5090 C -> ZKDY360200TD10001

5100 C -> ZKDY400200TD10001

5100 C -> ZKDY480200TD10001
5110 C -> ZKDY440200TD10001
5110 C -> ZKDY520200TD10001
5120 C -> ZKDY560200TD10001

Workshop manual
CONTENTS
0 - Introduction
0.1 - Introduction 0-2
0.1.1 - Safety notes 0-2
0.1.2 - General safety 0-2
0.1.3 - Precautions to use during performance of the work 0-3
0.1.4 - Lifting instructions 0-4
0.1.5 - Tightening torques 0-5
0.1.6 - Thread lock, adhesive, sealant and lubrication materials 0-8
0.1.7 - Unit of measurement conversion table 0-10
0.2 - Tightening torques for nuts and bolts of electrical connections 0-11
0.2.1 - Standard tightening torques 0-11
0.2.2 - Battery terminal tightening torques 0-11
0.2.3 - Starter motor tightening torques 0-12
0.2.4 - Alternator tightening torques 0-12
0.3 - Wheel rim to hub screws and nuts tightening torques 0-13
0.4 - Tightening torques 0-14
0.4.1 - General information 0-14
0.4.2 - Tightening classes and categories 0-14
0.4.3 - Coefficient of friction 0-14
0.4.4 - Tightening torques 0-15
0.5 - Installation of solenoid valves and cartridge valves 0-24
0.5.1 - Installation 0-24
0.5.2 - Solenoid valve tightening torques 0-24
0.5.3 - Cartridge valve tightening torques 0-25
0.6 - Installation of quick couplers 0-26
0.6.1 - Table of tightening torques 0-26

10 - Technical characteristics
10.1 - Engine 10-2
10.1.1 - Motor description - construction type 10-2
10.1.2 - Engine description - Views of engine 10-9
10.1.3 - Engine description - Lubricant oil diagram 10-13
10.1.4 - Engine description - Fuel circuit diagram 10-14
10.1.5 - Engine description - Coolant diagram 10-15
10.1.6 - Engine description - Exhaust gas recovery 10-16
10.1.7 - Engine description - Exhaust gas after-treatment 10-17
10.1.8 - Engine description - Electrical/electronic system 10-18
10.1.9 - Use - Environmental conditions 10-20
10.1.10 - Use - First start-up 10-21
10.1.11 - Usage - Starting procedure 10-25
10.1.12 - Usage - Monitoring engine operation 10-27
10.1.13 - Use - exhaust gas after-treatment systems 10-32
10.1.14 - Use - Stop procedure 10-34
10.1.15 - Operating materials - lubricant oil 10-35
10.1.16 - Operating materials - Fuel 10-37
10.1.17 - Operating materials - Coolant 10-38
10.1.18 - Maintenance - Maintenance schedule 10-40

III
 CONTENTS
10.1.19 - Care and maintenance work - Lubricant oil system 10-42
10.1.20 - Care and maintenance work - Fuel distribution system 10-46
10.1.21 - Care and maintenance work - Cooling system 10-51
10.1.22 - Care and maintenance work - Engine cleaning 10-55
10.1.23 - Care and maintenance work - Intake system 10-55
10.1.24 - Care and maintenance work - Belt transmissions 10-58
10.1.25 - Care and maintenance work - Electrical system 10-62
10.1.26 - Malfunctions - Malfunction table 10-64
10.1.27 - Faults - Engine management 10-67
10.1.28 - Transport and storage - Transport 10-70
10.1.29 - Transport and storage - Engine protection treatment 10-71
10.1.30 - Technical data - Engine data and adjustment data 10-74
10.1.31 - Technical data - Tools 10-75
10.2 - Transmission 10-78
10.2.1 - Transmission (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 10-78
10.2.2 - Transmission (5110 C -> ZKDY440200TD10001) 10-79
10.2.3 - Transmission (5100 C -> ZKDY480200TD10001) 10-81
10.2.4 - Transmission (5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 10-82
10.2.5 - Hydraulic reverse shuttle (5100 C -> ZKDY480200TD10001) 10-85
10.2.6 - Hydraulic reverse shuttle (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)10-88
10.2.7 - Rear PTO (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 10-93
10.2.8 - Rear PTO (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C
-> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 10-97
10.2.9 - Views of transmission 10-100
10.2.10 - HI-LO unit (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 10-102
10.2.11 - HI-LO unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C
-> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 10-104
10.2.12 - HML unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 10-106
10.3 - Rear axle 10-109
10.3.1 - Rear differential 10-109
10.3.2 - Rear axle (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110 C
-> ZKDY440200TD10001) 10-111
10.3.3 - Rear axle (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 10-111
10.4 - Front axle 10-112
10.4.1 - Front axle 10-112
10.5 - Bodywork - Cab - Platform 10-116
10.5.1 - A/C system - Version with standard roof 10-116
10.5.2 - A/C system - High visibility version 10-119
10.6 - Hydraulic system 10-122
10.6.1 - Distributor hydraulic circuits 10-122
10.6.2 - Transmission hydraulic circuits (5090 C -> ZKDY360200TD10001) 10-126
10.6.3 - Transmission hydraulic circuits (5100 C -> ZKDY400200TD10001) 10-132
10.6.4 - Transmission hydraulic circuits (5110 C -> ZKDY440200TD10001) 10-137
10.6.5 - Transmission hydraulic circuits (5100 C -> ZKDY480200TD10001) 10-143

IV
CONTENTS
10.6.6 - Transmission hydraulic circuits (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)10-148
10.6.7 - STEERING/TRANSMISSION pump (14 cm³) (5090 C -> ZKDY360200TD10001, 5100 C
-> ZKDY400200TD10001) 10-157
10.6.8 - Power steering 160 cc 10-159
10.6.9 - Power steering SDD 125-250cc 10-160
10.6.10 - Rear PTO 10-165
10.6.11 - Shuttle control unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 10-168
10.6.12 - 60 l/min. ECO AUX block 10-170
10.6.13 - Park Brake (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001) 10-175
10.6.14 - Suction pump filter 10-181
10.6.15 - HYDAC delivery line filter 10-184
10.6.16 - Transfer pump 10-185
10.6.17 - Hydraulic pumps unit 10-187
10.6.18 - Power steering pump (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)10-189
10.6.19 - Distributor unit 10-191
10.6.20 - Pressure regulator valve unit 10-197
10.6.21 - Services command unit 10-199
10.6.22 - HML control block (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 10-200
10.6.23 - Braking system 10-202

20 - Calibrations and electronic diagnosis

20.1 - Diagnostic tools 20-2
20.1.1 - SDF Analyser 20-2
20.1.2 - Serdia 2010 20-7
20.2 - Diagnostic tool screens 20-93
20.2.1 - Position of ECUs and diagnostic instruments 20-93
20.2.2 - ECU interrogation 20-94
20.2.3 - Instrument Cluster Diagnostics - “Monitor”/Monitor screens for ART/PC Tester (SP286AD) 20-97
20.2.4 - Instrument Cluster Diagnostics - “Tests”/Test screens for ART/PC Tester (SP286AD) 20-101
20.2.5 - Instrument Cluster Diagnostics - “Alarms”/Alarms screens for ART/PC Tester (SP286AD) 20-103
20.2.6 - HLHP2 ECU diagnostics (TS171AC) - “Monitors”/Monitor screens for ART/PC Tester 20-105
20.2.7 - HLHP2 ECU diagnostics (TS171AC) - “Tests”/Test screens for ART/PC Tester 20-115
20.2.8 - HLHP2 ECU diagnostics (TS171AC) - “Alarms”/Alarms screens for ART/PC Tester 20-122
20.3 - Commissioning and calibrating the tractor 20-128
20.3.1 - Digital Instrument Calibration 20-128
20.3.2 - Wheels constants 20-132
20.3.3 - Commissioning (939571) - Basic procedure 20-132
20.3.4 - Commissioning (939571) - Eeprom re-initialisation 20-135
20.3.5 - Commissioning (939571) - Line end programming of the tractor 20-135
20.3.6 - Commissioning (939571) - Accelerators calibration (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 20-139
20.3.7 - Commissioning (939571) - Accelerators calibration (5100 C -> ZKDY480200TD10001,

V
 CONTENTS
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 20-141
20.3.8 - Commissioning (939571) - Clutch pedal calibration (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 20-143
20.3.9 - Commissioning (939571) - Options selection 20-144
20.3.10 - Commissioning (939571) - Hicth calibration 20-145
20.3.11 - Commissioning (939571) - Steering sensor calibration (SDD) (5100 C
-> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)20-147
20.3.12 - Transmission calibration (939570) - Calibration of the shuttle clutches (5100
C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)20-148
20.3.13 - Transmission calibration (939570) - Calibrating HML clutches (5100 C
-> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)20-156
20.3.14 - Transmission calibration (939570) - Calibrating the Stop&Go function (5100
C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)20-161
20.4 - ECU alarms 20-166
20.4.1 - Engine alarms 20-166
20.4.2 - Instrument panel alarms 20-189
20.4.3 - HLHP alarms 20-191
20.4.4 - AC system alarms 20-195
20.4.5 - Lift alarms 20-197

