleddifferentiallock 6 andtwohydraulicallyoperatedbrakes 3 COMPONENTS 1 Wheels 2 Epicyclic reduction unit 3 Brake 4 Pinion 5 Differential 6 Differential lock D0004450 1 2 3 4 3 2 1 5 6 REAR AXLE DESCRIPTION ...

Page 48: ... D0004470 3 4 5 6 7 8 12 REAR AXLE COMPONENTS 1 Differential lock 2 Central axle housing 3 Differential 4 Brake control device 5 Brake 6 Half shaft 7 Hub 8 Axle casing 9 Planet carrier 10 Ring gear 11 Planet pinion 12 Crown wheel ...

Page 49: ...gh a 2 or 4 speed gearbox with manual speed selection The PTO is engaged by way of an electro hydraulically controlled clutch D0004460 1 4 3 2 5 3 4 5 562 1046 c d a b 1 6 6 REAR AXLE DESCRIPTION 1 Clutch 2 Synchronizer 1 3 Intermediate shaft 4 Intermediate shaft 5 PTO shaft 6 Synchronizer 2 Speed of PTO output shaft 4 speed version Synchronizer 1 Synchronizer 2 c d a 562 1046 b 772 1437 ...

Page 50: ...3 4 5 7 6 8 a b c d c d 2 SPEED VERSION 4 SPEED VERSION REAR PTO COMPONENTS 1 PTO engagement clutch 2 PTO input shaft 3 Intermediate shaft 4 Intermediate shaft 5 Synchronizer speeds a b 6 PTO end shaft 7 PTO output shaft 8 Synchronizer speeds c d ...

Page 51: ...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 D0004510 8 5 6 7 4 3 2 1 BRAKING SYSTEM DESCRIPTION 1 Brake fluid reservoir 2 Right master cylinder 3 Brake microswitches n 2 4 Brake pedal 5 Rear axle 6 Right brake 7 Left brake 8 Left master cylinder ...

Page 52: ...MASTER CYLINDER D0004520 3 2 1 BRAKING SYSTEM MASTER CYLINDER 1 Bleed screw 2 Barrel 3 Push rod TECHNICAL DATA Piston diameter 23 81 mm 0 938 in Piston stroke 30 mm 1 182 in Maximum operating pressure 120 bar 1740 psi ...

Page 53: ...10 35 2 2 BRAKE D0004530 A A A A 4 3 2 5 1 6 7 BRAKING SYSTEM BRAKE 1 Piston 2 Plunger 3 Adjustment nuts 4 Lever 5 Support 6 Rod 7 Parking brake control lever ...

Page 54: ...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 i...

Page 55: ...brication line Port B To trailer brake Port T Drain Port Y Connection to tractor braking system Port LS Load Sensing signal TECHNICAL DATA Maximum pressure at port N 210 bar 3046 psi Minimum constant pressure at port B 12 5 2 bar 181 3 29 psi Maximum pressure at port B 135 5 bar 1957 5 72 5 psi Feed flow rate 20 80 min 5 3 21 14 US gpm 0 0 ...

Page 56: ...ed 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 D0004560 N LS B BRAKING SYSTEM TRAILER BRAKING SYSTEM ...

Page 57: ...Valve feed Port N To lubrication line Port B To trailer brake Port Y Connection to tractor braking system Port T Drain TECHNICAL DATA Maximum pressure at port N 210 bar 3046 psi Minimum constant pressure at port B 0 bar 0 psi Maximum pressure at port B 142 bar 2059 psi Feed flow rate 20 80 min 5 3 21 14 US gpm 8 0 116 0 ...

Page 58: ...ed Port N To lubrication line Port B To trailer brake Port T Drain Port Y Connection to tractor braking system Port LS Load Sensing signal TECHNICAL DATA Maximum pressure at port N 210 bar 3046 psi Minimum constant pressure at port B 0 bar 0 psi Maximum pressure at port B 142 bar 2059 psi Feed flow rate 20 80 min 5 3 21 14 US gpm 8 0 116 0 ...

Page 59: ...KING SYSTEM TRAILER BRAKING SYSTEM COMPONENTS 1 Compressed air reservoir 2 Air compressor 3 Engine 4 Pressure limiting valve 7 8 bar 113 psi 5 Quick action coupler for trailer 6 Feed valve for cab air suspension 7 Trailer braking valve 8 Circuit pressure sensor 9 Circuit pressure indicator 10 Brake master cylinder 11 Brake ...

Page 60: ...ING SYSTEM TRAILER BRAKING SYSTEM 1 Compressed air reservoir 2 Air compressor 3 Engine 4 Pressure limiting valve 7 8 bar 113 psi 5 Quick action coupler for trailer 6 Feed valve for cab air suspension 7 Trailer braking valve 2 way 8 Trailer braking valve 1 way 9 Circuit pressure sensor 10 Circuit pressure indicator 11 Brake master cylinder 12 Brake ...

Page 61: ...t 0 1 Compressor lubrication b Port 0 c Port 2 Compressed air delivery 1 Cylinder head 2 Cylinder 3 Flange 4 Crankshaft TECHNICAL DATA Bore 90 mm 3 546 in Stroke 36 mm 1 418 in Displacement 229 cm Max pressure 10 bar 145 psi Crankshaft end float 0 08 0 38 mm 0 003 0 015 in ...

Page 62: ...2 2 bar DIAGRAM BRAKING SYSTEM PRESSURE LIMITING VALVE Port 1 From compressor Port 3 Excess pressure vent Port 21 To compressed air reservoir TECHNICAL DATA Cut out pressure 7 8 0 2 bar 113 2 9 psi Cut in pressure 0 6 1 bar 8 7 14 5 psi Relief valve setting 12 2 bar 174 29 psi 0 0 ...

Page 63: ...e pneumatic cab suspension system only when the pressure in the trailer braking circuit exceeds 6 0 3 bar 87 4 35 psi TECHNICAL DATA Opening pressure 6 0 3 bar 87 4 35 psi Maximum operating pressure 13 bar 188 psi 0 0 D0004700 0 0 BRAKING SYSTEM CAB SUSPENSION FEED VALVE ...

Page 64: ...ure Hydraulic control pressure P41 P42 bar 1 41 42 2 3 D0004761 1 42 41 2 1 2 P 4 2 f P 4 1 4 2 P42 f P41 P42 f 42 DIAGRAM BRAKING SYSTEM TRAILER BRAKING VALVE 2 WAY 1 Parking brake actuating lever 2 Bleed screw Port 1 From compressed air reservoir Port 2 To trailer brake Port 41 From left brake Port 42 From right brake ...

Page 65: ...7 TRAILER BRAKING VALVE 1 WAY Port 1 From compressed air reservoir Port 2 To trailer brake Port 4 Pilot from delivery line to trailer 2 way braking D0004710 2 1 4 BRAKING SYSTEM TRAILER BRAKING SYSTEM 1 WAY ...

Page 66: ...orb 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 D0004720 3 4 5 2 1 HYDRAULIC FRONT AXLE SUSPENSION DESCRIPTION ...

Page 67: ...BL2 BL3 BL1 AV2 RV2 AV1 DBV1 LS A B RV1 ASP ASP ZSP1 A B LS P T D0004750 H ZSP1 SV1 LS SV2 S ASP1 ASP2 LS V BL3 DBV1 DBV2 AV BL2 RV3 RV2 RV1 BL1 A P T 250 10 bar AV2 250 10 bar 5 6 4 1 2 3 4 5 DIAGRAM HYDRAULIC FRONT AXLE SUSPENSION FRONT SUSPENSION CONTROL VALVE 1 Cylinder retraction control solenoid valve 2 LS signal control solenoid valve 3 Cylinder extension control solenoid valve 4 Accumulato...

Page 68: ...embrane 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 1 H SV1 LS SV2 S LS V BL3 DBV1 DBV2...

Page 69: ...ases 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 t...

Page 70: ...le the pressure P1 decreases accumulator 3 is decompressed The pressure balance is thus altered and the system which is closed acts to restore the original condition 1 5 6 4 2 H SV1 LS SV2 S LS V BL3 DBV1 DBV2 AV BL2 RV3 RV2 RV1 BL1 A P T LS P T ZSP1 ASP1 ASP2 A B P1 P2 AV2 D0004660 3 S t t P1 P1 min tshock tdamping S P2 S max P2 max S min D0002411 HYDRAULIC FRONT AXLE SUSPENSION FRONT SUSPENSION ...

Page 71: ...10 53 4 FRONT AXLE D0004780 1710 1710 B B A A 0 52º 2 FRONT AXLE ...

Page 72: ...4 13 15 16 17 18 A A FRONT AXLE HUB CARRIER AND FINAL REDUCTION UNIT 1 Planet carrier 2 Planet pinion 3 Ring gear 4 Bearing 5 Flange 6 Oil seal 7 Upper kingpin 8 Hub carrier 9 Front axle 10 Oil seal 11 Plain bearing 12 Half shaft 13 Lower kingpin 14 Oil seal 15 Bearing 16 Oil seal 17 Bearing 18 Sun wheel ...

Page 73: ...CARRIER AND FINAL REDUCTION UNIT 1 Planet carrier 2 Planet pinion 3 Ring gear 4 Bearing 5 Flange 6 Oil seal 7 Upper kingpin 8 Hub carrier 9 Front axle 10 Oil seal 11 Plain bearing 12 Half shaft 13 Lower kingpin 14 Oil seal 15 Bearing 16 Oil seal 17 Bearing 18 Sun wheel 19 Steering sensor n 2 20 Shim 21 Disc 22 Lock ring ...