30 - Method of intervention
30.1 - Tools for engine disassembly and reassembly 30-2
30.1.1 - Commercially available tools 30-2
30.2 - Workshop tools for engine disassembly and reassembly (Lv.2) 30-5
30.2.1 - Workshop tools for engine disassembly and reassembly (Lv.2) 30-5
30.3 - Workshop tools for engine disassembly and reassembly (Lv.3) 30-9
30.3.1 - Workshop tools for engine disassembly and reassembly (Lv.3) 30-9
30.4 - Workshop tools for disassembly and reassembly (5090 C -> ZKDY360200TD10001, 5100 C
-> ZKDY400200TD10001) 30-16
30.5 - Workshop tools for disassembly and reassembly (5110 C -> ZKDY440200TD10001) 30-19
30.6 - Workshop tools for disassembly and reassembly (5100 C -> ZKDY480200TD10001) 30-22
30.7 - Workshop tools for disassembly and reassembly (5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 30-26
30.8 - B0 - Engine 30-30
30.8.1 - Separating engine from transmission 30-30
30.8.2 - Replace the crankshaft O-ring (flywheel end) 30-35
30.8.3 - Fitting and removing seal seat 30-38
30.8.4 - Fitting and removing transition pipe 30-40
30.8.5 - Line 30-42
30.8.6 - Removal and refitting of the oil sump pan. 30-42
30.8.7 - Closing components 30-47
30.8.8 - Topping up with oil 30-47
30.8.9 - Removal and refitting of the flywheel (fixing elements) 30-47

VI
CONTENTS
30.8.10 - Removal and refitting of the cylinder head cover 30-49
30.8.11 - Support 30-52
30.8.12 - Intermediate gear 30-52
30.8.13 - Removal and refitting of the oil cooler 30-52
30.8.14 - Lubricating oil filter console 30-54
30.8.15 - Removal and refitting of the oil pickup pipe 30-54
30.8.16 - Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger) 30-56
30.8.17 - Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger) 30-58
30.8.18 - Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger) 30-61
30.8.19 - Removal and refitting of the lubricating oil return pipe (exhaust gas turbocharger) 30-65
30.8.20 - Fitting and removing the high pressure pump 30-68
30.8.21 - Removal and refitting of the injectors 30-74
30.8.22 - Removal and refitting of the common rail 30-79
30.8.23 - Removal and refitting of the charge air duct 30-87
30.8.24 - Removal and refitting of the charge air manifold 30-88
30.8.25 - Intake manifold (turbocharger) 30-90
30.8.26 - Charge air manifold 30-90
30.8.27 - Charge air duct 30-91
30.8.28 - V-belt pulley 30-91
30.8.29 - Actuating elements 30-91
30.8.30 - V-belt pulley 30-92
30.8.31 - Removal and refitting of the thermostat 30-92
30.8.32 - Testing the thermostat (after removal) 30-94
30.8.33 - Line 30-96
30.8.34 - Line 30-97
30.8.35 - Line 30-97
30.8.36 - Connection (crankcase, exhaust gas recovery, coolant pipe) 30-97
30.8.37 - Fitting compensator (exhaust pipe) 30-98
30.8.38 - Pipe (thermostat housing, exhaust gas recovery, coolant pipe) 30-98
30.8.39 - Removal and refitting of the turbocharger 30-99
30.8.40 - Removal and refitting of the turbocharger 30-101
30.8.41 - Exhaust manifold (turbocharger) 30-102
30.8.42 - Exhaust manifold (turbocharger) 30-102
30.8.43 - Exhaust manifold (turbocharger) 30-103
30.8.44 - Removing and refitting the belt tensioner (ribbed V-belt, level 1). 30-103
30.8.45 - Fitting and removing the console (ribbed V-belt, level 1) 30-104
30.8.46 - Engine mounting 30-107
30.8.47 - Engine mounting 30-107
30.8.48 - Engine mounting 30-107
30.8.49 - Disassembly and assembly of the connector box 30-108
30.8.50 - Disassembly and assembly of the connector box 30-110
30.8.51 - Disassembly and assembly of the connector box 30-112
30.8.52 - Disassembly and assembly of the connector box 30-114
30.8.53 - Disassembly and assembly of the connector box 30-116
30.8.54 - Connector casing 30-118
30.8.55 - Console 30-118
30.8.56 - Removing and fitting hydraulic pump drive 30-118
30.8.57 - Engine flywheel (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,

VII
 CONTENTS
5120 C -> ZKDY560200TD10001) 30-120
30.8.58 - Engine 30-121
30.8.59 - A/C compressor belt 30-125
30.8.60 - Alternator / water pump belt 30-126
30.8.61 - Connecting rod drum check (L3) 30-126
30.8.62 - Removing and fitting pistons (L3) 30-134
30.8.63 - Check the piston (L3) 30-136
30.8.64 - Removing and fitting piston rings (L3) 30-140
30.8.65 - Checking piston rings (L3) 30-141
30.8.66 - Disassembly and assembly the cylinder head (fastening elements) (L3) 30-142
30.9 - C0 - Engine accessories 30-147
30.9.1 - Intercooler 30-147
30.9.2 - Catalytic converter 30-148
30.9.3 - Coolant fluid radiator 30-149
30.9.4 - Fuel radiator 30-150
30.9.5 - Fuel tank 30-151
30.9.6 - Exhaust pipe 30-153
30.9.7 - Viscostatic fan 30-154
30.9.8 - Air filter container 30-154
30.9.9 - Radiator assembly 30-155
30.9.10 - Disassembling the radiator assembly 30-158
30.9.11 - Fuel prefilter 30-160
30.9.12 - Fuel filter 30-161
30.9.13 - Fuel line 30-162
30.9.14 - Fuel delivery pump 30-163
30.9.15 - Oil measuring device 30-163
30.9.16 - Removing and fitting fuel line (injector, rail, high pressure pump) 30-163
30.9.17 - Blower fan 30-167
30.9.18 - Removal and refitting of the exhaust manifold 30-167
30.9.19 - Removal and refitting of the exhaust manifold 30-169
30.9.20 - Removing and fitting the alternator (retainer bracket) 30-171
30.9.21 - Removing and fitting the alternator (fastener elements) 30-174
30.9.22 - Disassembly and assembly of the starter 30-176
30.9.23 - Disassembly and assembly of the starter 30-178
30.9.24 - Alternator 30-180
30.9.25 - Alternator 30-180
30.9.26 - Camshaft speed sensor 30-180
30.9.27 - Removal and refitting of the glowplugs 30-181
30.9.28 - Pressure transducer (L3) 30-182
30.9.29 - Pressure sensor (L3) 30-183
30.9.30 - Speed indicator (L3) 30-185
30.10 - D0 - Transmission 30-187
30.10.1 - Engine torsional spring plate (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-187
30.10.2 - Shuttle unit - Complete assembly (5100 C -> ZKDY480200TD10001) 30-187
30.10.3 - Shuttle unit - Complete assembly (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-189
30.10.4 - Disassembling the shuttle unit (5100 C -> ZKDY480200TD10001) 30-191

VIII
CONTENTS
30.10.5 - Disassembling the shuttle unit (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-194
30.10.6 - Disassembling cover assembly (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-197
30.10.7 - Removing the forward drive clutch unit (5100 C -> ZKDY480200TD10001) 30-198
30.10.8 - Removing the forward drive clutch unit (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-202
30.10.9 - Disassembling the reverse drive clutch unit (5100 C -> ZKDY480200TD10001) 30-206
30.10.10 - Disassembling the reverse drive clutch unit (5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 30-211
30.10.11 - Input shaft assembly and tone wheel (5100 C -> ZKDY480200TD10001) 30-217
30.10.12 - Input shaft assembly and tone wheel (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-218
30.10.13 - DT shaft in transmission 30-220
30.10.14 - Clutch housing - Separation from transmission 30-221
30.10.15 - Range selector assembly 30-224
30.10.16 - Disassembling the range selector assembly 30-225
30.10.17 - Gearbox internal cover 30-227
30.10.18 - HI-LO unit (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-229
30.10.19 - HI-LO unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110
C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-236
30.10.20 - Disassembling the HI range clutch housing (5090 C -> ZKDY360200TD10001, 5100 C
-> ZKDY400200TD10001) 30-242
30.10.21 - Disassembling the LO range clutch housing (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-254
30.10.22 - Disassembling the HI-LO planetary reduction gearbox (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-265
30.10.23 - Disassembling the HI-LO planetary reduction gearbox (5100 C ->
ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-266
30.10.24 - HML unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 30-268
30.10.25 - Disassembling the HML unit 30-272
30.10.26 - Disassembling M-L clutches (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-275
30.10.27 - Disassembling the H clutch (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-280
30.10.28 - Replacing the L clutch (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-284
30.10.29 - Disassembly of the HML planetary reduction gearbox (5100 C ->
ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-289
30.10.30 - Outer HML casing (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-291
30.10.31 - Gearbox and HI-LO unit 30-293
30.10.32 - Gearbox/HML assembly (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-295

IX
 CONTENTS
30.10.33 - Secondary shaft - Version with HI-LO (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)30-300
30.10.34 - Secondary shaft - Version with HI-LO (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-305
30.10.35 - Secondary shaft - Version with HML (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-310
30.10.36 - Primary shaft (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 30-314
30.10.37 - Disassembling the gearbox input shaft (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-315
30.10.38 - Disassembly of secondary shaft - Version with HI-LO (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-318
30.10.39 - Disassembly of secondary shaft - Version with HI-LO () 30-322
30.10.40 - Disassembly of the main shaft 30-326
30.10.41 - Disassembly of HI-LO unit output shaft (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)30-328
30.10.42 - Disassembly of HI-LO unit output shaft (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-329
30.10.43 - Disassembling the HML unit output shaft (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-330
30.10.44 - PTO output shaft - 2 speed version 30-332
30.10.45 - PTO output shaft - 4 speed version (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)30-334
30.10.46 - PTO output shaft - 4 speed version (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-337
30.10.47 - Disassembling the PTO output shaft - 2-speed version 30-341
30.10.48 - Removing the PTO output shaft - 4 speed version (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001) 30-342
30.10.49 - Removing the PTO output shaft - 4 speed version (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-344
30.10.50 - PTO engagement clutch 30-346
30.10.51 - Disassembling PTO engagement clutch (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)30-351
30.10.52 - Disassembling PTO engagement clutch (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-355
30.10.53 - Pump drive PTO - External gear 30-358
30.10.54 - Pump drive PTO - Internal gear 30-361
30.10.55 - Disassembling the PTO flange shaft - 2-speed version () 30-363
30.10.56 - Disassembling PTO final flange shaft - 4 speed version (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-367
30.10.57 - Disassembling PTO final flange shaft - 4 speed version (5100 C ->
ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-371

X
CONTENTS
30.10.58 - Removing the rear pinion - 2-range version (5090 C -> ZKDY360200TD10001, 5100 C
-> ZKDY400200TD10001) 30-376
30.10.59 - Removing the rear pinion - 2-range version (5110 C -> ZKDY440200TD10001) 30-381
30.10.60 - Removing the rear pinion - 2-range version (5100 C -> ZKDY480200TD10001, 5110 C
-> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-386
30.10.61 - Removing the rear pinion - 4-range version (5090 C -> ZKDY360200TD10001, 5100 C
-> ZKDY400200TD10001) 30-391
30.10.62 - Removing the rear pinion - 4-range version (5110 C -> ZKDY440200TD10001) 30-399
30.10.63 - Removing the rear pinion - 4-range version (5100 C -> ZKDY480200TD10001, 5110 C
-> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-407
30.10.64 - Adjustment of the differential - Bevel gear set (5090 C -> ZKDY360200TD10001, 5100
C -> ZKDY400200TD10001) 30-416
30.10.65 - Adjustment of the differential - Bevel gear set (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-424
30.10.66 - Disassembling the ground speed PTO flange output shaft 30-433
30.10.67 - Disassembling the ground speed PTO clutch engage mechanism 30-435
30.10.68 - Disassembly of dual traction output shaft (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)30-436
30.10.69 - Disassembly of dual traction output shaft (5110 C -> ZKDY440200TD10001) 30-438
30.10.70 - Disassembly of dual traction output shaft (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-441
30.10.71 - Removing dual traction output shaft - 4-range version (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-443
30.10.72 - Removing dual traction output shaft - 4-range version (5110 C ->
ZKDY440200TD10001)30-449
30.10.73 - Removing dual traction output shaft - 4-range version (5100 C ->
ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-455
30.10.74 - Disassembling EasyShift DT clutch system 30-461
30.10.75 - Disassembly of dual traction clutch - Easyshift with mechanical park brake 30-465
30.10.76 - Pump drive PTO - External gear without 60 l ECO pump 30-473
30.11 - E0 - Rear axle 30-475
30.11.1 - Wheel carriers 30-475
30.11.2 - Wheel mount disassembly 30-477
30.11.3 - Park Brake assembly (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-484
30.11.4 - Park Brake unit disassembly (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-487
30.11.5 - Rear differential (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-490
30.11.6 - Rear differential (5110 C -> ZKDY440200TD10001) 30-493
30.11.7 - Rear differential (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 30-496
30.11.8 - Removing rear differential 30-500
30.11.9 - Disassembling the brake carrier (versions without Park Brake) 30-503
30.11.10 - Brake carrier (versions without Park Brake) 30-504
30.12 - F0 - Front axle 30-506
30.12.1 - Front axle 30-506

XI
 CONTENTS
30.12.2 - Steering cylinders 30-508
30.12.3 - Removing steering cylinders 30-510
30.12.4 - 4WD shaft () 30-513
30.12.5 - Separating front carrier from engine 30-514
30.12.6 - Front mount 30-518
30.13 - G0 - Bodywork - Cab - Platform 30-520
30.13.1 - Cab 30-520
30.13.2 - Condenser 30-526
30.13.3 - Disassembling the condenser 30-527
30.13.4 - Dehydrator filter 30-528
30.13.5 - A/C unit 30-529
30.13.6 - Heater unit 30-530
30.13.7 - Cab access steps 30-531
30.13.8 - Expansion valve 30-531
30.13.9 - Engine cowl 30-532
30.13.10 - Hand brake bowden cable replacement 30-533
30.14 - H0 - Hydraulic system 30-536
30.14.1 - Rear ancillary utility distributor 30-536
30.14.2 - Services solenoid valve assembly 30-537
30.14.3 - Disassembling the ancillary solenoid valve block 30-539
30.14.4 - Shuttle solenoid valves assembly (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)30-541
30.14.5 - Disassembling shuttle solenoid valve block (5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 30-542
30.14.6 - Power steering valve 30-544
30.14.7 - Disassembling the complete pump assembly 30-547
30.14.8 - Transmission oil radiator 30-551
30.14.9 - 60L ECO 8-way distributor solenoid valve 30-552
30.14.10 - Disassembling the 60L ECO 8-way distributor solenoid valve 30-554
30.14.11 - 2-way distributor 30-556
30.14.12 - Disassembling the 2-way distributor 30-557
30.14.13 - Pressure transducer / Temperature sender (intake air) 30-559
30.14.14 - 4-rear way ancillary utility distributor 30-560
30.14.15 - 6-rear way ancillary utility distributor 30-563
30.14.16 - Replacing positioning for automatic release 30-567
30.15 - L0 - Electrical system 30-569
30.15.1 - Battery mount with wiring loom 30-569
30.16 - M0 - Front PTO 30-575
30.16.1 - Disassembling front PTO 30-575
30.17 - R0 - Rear lift 30-584
30.17.1 - S.A.C. Automatic control station 30-584
30.17.2 - Disassembling the hitch assembly (SAC) 30-587
30.17.3 - Bushes 30-592
30.17.4 - Auxiliary hitch cylinders 30-593
30.17.5 - Disassembling the rear hitch control distributor 30-594
30.17.6 - Mechanical draft sensor 30-595
30.17.7 - 3-point linkage 30-597

XII
CONTENTS
30.17.8 - Rear lift draft rod replacement 30-598
30.18 - S0 - Wheels 30-602
30.18.1 - Rear wheels 30-602
30.18.2 - Front Wheels 30-603
30.19 - V0 - Ballast - towing hitches 30-605
30.19.1 - Tow hook sled 30-605
30.20 - V1 - AFTERMARKET KITS 30-606
30.20.1 - Head and pin kit assembly procedure for automatic hitch 30-606

40 - Wiring diagrams
40.1 - Introduction 40-2
40.1.1 - Introduction 40-2
40.1.2 - Basic electronics for mechanics (1/2) 40-4
40.1.3 - Basic electronics for mechanics (2/2) 40-7
40.1.4 - Electrical and electronic components (1/2) 40-13
40.1.5 - Electrical and electronic components (2/2) 40-21
40.2 - Components 40-26
40.2.1 - A - Starting and charging (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)40-26
40.2.2 - A - Starting and charging (5110 C -> ZKDY440200TD10001) 40-26
40.2.3 - A - Starting and charging (5100 C -> ZKDY480200TD10001) 40-28
40.2.4 - A - Starting and charging (5110 C -> ZKDY520200TD10001) 40-28
40.2.5 - A - Starting and charging (5120 C -> ZKDY560200TD10001) 40-30
40.2.6 - B - Fuses (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-31
40.2.7 - B - Fuses (5110 C -> ZKDY440200TD10001) 40-37
40.2.8 - B - Fuses (5100 C -> ZKDY480200TD10001) 40-43
40.2.9 - B - Fuses (5110 C -> ZKDY520200TD10001) 40-49
40.2.10 - B - Fuses (5120 C -> ZKDY560200TD10001) 40-55
40.2.11 - C - Grounds (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-61
40.2.12 - C - Grounds (5110 C -> ZKDY440200TD10001) 40-63
40.2.13 - C - Grounds (5100 C -> ZKDY480200TD10001) 40-64
40.2.14 - C - Grounds (5110 C -> ZKDY520200TD10001) 40-66
40.2.15 - D - Intermediate connections (5090 C -> ZKDY360200TD10001) 40-67
40.2.16 - D - Intermediate connections (5100 C -> ZKDY400200TD10001) 40-72
40.2.17 - D - Intermediate connections (5110 C -> ZKDY440200TD10001) 40-76
40.2.18 - D - Intermediate connections (5100 C -> ZKDY480200TD10001) 40-81
40.2.19 - D - Intermediate connections (5110 C -> ZKDY520200TD10001) 40-86
40.2.20 - D - Intermediate connections (5120 C -> ZKDY560200TD10001) 40-91
40.2.21 - E - On-board instruments and visual and audible indicators (5090 C ->
ZKDY360200TD10001)40-96
40.2.22 - E - On-board instruments and visual and audible indicators (5100 C ->
ZKDY400200TD10001)40-97
40.2.23 - E - On-board instruments and visual and audible indicators (5110 C ->
ZKDY440200TD10001)40-97
40.2.24 - E - On-board instruments and visual and audible indicators (5100 C ->
ZKDY480200TD10001)40-98
40.2.25 - E - On-board instruments and visual and audible indicators (5110 C ->