Page 74: ... 20 21 FRONT AXLE DIFFERENTIAL 1 Roller cage 2 Belleville springs 3 Bearing 4 Cover 5 Clutch plates 6 Differential cage 7 Planet pinion 8 Differential cage 9 Sun gear 10 Bearing 11 Half shaft 12 Spacer 13 Bearing 14 Oil seal 15 Hub 16 Pinion shaft 17 Bearing 18 Crown wheel 19 Thrust plate 20 Thrust levers 21 Piston ...

Page 75: ... 3 5 8 9 11 12 1 2 4 6 10 13 14 FRONT AXLE DIFFERENTIAL 1 Bearing 2 Clutch plates 3 Differential cage 4 Planet pinion 5 Differential cage 6 Sun gear 7 Bearing 8 Half shaft 9 Bearing 10 Oil seal 11 Hub 12 Pinion shaft 13 Bearing 14 Crown wheel ...

Page 76: ...e if two or more actuators are operated when the engine is running at low speed the pump will be unable to meet the demand and consequently the actuators will operate at a lower speed in accordance with the available oil flow The LS systemhasavariabledisplacementpiston pumpwhichsendsoiltothehydraulicfunctionsonlyaccordingtoneed In this system when the engine is running at maximum speed and no hydr...

Page 77: ...Lenkung β10 1 5 N B T P Y P A B T LS Schmierkreis DBV 4 bar Bypass Ventil 3 bar G Einfuellstutzen Pumpe 16 ccm 250 10 bar 250 10 bar RV3 BL2 BL3 A P T AP R1 Y P X X B A S H F 1 0 2 P Magnetventil Hinterachs differential Sperre Mech betätigtes Ventil für Zapfwellenkupplung M6 Druckloser Ruecklauf M7 R Durchm 0 5mm M3 Hydraulikpumpe 32 cm3 Ansaugfeinfilter 25 m Bypassventil Motor p 8 4 bar in Schalt...

Page 78: ...Schmierung Hinterachse Motor Hydrostatische Lenkung Getriebegehäuse LS B T P Y P A B T LS Einfuellstutzen 250 10 bar 250 10 bar BL1 RV3 BL2 BL3 A P T p 140bar 0 3 ø 3 ø ZSP1 AP R1 Y P X X A A S H F 1 0 2 Nx p 65bar 0 p 65bar 0 ASP1 ASP2 DBV1 DBV2 AV1 LS V LS S SV1 RV2 AV2 SV2 H RV1 F 1 0 2 F 1 0 2 Y EP B B F 1 0 2 B F 1 0 2 HYDRAULIC SYSTEM 120 165 CV models CCLS version HYDRAULIC SYSTEM 120 165 C...

Page 79: ...use N B T P Y P A B T LS Schmierkreis DBV 4 bar Bypass Ventil 3 bar G Einfuellstutzen Pumpe 16 ccm 250 10 bar 250 10 bar BL1 RV1 RV2 RV3 BL2 BL3 AV2 A P T S SV2 SV1 H AP R1 Y P X X B A A S H F 1 0 2 P Magnetventil Hinterachs differential Sperre Mech betätigtes Ventil für Zapfwellenkupplung Power Beyond Y 57 S X Ls filter DS M5 M3 0 3 M1 M2 G B M6 Druckloser Ruecklauf M7 Feinfilter mit Bypass Venti...

Page 80: ...ar BL1 RV1 RV2 RV3 BL2 BL3 AV2 A P T 3 ø 3 ø SV2 H AP R1 Y P X X A S H F 1 0 2 Druckloser Ruecklauf M7 M4 CF EF LS P P M2 filter DS M1 B X LS M5 P Power Beyond M3 x p 65bar 0 p 65bar 0 ASP1 ASP2 AV1 DBV1 DBV2 p 140bar 0 ZSP1 LS LS V SV1 S Y B F 1 0 2 A Y EP B F 1 0 2 FO L1 L FI 100 280 m P max 0 2bar at 130 l min 5 bar 235 bar S 0 5 bar B F 1 0 2 HYDRAULIC SYSTEM 120 165 CV models LS version HYDRA...

Page 81: ... FI X L 2 3 1 4 HYDRAULIC DIAGRAM HYDRAULIC SYSTEM VARIABLE DISPLACEMENT PUMP FUNCTION Port L drain Port X LS signal Port S suction Port B delivery Port G transmission lubrication Port FI filter inlet Port FO filter outlet COMPONENTS 1 Antishock valve 2 Load Sensing valve 3 Pressure cut off valve 4 By pass valve ...

Page 82: ...NENTS 1 Input shaft 2 Oil seal 3 Swash plate return spring 4 Swash plate 5 Control rod 6 Control piston 7 Cylinder barrel 8 Spacer 9 End cover 10 Roller bearings 11 Boost pump 12 Boost pump housing 13 Bearing 14 Valve plate 15 Pistons n 9 16 Piston retainer ring 17 Piston shoe 18 Taper roller bearing 19 Pump housing ...