XIII
 CONTENTS
ZKDY520200TD10001)40-98
40.2.26 - E - On-board instruments and visual and audible indicators (5120 C ->
ZKDY560200TD10001)40-99
40.2.27 - F - External lights (rotating beacon) (5090 C -> ZKDY360200TD10001) 40-99
40.2.28 - F - External lights (rotating beacon) (5100 C -> ZKDY400200TD10001) 40-102
40.2.29 - F - External lights (rotating beacon) (5110 C -> ZKDY440200TD10001) 40-105
40.2.30 - F - External lights (rotating beacon) (5100 C -> ZKDY480200TD10001) 40-108
40.2.31 - F - External lights (rotating beacon) (5110 C -> ZKDY520200TD10001) 40-111
40.2.32 - F - External lights (rotating beacon) (5120 C -> ZKDY560200TD10001) 40-114
40.2.33 - G - Interior lights 40-117
40.2.34 - H - Manual electrical controls (steering column switch) (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110 C ->
ZKDY440200TD10001)40-117
40.2.35 - H - Manual electrical controls (steering column stalk) (5100 C -> ZKDY480200TD10001)
40-117
40.2.36 - H - Manual electrical controls (steering column switch) (5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-118
40.2.37 - I - Circuit breakers (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)
40-119
40.2.38 - I - Circuit breakers (5110 C -> ZKDY440200TD10001) 40-122
40.2.39 - I - Circuit breakers (5100 C -> ZKDY480200TD10001) 40-126
40.2.40 - I - Circuit breakers (5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
40-129
40.2.41 - J - Relays (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-133
40.2.42 - J - Relays (5110 C -> ZKDY440200TD10001) 40-135
40.2.43 - J - Relays (5100 C -> ZKDY480200TD10001) 40-137
40.2.44 - J - Relays (5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-139
40.2.45 - K - Sensors and transmitters (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)40-141
40.2.46 - K - Sensors and transmitters (5110 C -> ZKDY440200TD10001) 40-143
40.2.47 - K - Sensors and transmitters (5100 C -> ZKDY480200TD10001) 40-145
40.2.48 - K - Sensors and transmitters (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)40-148
40.2.49 - L - Electromagnets and solenoid valves (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)40-150
40.2.50 - L - Electromagnets and solenoid valves (5110 C -> ZKDY440200TD10001) 40-151
40.2.51 - L - Electromagnets and solenoid valves (5100 C -> ZKDY480200TD10001) 40-152
40.2.52 - L - Electromagnets and solenoid valves (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)40-152
40.2.53 - M - Electrical/electronic devices, Flasher units and Timers (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-153
40.2.54 - M - Electrical/electronic devices, Flasher units and Timers (5110 C ->
ZKDY440200TD10001)40-154
40.2.55 - M - Electrical/electronic devices, Flasher units and Timers (5100 C ->
ZKDY480200TD10001)40-154
40.2.56 - M - Electrical/electronic devices, Flasher units and Timers (5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-155
40.2.57 - N - Electric motors and actuators (5090 C -> ZKDY360200TD10001, 5100 C ->

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CONTENTS
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-156
40.2.58 - O - Resistors and rheostats (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-156
40.2.59 - O - Resistors and rheostats (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-156
40.2.60 - P - Various services (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-156
40.2.61 - P - Various services (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-157
40.2.62 - R - Diagnostics (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001) 40-158
40.2.63 - R - Diagnostics (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-158
40.2.64 - 04217755 - Engine control unit 40-158
40.2.65 - 2.8519.171.0/20 - HLHP2 ECU (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-160
40.2.66 - 2.8519.171.0/20 - HLHP2 ECU (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-162
40.2.67 - 2.8339.285.0/30 - Digital instrument cluster (MTA 2.0) 40-164
40.2.68 - 2.8519.148.0 - ISO 11786 ECU 40-166
40.3 - Systems 40-167
40.3.1 - S001 - Electronic engine throttle (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-167
40.3.2 - S001 - Electronic engine throttle (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-179
40.3.3 - S002 - Preheating (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001) 40-192
40.3.4 - S002 - Preheating (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-200
40.3.5 - S003 - Starter (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110
C -> ZKDY440200TD10001) 40-208
40.3.6 - S004 - Hitch (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-214
40.3.7 - S004 - Lift (5110 C -> ZKDY440200TD10001) 40-224
40.3.8 - S004 - Lift (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001) 40-235
40.3.9 - S005 - Lights (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110
C -> ZKDY440200TD10001) 40-246
40.3.10 - S005 - Lights (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-261
40.3.11 - S006 - Work lights (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001) 40-276
40.3.12 - S006 - Work lights (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-301
40.3.13 - S007 - Windscreen wiper 40-326
40.3.14 - S008 - Instrument panel (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-338
40.3.15 - S008 - Instrument panel (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-354

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 CONTENTS
40.3.16 - S009 - Radio 40-369
40.3.17 - S010 - Manual air conditioner (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-377
40.3.18 - S010 - Manual air conditioner (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-388
40.3.19 - S011 - Transmission (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-399
40.3.20 - S011 - Transmission (5100 C -> ZKDY480200TD10001) 40-412
40.3.21 - S011 - Transmission (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)40-425
40.3.22 - S012 - PTO (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110
C -> ZKDY440200TD10001) 40-438
40.3.23 - S012 - PTO (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001) 40-449
40.3.24 - S013 - Accessories (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-460
40.3.25 - S013 - Accessories (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-474
40.3.26 - S014 - CAN BUS (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001) 40-488
40.3.27 - S014 - CAN BUS (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-499
40.3.28 - S015 – CAN BUS (Engine line) (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-510
40.3.29 - S015 – CAN BUS (Engine line) (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-515
40.3.30 - S016 - Brakes (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001) 40-521
40.3.31 - S017 - Trailer brake (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-531
40.3.32 - S018 - Diagnostics 40-540
40.3.33 - S019 - Distributors (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001) 40-545
40.3.34 - S003 - Starter (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-552
40.3.35 - S016 - Brakes (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-558
40.3.36 - S017 - Trailer brake (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-567
40.3.37 - S019 - Distributors (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001) 40-576
40.4 - Wiring harnesses 40-583
40.4.1 - 0.019.3018.4/20 - Front wiring loom 40-583
40.4.2 - 0.020.6707.4/20 - Cab () 40-587
40.4.3 - 0.020.3229.4/30 - Rear wiring loom (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001) 40-596
40.4.4 - 0.020.2857.4/10 - Rear wiring loom (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-606

XVI
CONTENTS
40.4.5 - 0.014.1567.4/20 - Front windscreen wiper 40-611
40.4.6 - 0.014.8453.4 - Front wiper motor - fixed windscreen version 40-612
40.4.7 - 0.020.6706.4/20 - Roof 40-612
40.4.8 - 0.020.7971.4/10 - Right hand console 40-620
40.4.9 - 0.019.9803.4 - Front light-horn - High (5090 C -> ZKDY360200TD10001) 40-623
40.4.10 - 0.019.9803.4 - Front light-horn - High (5100 C -> ZKDY400200TD10001) 40-625
40.4.11 - 0.019.9803.4 - Front light-horn - High (5110 C -> ZKDY440200TD10001) 40-627
40.4.12 - 0.019.9803.4 - Front light-horn - High (5100 C -> ZKDY480200TD10001) 40-629
40.4.13 - 0.019.9803.4 - Front light-horn - High (5110 C -> ZKDY520200TD10001) 40-631
40.4.14 - 0.019.9803.4 - Front light-horn - High (5120 C -> ZKDY560200TD10001) 40-633
40.4.15 - 0.020.8203.4 - Cab roof work lights 40-635
40.4.16 - 0.020.9462.4/10 - Rotating beacon 40-637
40.4.17 - 0.021.1196.4 – Lower front work lights wiring loom – H9 40-639
40.4.18 - 0.012.2756.3 - Front PTO solenoid valve 40-641
40.4.19 - 0.011.3797.3 - SBA-ASM (GS-LS 110 HP) (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)40-641
40.4.20 - 0.017.9311.4/30 – Hydraulic reverse shuttle wiring loom - Stoll (GS only) (5100
C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)40-642
40.4.21 - 0.015.1440 – Shuttle SV wiring loom, 100 HP (for GS 110/120 HP only) (5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 40-644
40.4.22 - 0.014.1645.4/10 - ITA-D Air braking pressure switch 40-645
40.4.23 - 0.019.8827.4 - S.D.D (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)40-645
40.4.24 - 0.016.1001.4/20 - Hydraulic trailer braking valve 40-648
40.4.25 - 0.018.5346.4 – 2-way electronic distributor electrical system wiring loom 40-649
40.4.26 - 0.020.0726.4 - Fuel pre-filter 40-651
40.4.27 - 0.020.6714.4 - Battery wiring (-) 40-653
40.4.28 - 0.021.1202.4 - Battery wiring (+) 40-655
40.4.29 - 04219367 - Alternator fuse wiring loom (GS 100/110 HP - LS) (5090
C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5100 C
-> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C ->
ZKDY520200TD10001)40-657
40.4.30 - 0.019.5702.4 - ISO 11786 40-658