Page 83: ...ensing spool valve 2 Restrictor 3 Collar 4 Load Sensing valve spring 5 Spring cover 6 Adjustment nuts 7 Adjustment nuts 8 Spring cover 9 Pressure cut off valve spring 10 Collar 11 Restrictor Ø 0 6 mm 0 024 in 12 Pressure cut off valve spool COMPONENTS 1 Pressure limiting valve 2 Filter by pass valve 3 Filter by pass valve spring ...

Page 84: ...e displacement pump 3 The pressurised oil from the boost pump is also used for lubrication of the transmission 4 The pressure generated by the boost pump is regulated by the pressure limiting valve 5 setting 5 bar 72 3 psi that prevents excessive pressure from building in the lubrication circuit on cold starting and during cold weather conditions The pressure boosting circuit also includes a low b...

Page 85: ... 5 have ball ends the piston shoes 6 fit around the ball ends of the pistons to form a single assembly The pistons 5 and the shoes 6 together form a ball joint Theswashplate 3 hasaflat surfaceAagainstwhich the piston shoes slide 6 with a circular motion D0005010 4 3 2 1 5 7 6 A B The pistons 5 stroke axially within their bores in the cylinder block 4 The rotation of the cylinder block 4 causes the...

Page 86: ...tage in chamber D and the delivery stage in chamber C 3 When the axis X of the swash plate 3 is parallel to the axis of the cylinder block 4 swash plate angle α 0 the difference between the volumes C and D inside the cylinder block 6 is zero and no oil is pumped Fig 2 Inreality theswashplateangle α isnevertruly equal to 0 4 The pump delivery is therefore directly proportional to the swash plate an...

Page 87: ...P PR PLS PA PA HYDRAULIC SYSTEM LOAD SENSING VALVE PRESSURE CUT OFF VALVE COMPONENTS 1 Load Sensing valve spool 2 Load sensing valve spring 3 Pressure cut off valve spool 4 Pressure cut off valve spring 5 Swash plate return spring 6 Control piston 7 Directional control valve 8 Load ...

Page 88: ... is maintained at a constant value PR Pump delivery pressure PP PLS delivery pressure to load If thepressure difference PRfalls relative to the pressure setting of theLSvalve the swashplateangle willincrease If the pressure difference PR rises the swash plate angle will decrease For details of this mechanism see the description of the HYDRAULIC PUMP Directional control valve Delivery pump Control ...

Page 89: ...pressure the pressure of the Load Sensing signal and difference between these two pressures In other terms the LS valve detects the pressure difference PR generated by the the flow of oil passing through the passages uncovered by the spool and regulates the pump delivery Q so as to maintain a constant pressure drop This means that the pump delivery is proportional to the demand from the directiona...

Page 90: ...LS of the LS signal remainsat0bar 0psi becausethereisnoflowthroughthecontrolvalvesandthesignal isconnectedtodrain At the same time the pump delivery pressure PP increases because the hydraulic actuators are stationary When the force exerted by the pressure PP in chamber b overcomes the force of the spring 2 the spool 1 shifts to the right thereby allowing the pressure PP to flow to the chamber X o...

Page 91: ...by connecting the passages d and e The chamber X is depressurised and the spring 5 causes the swash plate to move to the maximum displacement angle Systembalance isrestored whenthe pressure PR exerts on thespool 1 a force equal to the difference in force due to the spring 2 thus restoring the connection between the passages c and d M Min Max D0004860 8 7 6 5 2 1 PLS PP T PEN a b X e d c f PP HYDRA...

Page 92: ...d An oil flow enters the control piston 6 at a sufficient pressure to balance the force exerted by the spring 5 The stability of this equilibrium is ensured by a stabilised flow from the restrictor g The force of the spring 2 is regulated so that the piston 1 is balanced when PP PLS PR 22 bar 319 psi Inpracticalterms pumpdeliveryismadeproportionaltotheapertureoftheauxiliarycontrolvalve maintaining...

Page 93: ...sent in chamber a of the LS valve will be nearly equal to the pressure PP and the piston 1 will be moved left by the combined force of the pressure PLS and the spring 2 The piston thus closes the passage c and connects the passages d and e The pressurised oil in chamber X of the control piston 6 flows through the passages d and e to reach the pump drain chamber in this way the pressure in chamber ...

Page 94: ... on reaching the maximum pressure setting reduces the pump delivery to zero by passing the action of the LS valve The pump delivery is thus returned to a minimum value sufficient for the internal lubrication of the pump of the main auxiliary services and to maintain the hydraulic system at maximum pressure Min Max M D0004890 PLS T PP PP PEN HYDRAULIC SYSTEM LOAD SENSING VALVE PRESSURE CUT OFF VALV...

Page 95: ...RVICES GEAR PUMP 106 115 CV models D0005280 P L HYDRAULIC SYSTEM HYDRAULIC SERVICES GEAR PUMP 106 115 CV models FUNCTION Port L suction Port P delivery TECHNICAL DATA Displacement 32 cc rev Maximum pressure 200 bar 2900 psi ...