XVII
 CONTENTS

PAGE LEFT INTENTIONALLY BLANK

XVIII
0 - Introduction

0-1
 Introduction
0.1 - Introduction
This workshop manual has been prepared to provide instructions for repair technicians and as a practical guide to improve the
quality of repairs. This manual is intended as a guide for repair technicians to give them a thorough understanding of the machine,
and describes the correct procedures for troubleshooting and performing repair jobs safely, the methods and conditions necessary
for checking the dimensions of and visually inspecting parts subject to repair and, lastly, indicates the products, tightening torques,
and correct adjustment or setting data to be used. The material contained in this manual is of a confidential technical nature, and is
intended for dealers and authorised workshops only. In the event of any changes of a strictly technical nature regarding the machines,
the intended recipients will be notified promptly with supplements to the manual illustrating modifications, updates and additional
optional devices. Technicians and their employees shall not distribute, reproduce or divulge the material contained herein to others
without written permission from the Manufacturer who is the exclusive owner thereof and who reserves the right to take legal action
based on current laws to protect its rights.
0.1.1 - Safety notes
For the machine to continue to function correctly, it is crucial that all repairs are performed properly by a service centre authorised to
repair and service these machines. The testing and repair techniques recommended and described in this manual are effective and
safe methods for obtaining good operation. Some of the described operations require the use of special and dedicated tools; these
can be requested from the Manufacturer who has specifically designed them for their intended purpose. DO NOT USE IMPROVISED
TOOLS; they could create potentially dangerous situations and do not always correspond to the specific functions for which they
are created and used. If a dangerous situation occurs or is anticipated, consider safety first of all and take the necessary actions to
handle the situation
0.1.2 - General safety
l Even if you are completely familiar with the construction, functions and controls of this machine, always observe extreme cau-
tion when manoeuvring and operating the machine Always bear in mind that a machine brought to the workshop is in need of
repair or servicing, and may therefore react unpredictably to controls.
l Before starting work, clean the machine thoroughly to remove mud, dust and gravel. Also clean the cab thoroughly to remove
all residue of oil, snow or ice from the steps, handles and grips normally used to access and leave the cab.
l When climbing into or out of the machine, maintain three points of contact at all times prevent loss of balance and the risk of
falling.
l Observe extreme caution when troubleshooting faults, which must often be performed by two operators: never stand in front
of the wheels while the engine is running.
l When performing tests and repairs, always wear close fitting clothing, goggles and gloves suitable for the operation to perform
(cleaning, draining fluids, repairs). Do not go near moving parts with long hair that has not been tied back, hair can get caught
and create serious injury.
l Keep unauthorised persons away from the machine they must be required to remain at a safe distance.
l Keep away from moving parts; with the engine on, some parts are not very visible and thus, even if protected, may represent
a potential danger of being drawn in.
l When starting the engine, make sure that the area is well ventilated to avoid a build up of toxic gases; always apply the ex-
haust pipe of the forced fume extraction devices.
l Absolutely avoid running the engine without guards; all repair and/or adjustment operations must be performed with the en-
gine off.
l Do not fill up fuel, oil or coolant with the engine running.
l Do not smoke when filling up fuel or lubricant and make sure there are no open flames in the vicinity. Do not charge the battery
on board the machine.
l Before working on the battery to check it or remove it, stop the engine and remove the key.
l Remove the battery and recharge it in a well ventilated area and with a temperature greater than 0°C.
l Do not smoke during battery testing and recharging, and do not go near it with open flames since the hydrogen emitted during
chemical reactions may explode.
l The liquid (electrolyte) contained in the battery is dangerous for the skins and above all for the eyes; for this reason when test-
ing the battery always wear gloves and safety goggles with side shields. If you accidentally get electrolyte on you immediately
wash the contaminated parts for a long time with water; if your clothes are contaminated change them as quickly as possible.
If you accidentally swallow electrolyte, drink plenty of water, milk, vegetable oil and antacids such as magnesium, bicarbonate,
etc., and go to an emergency room as soon as possible.
l If work needs to be done on the electrical circuits, disconnect the terminals from the battery.

0-2
Introduction
DANGER
First disconnect the negative terminal (--) then the positive one (+); after the repair work, first connect the positive pole
(+) then the negative one (--).

l If any arc welding is necessary (which is permitted in certain special cases only on implements attached to the machine),
disconnect the battery terminals, all electronic control unit connectors and the alternator.
l When filling up or changing lubricants, always use waterproof gloves.
l Do not wear clothing contaminated with engine oil or hydraulic circuit oil; prolonged contact with the skin may be harmful and
for some people cause allergic reactions.
l Engine oil and hydraulic circuit oil are considered special wastes; recover the lubricants and have them disposed of according
to current laws.
l Discharge any remaining pressure before working on the hydraulic and pneumatic circuits.
l Wait for the oil and water to cool before working on the hydraulic circuits and on the engine.
l During the removal and installation of certain assemblies on the machine, the weight of the engine must be adequately sup-
ported; use saw horses, jacks or blocks suitable for the weight to support and put it in a triangular position to prevent it from
flipping over.
l Use a hoist or a crane to lift heavy components. Make sure that metal cables, chains or fibre belts are not worn and that the
hooks are not damaged.
l Always use lifting equipment which can easily support the weight of the units to remove and connect correctly.
l When lifting or supporting an assembly or part of the machine, work slowly to prevent swinging and collisions with other parts,
which may cause injury or damage.
l Never work on parts or units hanging on a hoist or crane.
l If removing the screws from units which can fall, always leave two opposite screws for safety purposes; remove these screws
only after having hooked the unit to a lifting device or after having positioned support blocks.
l If fuel or oil drips on the floor during removal or assembly operations, clean it as soon as possible to avoid operators slipping
and possible fires.
l If electrical cables or wires are removed, make sure that they are reassembled with their original fastening, to prevent machine
vibration from damaging them.
l Never insert your hands or fingers to check the alignment between two holes, use soft material pins.
l When installing units or parts, always use the torques indicated in the general tables; the torques indicated in the paragraphs
regarding assembly, are specific torques whose values have been determined by testing and they must absolutely be com-
plied with.
l If installing parts subject to strong vibrations or which turn at high speed, pay particular attention during the final test of the
installation.

0.1.3 - Precautions to use during performance of the work

When disassembling or assembling a part, always follow the general precautions below.
Precautions for disassembly
l Unless indicated otherwise, lower all implements to the ground.
l After disconnecting the pipes of the hydraulic system and fuel supply system, fit the caps to prevent impurities from entering.
l Before removing a cylinder, retract the piston completely and secure it in this position with a clamp.
l Use a container with sufficient capacity to recover oil, coolant or fuel.
l Before removing a machine part, check the alignment references which indicate the correct assembly position. Add additional
marks if necessary to avoid incorrect assembly.
l When disassembling the connectors, always hold them tightly to prevent forcing on the electrical cables.
l Mark the electrical cables and pipes if necessary to avoid mixing them up during assembly.
l Check the number and height of the shims and put them in a safe place.
l Use lifting equipment of suitable load capacity when lifting the machine or parts thereof.
l When using eye-bolts to remove parts of the machine, ensure that there are not damaged; completely tighten them and then
align the direction of the eye with the lifting hook.
l Before removing a part, accurately clean the surrounding area and, after removing the part, cover it to prevent dirt and dust
from getting on it.

0-3
 Introduction
Precautions for assembly
l Tighten nuts and screws with the specified torques.
l Fit hoses and wiring being careful not to bend or twist them.
l Replace gaskets, O-rings, split pins and safety stop rights with new parts; make sure the tines of the split pin are separated
and bent and thus so they cannot come out of their seats.
l After fitting the snap rings, make sure they are well inserted in their seat.
l When you need to lock threading with sealant, clean the part removing oil and grease, then apply drops of adhesive in order
to uniformly cover the threading.
l To apply sealants, clean the involved surface, remove any residual oil and grease, make sure there are no dents or dirt, then
apply the sealant uniformly making sure it completely surrounds any holes.
l Clean all the parts, remove dirt, oxidation, carbonaceous deposits, burrs and dents.
l Apply a film of engine oil to all moving parts.
l When fitting the electrical system connectors, remove oil, dust or water which can penetrate between the contacts and then
connect them tightly; when required force the connectors until the twin lock catch.
l Lock the flanged couplings uniformly, tightening the screws in a crossed and alternating sequence.
Precautions to observe at the end of disassembly/assembly operations
l If you drained the coolant, screw down the drain cap and add new coolant up to the level. Start the engine and let the coolant
circulated in the cooling system and then top up.
l When the hydraulic equipment has been disassembled, add oil up to the indicated level. Start the engine and let the oil circu-
late in the hydraulic circuits and then top up.
l When the variable displacement pump is removed, connect the drain pipe and fill the casing using the cap provided for this
purpose.
l After having reassembled the joint boxes, cylinder joints and driveshafts, grease completely.

0.1.4 - Lifting instructions

DANGER
Machine units with a weight over 25 kg or with large dimensions, must be supported or removed with a lifting device
and metal cables or polyester belts.

Metal cables - belts

l Use cables or polyester belts suitable for the weight to lift, referring to the following tables:
Table 1
METAL CABLES (standard «S» or «Z» twisted type) POLYESTER BELTS (with slots - simple)
cable Ø mm Capacity (kg) Width (mm) Capacity (kg)
60° 90° 60° 90°

8 650 620 500 25 500 400 860 700

10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530
Note
The capacity is calculated with a safety coefficient.

l The cables and belts must be connected to the lifting hook in the central part; hooking the cables towards the end may cause
the load to slide during lifting.
l Never hang a heavy load from just one cable; always use two or more symmetrical cables.
DANGER
Suspension from just one cable can cause the load to rotate and cause the cable to come untwisted, or slide from the
winding position; these possibilities can cause serious accidents.

0-4
Introduction
l Do not lift a heavy load when the two ends of the cables form a wide suspension angle. The permitted load (kg) decreases
when the suspension angle increases; the table below, indicates the variation in permitted load (based on the suspension
angle), for two Ø 10 mm diameter cables each with a load capacity of 1000 kg.

2000
1900
Capacità di carico: kg
1700
2000
1400

1000
1000
500

30° 60° 90° 120° 150°

Angolo di sospensione:

Fig. 1

0.1.5 - Tightening torques

Screws and nuts
DANGER
The specific torques for important parts and the tightening to perform with special procedures, are given within the
individual assembly paragraphs.