Page 96: ...EERING GEAR PUMP 106 115 CV models D0005290 P L HYDRAULIC SYSTEM STEERING GEAR PUMP 106 115 CV models FUNCTION Port L suction Port P delivery TECHNICAL DATA Displacement 16 cc rev Maximum pressure 180 bar 2610 psi ...

Page 97: ... S D0004970 EF A CF S A LS HYDRAULIC DIAGRAM HYDRAULIC SYSTEM GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING 120 165 CV models FUNCTION Port S suction Port CF priority delivery Port EF secondary delivery Port LS LS signal TECHNICAL DATA Displacement 32 cc rev Maximum pressure 200 bar 2900 psi ...

Page 98: ...hespring 6 through the passage d As the LS line is sent to drain by the power steering a small amount of oil about 1 litre min flows through the port LS Thiscreates apressuredifference betweenthetwosides of thespool 5 thatisconsequently pushed downwards thereby allowing the oil to flow to chamber e and from there to the auxiliary services Whenthesteeringwheelisturned theconnectionbetweenthedrainan...

Page 99: ...CF P LS D0005310 HYDRAULIC DIAGRAM HYDRAULIC SYSTEM PRIORITY VALVE FUNCTION Port P Valve feed Port LS Load Sensing signal Port CF Delivery to power steering Port EF Delivery to services Port PP Valve pilot flow FUNCTION Port CF Delivery to the power steering Port P Valve feed Port EF Delivery to services Port LS Load Sensing signal ...

Page 100: ...re to supply the auxiliary valves 6 in this way that it is always corresponding to the spring force 9 higher than the pressure of the LS signal The pressure limitation is provided by limitation of the LS signal pressure done by valve 3 All the spools when operated generate a pressure signal Load Sensing signal that is equal to the pressure demand from each load The highest of these pressure signal...

Page 101: ...All the spools when operated generate a pressure signal Load Sensing signal that is equal to the pressure demand from each load The highest of these pressure signals selected by the bistable valves 3 is sent to the variable displacement pump through port Y of the control valve On the lift spool section 6 there is an antishock valve 4 on the UP control side that serves to prevent excessive pressure...

Page 102: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 103: ...50 7 6 7 5 HYDRAULIC DIAGRAM A 5 4 3 2 1 7 7 R1 B A B A P R 4 2 3 6 1 Y R P B A R A B A X X F 1 0 2 S H F 1 0 2 Y D0005160 7 6 7 5 HYDRAULIC DIAGRAM HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE 1 Cover plate 2 Control valve section n 1 3 Lift control valve section 4 Control valve section n 2 5 Inlet manifold 6 Relief valve 7 Check valve 1 Cover plate 2 Control valve section n 1 3 Lift control...

Page 104: ... X X F 1 0 2 F 1 0 2 Y Y D0005140 10 6 10 5 10 10 HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE 1 Cover plate 2 Control valve section n 1 3 Lift control valve section 4 Control valve section n 2 5 Inlet manifold 6 Relief valve 7 Control valve section n 3 8 Control valve section n 4 9 Inlet manifold 10 Check valve ...

Page 105: ...2 S H F 1 0 2 Y Y R P B A B A X X F 1 0 2 F 1 0 2 Y D0005130 9 9 9 9 2 1 5 4 3 8 7 6 1 HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE 1 Cover plate 2 Control valve section n 1 3 Lift control valve section 4 Control valve section n 2 5 Inlet manifold 6 Check valve 1 Cover plate 2 Control valve section n 1 3 Lift control valve section 4 Control valve section n ...

Page 106: ...5 6 3 SERVICES CONTROL SECTION P Y A B R R D0005100 6 2 1 5 4 3 HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE 1 Spool return device 2 Check valve 3 Spool 4 Flow control 5 Flow control spool 6 Check valve ...

Page 107: ...NS OF COMPONENTS SPOOL RETURN DEVICE Check valve NR 2 D0005040 1 B R D0005050 3 2 1 5 4 HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE 1 Spool return spring 2 Spool 1 Slide 2 Ball 3 Check valve spring 4 Valve seat 5 Spool ...

Page 108: ...10 90 FLOW CONTROL VALVE 1 Spring 2 Flow control spool 3 Control shaft D0005060 1 2 3 HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE ...

Page 109: ...d any excess oil supplied by the pump to the drain circuit The inlet manifold also includes a relief valve that limits the operating pressure of the actuators 1 Pressure compensating valve spool 2 Compensating valve spring 3 Relief valve 4 Relief valve spring R P D0005070 3 1 4 4 2 3 2 1 HYDRAULIC DIAGRAM HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE ...

Page 110: ... 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 downwards allowing the excess oil from the pump to flow to drain a b D0005080 P R 1 2 CONTROL VALVE HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE ...

Page 111: ...en 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 a b c y D0005090 P R 1 5 4 2 CONTROL VALVE HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE ...