The indicated torques refer to screws and nuts fitted without lubrication, possible with threading spread with anaerobic threadlock.
The values indicated refer to tightening on steel or cast iron material; for soft material such as aluminium, copper or plastics, plated
or panels, the torques need to be reduced by 50%.
See para. 0.4 - Tightening torques - page 0-14
Unions
The indicated torques refer to fitting unions on any material.
Table 2
MET- Unions with straight Unions with “T” ends Unions with “L” ends Unions with 90° ends
RIC ends

Thread Spanner Torque Nm Spanner Torque Nm Spanner Torque Nm Spanner Torque Nm

±10% ±10% ±10% ±10%
M10x1.25 17 14 14 14 14 14 14 14
19 14 17 14 17 14
M12x1.25 19 30 17 30 17 30 17 30
M14x1.5 19 40 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48 22 48
M18x1.5 24 58 24 58 24 58 24 58
M20x1.5 27 65 27 65 27 65 27 65
M22x1.5 30 73 30 73 30 73 30 73
M26x1.5 36 95 36 95 36 95 36 95
M27x2 36 100 36 100 36 100 36 100
M33X2 41 160 41 160 41 160 41 160
M42x2 50 250 50 250 50 250 50 250

0-5
 Introduction
M48x2 60 305 60 305 60 305 60 305
G 1/8” 17 13 14 13 14 13 14 13
19 13
G 1/4” 19 37 19 37 19 37 19 37
22 37
G 3/8” 24 53 24 53 24 53 24 53
G 1/2” 27 73 27 73 27 73 27 73
30 73
G 3/4” 36 100 36 100 36 100 36 100
G 1” 41 160 41 160 41 160 41 160
46 160
G 1 1/4” 50 250 50 250 50 250 50 250
G 1 1/2” 60 305 60 305 60 305 60 305
Plugs
Table 3
Hexagonal head plugs Socket head threaded plugs

Thread Spanner Torque Nm ±10% Spanner Torque Nm ±10%

MET- M6x1 10 10 – –
RIC M8x1 13 12 – –
M10x1 13 14 5 14
M10x1.25 13 14 – –
M10x1.5 13 14 – –
M12x1.25 17 30 – –
M12x1.5 17 30 6 30
M12x1.75 17 30 – –
M14x1.5 19 40 6 40
M14x2 19 40 – –
M16x1.5 22 48 8 48
M16x2 22 48 – –
M18x1.5 17 58 10 58
M18x2.5 17 58 – –
M20x1.5 19 65 – –
M22x1.5 – – 12 73
M24x1.5 22 80 12 80
M24x2 22 80 – –
M27x2 22 100 – –
M28x1.5 – – 17 110
M30x1.5 22 130 – –
M32x1.5 – – 19 150
M35x1.5 – – 22 180
M40x1.5 – – 24 225
G 1/8” 14 13 – –
G 1/4” 19 37 – –
G 3/8” 22 53 – –
G 1/2” 19 73 – –
G 5/8” 22 85 – –
G 3/4” 22 100 – –
G 1” 22 160 – –

0-6
Introduction
Unions with seal at 37°
Table 4

Thread Spanner Torque Nm ±10%

7/16” - 20 14 13
1/2” - 20 16 19
9/16” - 18 17 28
3/4” - 16 22 47
7/8” - 14 27 76
1 1/16” - 12 32 110
36 110
1 3/16” - 12 36 138
1 5/16” - 12 38 155
1 5/8” - 12 50 215
1 7/8” - 12 60 290
2 1/2” - 12 75 345
Union for pipes with eye mounting
These torques refer to tightening of unions with new copper sealing washers.
Table 5
One-way pipe unions Three-way pipe unions Four-way pipe unions

Thread Spanner Torque Nm Spanner Torque Nm Spanner Torque Nm

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

0-7
 Introduction
0.1.6 - Thread lock, adhesive, sealant and lubrication materials
Table 6
FUNCTION DESIGNATION DESCRIPTION
THREAD LOCK Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for weak thread locking of set, adjust-
purple ing and precision screws and nuts. It must be used after having
removed all traces of lubricant with a specific activator.
Loctite 242 Colour: fluorescent blue Anaerobic product suitable for preventing loosening of all types
of screws and nuts and to replace mechanical locks. Used for
medium resistance thread locking. It must be used after having
removed all traces of lubricant with a specific activator.
Loctite 243 Colour: opaque fluorescent Alternative product to 242 which, since it is oil compatible, it does
blue not require the activation of slightly lubricated surfaces.
Loctite 270 Colour: fluorescent green Anaerobic product for extra strength locking of threaded parts,
bolts and stud bolts which normally do not need to be removed.
Removal of parts may require heating to around 80°C. It must be
used after having removed all traces of lubricant with a specific
activator.
DEGREASING Loctite 703 Product for degreasing and cleaning parts before application of
AGENTS AND AC- Loctite anaerobic products; after it is allowed to dry, thread locks
TIVATORS will cure uniformly
Loctite 747 Specific product for treatment of surfaces not very active towards
anaerobic products with slow curing (series 5 and 6). It can also
be used to accelerate curing in low temperatures or if there is a
lot of backlash between parts.
SEALANTS (for Loctite 510 Colour: Red Very fast anaerobic product suitable for sealing between metallic
surfaces and surfaces, can be used to eliminate traditional gaskets, since it can
unions) fills gaps up to 0.4 mm. Since it does not settle, the torque does
not need to be reset.
Loctite 542 Colour: Brown Anaerobic product used as a liquid gasket for sealing threaded
unions with a measurement under 3/4” gas; it cures quickly and
the parts can be disassembled with normal tools.
Loctite 554 Colour: Red Anaerobic sealant and locking product used to seal cooling and
industrial fluid circuits. It cures slowly and is also suitable for use
on non-ferrous alloys
Loctite 572 Colour: White Anaerobic sealant and locking product used to seal pipes and
threaded unions up to a diameter of 2”. It cures very slowly on
most metallic surfaces.
Loctite 573 Colour: green Thixotropic anaerobic product suitable for sealing metal surfaces.
It ensures total contact between the surfaces with a maximum
backlash of 0.10 mm even filling microspaces due to planarity
imperfections. It cures very slowly on most metallic surfaces and
requires the use of an activator.
Loctite 576 Colour: brown Anaerobic product used as a liquid gasket for sealing large di-
mension threaded unions (up to 2”). It cures very slowly and is
also suitable for non-ferrous alloys and parts which require later
removal.
INSTANT ADHE- Loctite 401 Colour: colourless Instant cyanoacrylate adhesive suitable for bonding acid and
SIVES porous surfaces of a wide range of materials including ceramic,
wood, rubber and plastic (with the exception of polyolefins). It
cures in just a few seconds due to the effect of the atmospheric
humidity on the surfaces to bond, regardless of the ambient con-
ditions.
Loctite 495 Colour: colourless Instant cyanoacrylate adhesive suitable for bonding rubber and
plastics even in different combinations, including metals.

0-8
Introduction
SILICON SEAL- Silastic 738 (Dow Corning) colour: milky Single compound silicon adhesive/sealant, not settling, ready for
ANTS white use. It cures into a solid rubbery consistency when it reacts with
humidity in the air and makes it possible to eliminate traditional
gaskets on elastic joints covering backlashes even greater than
a millimetre.
Dirko Transparent Colour: transparent Single compound silicon adhesive/sealant, settling, ready for
use. It cures quickly forming a rubbery solid when curing starts
due to moisture in the air and it is resistant to high temperatures.
POLYURETHANE Betaseal HV3 (Gurit Essex) Colour: Black Polyurethane prepolymer based adhesive and sealant which is
SEALANTS highly viscose, suitable for highly resistant permanent elastic
bonding. It cures slowly and is used for bonding glass on struc-
tures, metallic protection meshes, plates, etc., after degreasing
with a primer.
RETAINERS Loctite 601 Colour: fluorescent green Fast curing anaerobic product with high mechanical resistance. It
is suitable for sealing and retaining freely moving cylindrical cou-
plings with backlash up to 0.10 mm, for fastening shafts on rotors,
gears, bearings, pulleys, bushes, main bearings, etc.
Loctite 638 Colour: fluorescent green Fast curing anaerobic structural adhesive with very high me-
chanical resistance; suitable for fastening non-ferrous alloy freely
moving cylindrical couplings.
Loctite 648 Colour: fluorescent green Fast curing anaerobic structural adhesive with high mechanical
resistance; suitable for retaining freely moving cylindrical cou-
plings, permanent retaining of threaded parts, sealing of cooling
systems, fastening of bearings, etc. It is an alternative product to
Loctite 601 for use at higher operating temperatures.
Loctite 986/AVX Colour: fluorescent red Anaerobic sealant and retaining product for cylindrical couplings
between metallic parts. It cures slowly and offers a good mechan-
ical and temperature resistance as well as excellent resistance to
chemical pressure. It must be used after activation of the parts.
LUBRICANTS Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose lithium grease used to lubricate gaskets, prevent
oxidation and make assembly operations easier.
Molikote (Dow Corning) Anti-wear lubricant compound, containing Molybdenum disul-
phide, used pure or diluted with a percentage of engine oil during
engine main bearing assembly phases.
Vaseline Neutral PH compound used to protect the poles and terminals of
batteries from oxidation and corrosion.
10W - 30 engine oil Used to dilute Molikote anti-wear lubricant during engine assem-
bly phases.

0-9
 Introduction
0.1.7 - Unit of measurement conversion table
Conversion from imperial to metric units
Table 7
inch x 25.40 = mm
foot x 0.305 =m
yard x 0.914
Eng.miles x 1.609 = km
Sq.in. x 6.452 = cm²
Sq.ft. x 0.093 = m²
Sq.yard x 0.835
Cu.in. x 16.39 = cm³
Cu.ft. x 28.36 = m³
Cu.yard x 0.763
Imp.gall. x 4.547 = litres
US gall. x 3.785
pint x 0.568
quart x 1.137
US.gpm x 3.785 = ,/min
oz. x 0.028 = kg
lb. x 0.454
lb.ft. x 0.139 = kgm
lb.in. x 17.87 = kg/m
psi x 0.070 = kg/cm²
lb./Imp.gall x 0.100 = kg/,
lb./US.gall x 0.120
lb./cu.ft. x 16.21 = kg/m³
lb.ft. x 1.356 = Nm
psi x 1.379 = bar
Conversion from metric to imperial units
Table 8
mm x 0.0394 = inch
m x 3.281 = foot
m x 1.094 = yard
km x 0.622 = Eng.miles
cm² x 0.155 = Sq.in.
m² x 10.77 = Sq.ft.
m² x 1.197 = Sq.yard
cm³ x 0.061 = Cu.in.
m³ x 0.035 = Cu.ft
m³ x 1.311 = Cu.yard
litres x 0.220 = Imp.gall.
litres x 0.264 = US gall.
litres x 1.762 = pint
litres x 0.880 = quart
,/min x 0.2642 = US.gpm
kg x 35.25 = oz.
kg x 2.203 = lb.
kgm x 7.233 = lb.ft.
kg/m x 0.056 = lb.in.
kg/cm² x 14.22 = psi
kg/, x 10.00 = lb./Imp.gal.
kg/, x 8.333 = lb./US.gal.
kg/m³ x 0.062 = lb./cu.ft.
Nm x 0.737 = lb.ft.
bar x 14.503 = psi

0-10
Introduction
0.2 - Tightening torques for nuts and bolts of electrical connec-
tions
Tighten all nuts and bolts of wiring harnesses, leaving the battery negative cable until last.
l For closing torque, where not specified use class 9 N.93810

0.2.1 - Standard tightening torques

Table 9
General table
Pitch Torque
6x1 5.5
8x1 14.4
8x1.25 13.4
10x1 29.5
10x1.5 26.5
12x1.25 50
12x1.75 46
14x1.5 79
Table 10
General table
Pitch Torque
14x2 73
16x1.5 121
16x2 113
Tolerance ±20%

0.2.2 - Battery terminal tightening torques

Fig. 2

0-11
 Introduction
0.2.3 - Starter motor tightening torques

Fig. 3

0.2.4 - Alternator tightening torques

Fig. 4

0-12
Introduction
0.3 - Wheel rim to hub screws and nuts tightening torques
DANGER
These tightening torques are not applicable to special self-locking fixing systems.

Table 11
p/n Description Class Tightening torque Tolerance
2.0122.511.6 Screw M14x1.5 8.8 120 Nm (12.2 kgm) ± 5%
2.0122.615.2 Screw M16x1.5 8.8 184.5 Nm (18.8 kgm) ± 5%
2.0399.235.6 Screw M16x1.5 10.9 271 Nm (27.6 kgm) ± 5%
2.0399.129.6 Screw M18x1.5 10.9 395 Nm (40.3 kgm) ± 5%
2.0399.140.6 Screw M18x1.5 10.9 395 Nm (40.3 kgm) ± 5%
2.0399.003.6/10 Screw M20x1.5 10.9 550 Nm (56 kgm) ± 5%
2.1011.308.6 Nut M14x1.5 8 120 Nm (12.2 kgm) ± 5%
01101323 Nut M18x1.5 10 395 Nm (40.3 kgm) ± 5%
2.1099.175.6 Nut M18x1.5 10 395 Nm (40.3 kgm) ± 5%
0.012.8307.0 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
2.1019.176.6 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
2.1099.083.0/20 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
01104070 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
2.1099.085.0/20 Nut M22x1.5 10 745 Nm (76 kgm) ± 5%
2.1099.177.6 Nut M22x1.5 10 650 Nm (66.2 kgm) ± 5%

0-13
 Introduction
0.4 - Tightening torques
0.4.1 - General information
This chapter specifies the tightening torque values and resulting tension forces for tightening standard fastener hardware with ISO
metric threads.
It is not applicable for components with special self-locking systems, such as micro capsules, nylon lock rings etc.
0.4.2 - Tightening classes and categories
Four different tightening torque categories are applicable (1, 2, 3, 4), for three different joint classes (A, B, C), in accordance with
procedure GSPO PSM 13.0.0.
Table 12
Tightening categories
1 2 3 4
Joint classes A Torque/angle con- Torque control tight-
trol tightening with ening with manual
manual or auto- or automatic tools
matic tools, subject subject to periodic
to monitoring and/ inspection and used
or with certification, by trained personnel
and used by trained
personnel
B Torque/angle con- Torque control tight- Torque control tight-
trol tightening with ening with manual ening with manual
manual or auto- or automatic tools or automatic tools
matic tools, subject subject to periodic subject to periodic
to monitoring and/ inspection and used inspection
or with certification, by trained personnel
and used by trained
personnel
C Torque control tight- Manual tightening
ening with manual with suitable tools,
or automatic tools with no specified
subject to periodic torque value
inspection
Tolerances
Table 13
Tightening class Tolerance Application
1 ± 7.5% very difficult
2 ± 15% difficult
3 ± 30% common
4 None no specification

0.4.3 - Coefficient of friction

The friction coefficients used to calculate tightening torques have been defined in relation to the surface treatment applied.
Table 14
Surface treatment Coefficient of friction Reference symbol
With black post-treatment (Geoblack) μ 0.10 VI
Anti-seize phosphating μ 0.14 VII
Electrolytic zinc plating µ 0.17% II

0-14
Introduction
0.4.4 - Tightening torques
The method used to calculate tightening torques (Cs) and traction forces (F0) is compliant with the standard VDI 2230-1.
The coefficient of safety applied is 0.70 of the yield strength of the material.
Tightening torques for 4.8 UNI EN ISO 898-1 screws
Table 15
Thread Category Nominal tightening torques
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 0.9 1.1 1.2
2 0.8 1.0 1.1
3 0.7 0.9 1.0
5x0.80 1 1.8 2.2 2.4
2 1.7 2.0 2.3
3 1.5 1.8 2.0
6x1.00 1 3.0 3.6 4.0
2 2.8 3.4 3.8
3 2.5 3.0 3.3
7x1.00 1 4.9 6.0 6.7
2 4.6 5.6 6.3
3 4.0 5.0 5.6
8x1.00 1 7.8 9.7 10.9
2 7.3 9.1 10.2
3 6.5 8.0 9.0
8x1.25 1 7.3 9.0 10.0
2 6.9 8.4 9.4
3 6.1 7.4 8.3
10x1.00 1 15.9 20.0 22.5
2 14.9 18.7 21.1
3 13.2 16.6 18.6
10x1.25 1 15.2 18.9 21.2
2 14.2 17.7 19.8
3 12.6 15.6 17.5
10x1.50 1 14.4 17.8 19.9
2 13.5 16.7 18.6
3 12.0 14.7 16.4
12X1.25 1 27 34 38
2 25 31 35
3 22 28 31
12x1.50 1 26 32 36
2 24 30 34
3 21 27 30
12x1.75 1 25 31 34
2 23 29 32
3 20 25 28
14x1.50 1 42 53 59
2 40 49 56
3 35 44 49
14x2.00 1 39 49 54
2 37 46 51
3 33 40 45
16x1.50 1 65 82 92
2 61 76 86
3 54 67 76
16x2.00 1 61 76 85
2 57 71 80
3 51 63 70
18x1.50 1 94 119 134
2 88 111 125
3 78 98 111
18x2.50 1 85 105 117
2 79 98 109
3 70 87 97

0-15
 Introduction
Thread Category Nominal tightening torques
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
20x1.50 1 130 166 187
2 122 155 175
3 108 137 155
20x2.00 1 125 157 177
2 117 147 165
3 103 130 146
20x2.50 1 119 148 166
2 112 139 155
3 99 123 137
22x1.50 1 177 225 255
2 165 210 238
3 146 186 211
22x2.50 1 163 204 229
2 153 191 214
3 135 169 189
24x2.00 1 222 280 317
2 207 262 296
3 183 232 262
24x3.00 1 206 256 286
2 192 239 268
3 170 211 237
27x3.00 1 301 376 422
2 281 351 395
3 249 311 349
Tightening torques for 5.8 UNI EN ISO 898-1 screws and 5 UNI EN ISO 898-1 nuts
Table 16
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 1.1 1.4 1.5
2 1.1 1.3 1.4
3 0.9 1.1 1.3
5x0.80 1 2.2 2.7 3.0
2 2.1 2.5 2.8
3 1.8 2.2 2.5
6x1.00 1 3.7 4.5 5.0
2 3.5 4.2 4.7
3 3.1 3.7 4.2
7x1.00 1 6.1 7.5 8.4
2 5.7 7.0 7.9
3 5.1 6.2 7.0
8x1.00 1 9.8 12.1 13.6
2 9.1 11.3 12.7
3 8.1 10.0 11.2
8x1.25 1 9.2 11.3 12.5
2 8.6 10.5 11.7
3 7.6 9.3 10.4
10x1.00 1 19.9 25.0 28.2
2 18.6 23.4 26.3
3 16.5 20.7 23.3
10x1.25 1 19.0 23.6 26.5
2 17.8 22.1 24.8
3 15.7 19.6 21.9
10x1.50 1 18.1 22.3 24.9
2 16.9 20.8 23.2
3 15.0 18.4 20.6
12X1.25 1 34 42 47
2 31 39 44
3 28 35 39

0-16
Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
12x1.50 1 32 40 45
2 30 37 42
3 27 33 37
12x1.75 1 31 38 43
2 29 36 40
3 26 32 35
14x1.50 1 53 66 74
2 49 62 70
3 44 55 61
14x2.00 1 49 61 68
2 46 57 64
3 41 50 56
16x1.50 1 81 102 115
2 76 95 107
3 67 84 95
16x2.00 1 77 95 107
2 72 89 100
3 63 79 88
18x1.50 1 117 148 168
2 110 139 157
3 97 123 139
18x2.50 1 106 131 146
2 99 122 137
3 88 108 121
20x1.50 1 163 207 234
2 152 194 219
3 135 171 194
20x2.00 1 156 196 221
2 146 183 207
3 129 162 183
20x2.50 1 149 185 208
2 140 173 194
3 123 153 172
22x1.50 1 221 281 319
2 206 263 298
3 183 232 264
22x2.50 1 204 255 286
2 191 238 268
3 169 211 237
24x2.00 1 277 350 396
2 259 327 370
3 229 290 327
24x3.00 1 257 319 358
2 240 299 335
3 213 264 296
27x3.00 1 376 470 528
2 351 439 493
3 311 388 436