Page 112: ...tpressuresurgescausedby jolting of the implement during work and transport D0004920 1 2 3 4 5 6 7 8 9 10 11 A R P Y R P Y R A R HYDRAULIC DIAGRAM HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE COMPONENTS 1 UP control solenoid valve 2 Check valve 3 Check valve spring 4 Antishock valve 5 Antishock valve spring 6 DOWN control spool 7 DOWN control solenoid valve 8 Flow control spring 9 Flow control...

Page 113: ...e 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 jolti...

Page 114: ...there to the lift cylinders Atthesametime thepressurepresentinpassagebcanflowintothechamberiand intothepassagef andfromthere 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 D0004940 1 e g b f 2 5 4 6 a h i R A P HYDRAULIC SYS...

Page 115: ... 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 obtai...

Page 116: ......

Page 117: ...GRADE FROM VERSION 2 5 TO VERSION 3 1 57 9 1 IMPROVEMENTS AND HELP WITH PROBLEMS IN COMMUNICATING WITH NOTEBOOKS WIN 98 57 9 2 NEW ENTRY MASK WITH MEASURED VALUES AND COLOURED CODED INDICATION OF CONNECTION STATUS 58 9 3 NEW SWITCH JOBS FOR PERFORMING SELECTED SERVICING OPERATIONS E G ADJUSTING CONTROLLER OR ADJUSTING OFFSET 59 9 4 IN AND OUTPUT ASSIGNMENT IS NOW ADDITIONALLY CONFIGURABLE USING PL...

Page 118: ... GEAR SHIFT T 7100 128 4 9 SENSORS AND SOLENOID VALVES AT THE TRANSMISSION T 7200 129 4 10 ELECTRO HYDRAULIC GEAR SHIFT T 7200 T 7300 130 4 11 ERROR ANALYSIS 131 5 AGROTRONIC HD ASM 133 5 1 PROGRAM DESCRIPTION 134 5 2 ERROR CODES OF THE AGROTRONIC HD 141 6 PREPARATIONS FOR DIAGNOSIS OF THE INFOCENTER 144 6 1 PROGRAM DESCRIPTION 145 6 2 CONSTANT VALUES FOR INFOCENTER 155 7 PREPARATIONS FOR DIAGNOSI...

Page 119: ...20 1 OPERATOR S MANUAL SERDIA LEVEL III SERDIA OPERATOR S MANUAL ...

Page 120: ... 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 ...

Page 121: ...olarity and surge voltage Decoupling Software Operating system DOS versione 5 0 or later User surface MS Windows 3 11 or Windows 95 Installation is also possible under Windows 3 1 however this creates a specific Windows problem Conflicts may occur when accessing serial interface COM1 see Chapter 8 What should you do if Further information is also given in the Readme file supplied with SERDIA For p...

Page 122: ...t you will only be able to operate it in offline mode Chapter 1 6 2 Offline mode tells you which program restrictions this involves TO INSTALL Switch on the computer Insert the SERDIA installation disk in the 3 5 disk drive drive A Start Windows With Windows 3 11 3 1 In the main group open File manager by double clicking on the symbol using the mouse Select disk drive A Start install exe by double...

Page 123: ...ORIZATION DEUTZ Service has defined three different user levels I II III for SERDIA users These levels are specified in the interface We make these distinctions in order to prevent unauthorized users from gaining access to the setting parameters com parable to the lead seals on fuel injection pumps Access authorization functions in such a way that only certain parameters and function fields are al...

Page 124: ...on the interface into the diagnostics socket on the vehicle equipment 3 Connect the other interface side with serial interface RS 232 COM1 9 pole plug at the back of your noteback ATTENTION On PCs the COM1 interface may sometimes be occupied by the mouse If this is the case you should connecttheinterfacetothesecondserialinterface COM2 Thismustthenbeconfigured seeChapter 8 What should you do if 4 Y...

Page 125: ...essage see Chapter Error in es tablishing the communication link Oncecommunicationhasbeensuccessfullyestablished themainscreen Diagnosticsservice isdisplayedwiththefields ECU electronic control unit and ECU identification This main screen contains a predefined selection menu 1 7 OFFLINE MODE If no ECU engine and or interface is available SERDIA can be operated for training purposes in the password...

Page 126: ... they cannot alter the files 1 7 2 DEMO MODE TRAINING WITHOUT ECU If No is selected in the Confirm window the user reaches the DEMO mode 1 Here handling of SERDIA can be practiced without actual figures 2 Stored graphics can be read and printed out provided that the graphics were stored in binary format file name ex tension egr See 3 1 2 Graphics ATTENTION It is not possible to carry out function ...

Page 127: ...gine not in operation but in this case with U Blatt RAM values Only for level III Data logger EMS Only Display recorder contents Input output assignment All Assignment of the signals used to the ECU pins CAN Status Parameters Configuration All Read and update configuration data Overall programming EMR EMS Calibration All Calibration of measured value sensor e g accelerator pedal sensor Error memor...

Page 128: ...anges to parametrization beconne necessary if custonner requiremenis abaptation to locai requirements replacement installation The pararneters can only be changed with SERDIA This menu point also does away with the neecl br screwdriver setting as is necessary with analog ECUs Individuai pa rameters suchasdynamicgo ernorcharacteristics canusoLEchanged nithinpredefsnedlimits Parametrizationiscar rie...

Page 129: ... displayed under the actual value The actuator statuses are always controlled in the ECU This control function can only be transferred to SERDIA by the ECU i e iftherequiredactualvalueisnotproduced thisisprobablyduetoawiringerror Itcanthenbehelpfultomakeuse of the combination of the menu points Error message and Function test in order to track down the cause For further information about function ...

Page 130: ...1 End SERDIA 2 Switch off engine power supply and then switch on again 3 Start SERDIA again 4 Re activate the ECU 5 Activate the menu point Parameters 6 Click on PC SG PC in the configuration screen 7 To print out the configuration data press Print Print ON 8 File the printout with the engine documentation 1 11 2 DISCONNECTING THE ECU You should only disconnect the engine ECU from the notebook i e...

Page 131: ...ng successful recognition the ECU selection screen is automatically overlayed Only the recognized ECUs are of fered for selection The ECUS which are not selectable are marked by a grey font 2 3 IDENTIFICATION DATA 2 3 1 EMR IDENTIFICATION Meaning of data displayed DEUTZ part number Product number Type of selected ECU 1 EMR 2 MVS 3 EMS Hardware version number This number indicates the development s...

Page 132: ...es Actual measured values The window Measured value selection is displayed with all measured values available Measured values to be displayed can be selected there In general the repeat rate of display is increased through a reduced number of measured values to be displayed The possible measured values available may vary according to the type of the ECU Graphics The Graphics switch is used to disp...

Page 133: ...d the lower the scanning rate will be File The current measured values can be stored in a file and reloaded later for example for further processing in Excel Print The displayed measured values are printed Close Return to the main window Service diagnosis 3 1 1 MEASURED VALUE SELECTION Figure Measured value selection EMR In this list you can activate or deactivate measured values for display You c...

Page 134: ...ed 2 crankshaft Ass F1 6 Out Dig PWM Freq 2000 2002 Control rod position mm Control rod position M9 Cooiant temperature C Coolant temperature Ass M9 Analnp3 CoolTemp 3551 Fuel injection quantity cmm Hub Fuel injection quantity Fuel consumption l h Fuel consumption F24 Accelerator pedal SWG1 V Accelerator pedal voltage Ass F24 Analnp1 Pedal 3511 Rel Accelerator pedal SWG1 Scanning pos acceleratorpo...

Page 135: ...the columns L left and R right a representation of an axis can be assigned to a measured variable EXPLANATION OF THE FUNCTION SWITCHES START This function switch is used to start recording of the data UPDATE This function switch is used to update the displayed information This is necessary if there has been a change in the minimum maximum or delta values The update process takes the new values int...

Page 136: ...e current input and output status Restriction Only applies for EMS and EMR ECUs 3 5 CAN Status This window displays the CAN bus activities of the EMR Sent ContainstheinformationCan TxCounter 0to65535 word ThevalueisincreasedwitheachCANsendingmessage and indicates the sending activity of the EMR Received Contains the information Can RxlrCounter 0 to 65535 word The values is increased with each CAN ...

Page 137: ...N error 2 2 Engine standstill phase2 CAN timeout error 3 3 Engine 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 Code Text 0 0 No fault existing 1 1 Message request not received bei controller object 15 2 2 Invalid controller obj...

Page 138: ...xt by entering dc for don t care that the text output is suppressed for this bit If the text 100 Receipt message failed is displayed there is an additional text output of the list of missing receipt mes sages 3 6 EXAMPLE OF A DISPLAYED ERROR INFORMATION 100 Receipt message failed Engine Temperature Engine Fluid Level Pressure Function shift Inlet Exhaust Conditions VanRxTimeOutBit Text 0 Engine Te...

Page 139: ...the key ECU PC Following satisfactory engine run the data record can be saved with the Save in file key on the hard disc or on a dis kette Figure Example of a choice of configuration parameters EXPLANATION OF THE FUNCTION SWITCH ECU PC The configuration data is read from the ECU and is displayed PC ECU Updated configuration data is uploaded to the ECU In order for the uploaded data to be permanent...

Page 140: ... RefVal EDCValueRefCoil 0 65535 1800 AutoCalib Current 0 100 78 2 AutoCalib WaitingTime s 0 100 1 0 Page 3 Engine speed settings Idling speed 1 min 500 4000 770 Idling speed engine rated speed Fixed eng speed 1 1 min 500 4000 1000 Fixed speed setpoint 1 Fixed eng speed 2 1 min 500 4000 1000 Rated speed engine Rated speed 1 min 500 4000 2300 Fixed speed setpoint 2 Rated speed limp home 1 min 500 40...

Page 141: ...p speed 4 w actual speed 5 two setpoint transmitters Ass droop config 0 3 0 Speed droop selection 4 variants Perm values 0 constant speed droop 1 variable speed droop 2 switching between speed droop 1 and 2 3 switching betw const variable speed droop Ass governor config 0 6 0 Type of governing 4 variants Perm values 0 Variable speed governing 1 Min max speed governing 2 Switching betw var min max ...

Page 142: ...wer err limit digits 0 1023 60 Boost pr sensor lower failure trigger point OilPrSens upper err limit digits 1023 820 Oil pr sensor upper failure trigger point OilPrSens upper ref 5 bar digits 0 1023 511 Oil pr sensor voltage at 5 bar OilPrSens lower ref 0 bar digits 0 1023 102 Oil pr sensor voltage at 0 bar OilPrSens lower err limit digits 0 1023 40 Oil pr sensor lower failure trigger point CoolTe...

Page 143: ...y 3 At Input Pin F19 the torque curve can be switched closed torque curve 2 open torque curve 1 Entry 3 At Input Pin F19 the torque curve can be switched closed torque curve 1 open torque curve 2 AssInp torque curve 1 or 2 5 5 3 Switching between two torque curves AssInp speed droop 1 or 2 5 5 2 Switching between two fixed speed droops AssInp speed specificationi 5 5 1 Switching between two eng sp...

Page 144: ...op 1 const speed droop 2 0 80 0 Speed droop 2 Enginespeedpositionvalues 1 min 600 20000 8 engine speed values Variable droop fct engine speed Speed droop fct engine speed Page 17 Speed dependent PID control Enginespeedpositionvalues 1 min 600 2500 7 Engine speed values Quantity position values mm3 Hub 0 100 4 fuel injection quantity values ref points Speed governor P map 100 200 P Part fct eng spe...

Page 145: ... fail Tacho Timeout s 0 100 5 Max consumption l ora 0 200 200 Page 23 CAN general settings CAN bus on off 0 1 0 CAN time out Mon on off 0 1 0 CAN EMR Adress Can Baud Rate kBaud 0 255 0 Can Start Time Out s 0 100 10 Can Rx Obj Mincount 0 255 4 Can Low Voltage V 0 66 9 Can Volt Timeout s 0 100 30 Can Rx Obj Missing No 0 255 4 Can Config Tel On 0 63 0 Can Dia Tel On 0 2047 1961 Can Meß Tel On 0 3 1 C...

Page 146: ...l active errorsi 0 255 3 Del error memory 0 255 3 Free 0 255 0 Page 26 CAN 7850 Priorities Object Telegr engine temperature 0 7 0 Inlet Exhaust conditions 0 7 0 engine fluid level pressure 0 7 0 TSC1 0 7 3 EMR Engine protection 0 7 3 EMR function shift 0 7 0 Request 0 7 6 Del active errors 0 7 6 Del error memory 0 7 6 free 0 7 0 EEC1 0 7 3 EEC2 0 7 3 Page 27 CAN 7865 Priorities Diagnosis Telegr Ac...

Page 147: ...rror memory ms 0 15000 0 free ms 0 15000 0 EEC1 ms 0 15000 80 EEC2 ms 0 15000 200 Page 31 CAN 776S SendRepeatRate DiagnosisTelegr Active errors ms 0 15000 1000 EMR status Dig lnputs ms 0 15000 0 EMR status Dig Outputs ms 0 15000 0 Engine temperature ms 0 15000 1000 engine fluid level pressure ms 0 15000 500 Inlet Exhaust conditions ms 0 15000 500 engine configuration ms 0 15000 0 Page 32 CAN 7788 ...

Page 148: ...Part Meas Values Telegr Fuel economy 0 65535 65266 EMR measured values 0 65535 0 Page 37 CAN 7960 Fault codes of rel fault messages Setpoint generator 1 0 65535 91 Setpoint generator 2 0 65535 201 Boost pressure sensor 0 65535 102 Coolant temperature sensor 0 65535 110 Oil pressure sensor 0 65535 100 Electronics temperature 0 65535 171 EngSpeedSensorl EngRun 0 65535 190 EngSpeedSensor2 EngRun 0 65...

Page 149: ...tor 2 0 1 1 Boost pressure sensor 0 1 1 Coolant temperature sensor 0 1 1 Oil pressure sensor 0 1 1 Electronics temperature 0 1 1 Eng Speed Sensorl Eng Run 0 1 1 Eng Speed Sensor 2 Eng Run 0 1 1 Rack Travel Sensor not vibr 0 1 1 Oversp only during shutd 0 1 1 Actuator deviation excessive 0 1 1 Coolant Temp high alarm 0 1 1 Coolant Temp high shutdown 0 1 1 Oil pressure low alarm 0 1 1 Oil pressure l...

Page 150: ...edited in the 4th column This data is also uploaded when uploading the configuration data to the ECU Figure Menu complete programming Overal programming EXPLANATION OF FUNCTION SWITCH ECU fi e The configuration data is read from the ECU displayed and can be saved as HEX file Programming Updatedconfiguration data is uploaded tothe ECU Inorder for the upload tobe permanent youmust op erate the Save ...

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