0-17
 Introduction
Tightening torques for 6.8 UNI EN ISO 898-1 screws and 6 UNI EN ISO 898-1 nuts
Table 17
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 1.4 1.7 1.8
2 1.3 1.5 1.7
3 1.1 1.4 1.5
5x0.80 1 2.7 3.3 3.6
2 2.5 3.0 3.4
3 2.2 2.7 3.0
6x1.00 1 4.5 5.4 6.0
2 4.2 5.1 5.7
3 3.7 4.5 5.0
7x1.00 1 7.3 9.0 10.1
2 6.9 8.4 9.4
3 6.1 7.5 8.3
8x1.00 1 11.7 14.6 16.3
2 10.9 13.6 15.3
3 9.7 12.0 13.5
8x1.25 1 11.0 13.5 15.1
2 10.3 12.6 14.1
3 9.1 11.2 12.5
10x1.00 1 23.9 30.0 33.8
2 22.3 28.1 31.6
3 19.8 24.8 28.0
10x1.25 1 22.8 28.4 31.8
2 21.3 26.5 29.7
3 18.9 23.5 26.3
10x1.50 1 21.7 26.7 29.8
2 20.3 25.0 27.9
3 18.0 22.1 24.7
12X1.25 1 40 50 57
2 38 47 53
3 33 42 47
12x1.50 1 39 48 54
2 36 45 50
3 32 40 45
12x1.75 1 37 46 51
2 35 43 48
3 31 38 42
14x1.50 1 63 79 89
2 59 74 83
3 52 66 74
14x2.00 1 59 73 82
2 55 68 76
3 49 60 67
16x1.50 1 97 122 138
2 91 114 129
3 80 101 114
16x2.00 1 92 114 128
2 86 107 120
3 76 94 106
18x1.50 1 141 178 201
2 132 166 188
3 116 147 166
18x2.50 1 127 157 176
2 119 147 164
3 105 130 145
20x1.50 1 196 248 281
2 183 232 263
3 162 205 232

0-18
Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
20x2.00 1 187 235 265
2 175 220 248
3 155 195 219
20x2.50 1 179 223 249
2 167 208 233
3 148 184 206
22x1.50 1 265 337 382
2 248 315 358
3 219 279 316
22x2.50 1 245 306 343
2 229 286 321
3 203 253 284
24x2.00 1 332 420 475
2 311 393 444
3 275 348 393
24x3.00 1 309 383 429
2 288 358 401
3 255 317 355
27x3.00 1 451 564 633
2 422 527 592
3 373 466 524

Tightening torques for 8.8 UNI EN ISO 898-1 screws and 8 UNI EN ISO 898-1 nuts
Table 18
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 1.8 2.2 2.4
2 1.7 2.1 2.3
3 1.5 1.8 2.0
5x0.80 1 3.5 4.3 4.8
2 3.3 4.1 4.5
3 2.9 3.6 4.0
6x1.00 1 5.9 7.3 8.1
2 5.5 6.8 7.5
3 4.9 6.0 6.7
7x1.00 1 9.8 12.1 13.5
2 9.1 11.3 12.6
3 8.1 10.0 11.1
8x1.00 1 15.6 19.4 21.8
2 14.6 18.2 20.3
3 12.9 16.1 18.0
8x1.25 1 14.7 18.0 20.1
2 13.7 16.8 18.8
3 12.1 14.9 16.6
10x1.00 1 31.9 40.0 45.1
2 29.8 37.4 42.2
3 26.3 33.1 37.3
10x1.25 1 30.4 37.8 42.4
2 28.4 35.4 39.6
3 25.2 31.3 35.1
10x1.50 1 29.0 35.6 39.8
2 27.1 33.3 37.2
3 23.9 29.5 32.9
12X1.25 1 54 67 76
2 50 63 71
3 44 56 63
12x1.50 1 52 64 72
2 48 60 67
3 43 53 59

0-19
 Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
12x1.75 1 50 61 68
2 46 57 64
3 41 51 56
14x1.50 1 85 106 119
2 79 99 111
3 70 88 98
14x2.00 1 79 97 109
2 74 91 102
3 65 81 90
16x1.50 1 130 163 184
2 121 153 172
3 107 135 152
16x2.00 1 122 152 170
2 114 142 159
3 101 126 141
18x1.50 1 188 237 268
2 175 222 251
3 155 196 222
18x2.50 1 170 210 234
2 159 196 219
3 140 173 194
20x1.50 1 261 331 375
2 244 310 350
3 216 274 310
20x2.00 1 250 314 354
2 234 293 330
3 207 260 292
20x2.50 1 239 297 332
2 223 277 311
3 197 245 275
22x1.50 1 353 450 510
2 330 421 477
3 292 372 422
22x2.50 1 327 408 458
2 305 381 428
3 270 337 379
24x2.00 1 443 560 633
2 414 524 592
3 366 463 524
24x3.00 1 411 511 573
2 385 478 535
3 340 423 473
27x3.00 1 601 752 844
2 562 703 789
3 497 622 698

0-20
Introduction
Tightening torques for 10.9 UNI EN ISO 898-1 screws and 10 UNI EN ISO 898-1 nuts
Table 19
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 2.6 3.2 3.6
2 2.5 3.0 3.4
3 2.2 2.7 3.0
5x0.80 1 5.2 6.4 7.1
2 4.9 6.0 6.6
3 4.3 5.3 5.9
6x1.00 1 8.7 10.7 11.8
2 8.1 10.0 11.1
3 7.2 8.8 9.8
7x1.00 1 14.4 17.7 19.8
2 13.4 16.5 18.5
3 11.9 14.6 16.3
8x1.00 1 22.9 28.5 32.0
2 21.4 26.7 29.9
3 19.0 23.6 26.4
8x1.25 1 21.5 26.5 29.5
2 20.1 24.7 27.6
3 17.8 21.9 24.4
10x1.00 1 46.8 58.8 66.2
2 43.7 55.0 61.9
3 38.7 48.6 54.8
10x1.25 1 44.7 55.6 62.3
2 41.8 51.9 58.2
3 36.9 46.0 51.5
10x1.50 1 42.5 52.4 58.4
2 39.7 48.9 54.6
3 35.2 43.3 48.3
12X1.25 1 79 99 111
2 74 92 104
3 65 82 92
12x1.50 1 76 94 106
2 71 88 99
3 63 78 87
12x1.75 1 73 90 100
2 68 84 94
3 60 74 83
14x1.50 1 124 155 175
2 116 145 163
3 103 129 144
14x2.00 1 116 143 160
2 108 134 149
3 96 118 132
16x1.50 1 190 240 270
2 178 224 253
3 157 198 223
16x2.00 1 180 223 250
2 168 209 234
3 149 185 207
18x1.50 1 276 349 394
2 258 326 368
3 228 288 326
18x2.50 1 249 308 344
2 233 288 321
3 206 254 284
20x1.50 1 383 486 551
2 358 455 515
3 317 402 455

0-21
 Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
20x2.00 1 367 461 519
2 343 431 485
3 304 381 429
20x2.50 1 351 436 488
2 328 407 456
3 290 360 404
22x1.50 1 519 661 749
2 485 618 700
3 429 546 619
22x2.50 1 480 599 673
2 448 560 629
3 397 495 556
24x2.00 1 651 823 930
2 608 769 869
3 538 681 769
24x3.00 1 604 751 841
2 565 702 786
3 500 621 695
27x3.00 1 883 1104 1240
2 826 1032 1159
3 730 913 1025

Tightening torques for 12.9 UNI EN ISO 898-1 screws and 12 UNI EN ISO 898-1 nuts
Table 20
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 3.1 3.8 4.2
2 2.9 3.5 3.9
3 2.6 3.1 3.5
5x0.80 1 6.1 7.5 8.3
2 5.7 7.0 7.8
3 5.0 6.2 6.9
6x1.00 1 10.2 12.5 13.9
2 9.5 11.7 13.0
3 8.4 10.3 11.5
7x1.00 1 16.8 20.7 23.1
2 15.7 19.4 21.6
3 13.9 17.1 19.1
8x1.00 1 26.8 33.4 37.4
2 25.1 31.2 35.0
3 22.2 27.6 30.9
8x1.25 1 25.2 31.0 34.5
2 23.6 28.9 32.3
3 20.8 25.6 28.5
10x1.00 1 54.8 68.8 77.5
2 51.2 64.3 72.5
3 45.3 56.9 64.1
10x1.25 1 52.3 65.0 72.9
2 48.9 60.8 68.1
3 43.2 53.8 60.3
10x1.50 1 49.8 61.3 68.3
2 46.5 57.3 63.9
3 41.1 50.7 56.5
12X1.25 1 92 116 130
2 86 108 122
3 76 96 108
12x1.50 1 89 110 124
2 83 103 115
3 73 91 102

0-22
Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
12x1.75 1 85 105 117
2 80 98 110
3 70 87 97
14x1.50 1 145 182 204
2 136 170 191
3 120 150 169
14x2.00 1 136 167 187
2 127 157 175
3 112 138 155
16x1.50 1 223 280 316
2 208 262 296
3 184 232 261
16x2.00 1 210 262 293
2 197 244 274
3 174 216 242
18x1.50 1 323 408 461
2 302 381 431
3 267 337 381
18x2.50 1 291 360 402
2 272 337 376
3 241 298 333
20x1.50 1 448 569 644
2 419 532 602
3 371 471 533
20x2.00 1 430 540 608
2 402 504 568
3 355 446 502
20x2.50 1 410 510 571
2 384 477 534
3 339 422 473
22x1.50 1 607 773 876
2 567 723 819
3 502 639 725
22x2.50 1 561 701 787
2 525 655 736
3 464 580 651
24x2.00 1 762 963 1088
2 712 900 1017
3 630 797 900
24x3.00 1 707 878 984
2 661 821 920
3 585 726 814
27x3.00 1 1034 1292 1451
2 966 1208 1357
3 855 1068 1200

0-23
 Introduction
0.5 - Installation of solenoid valves and cartridge valves
0.5.1 - Installation
1. Remove packaging and protective coverings from solenoid valve bodies and cartridge valves only at the moment of installa-
tion, so as to minimize the risk of contamination.
2. Lubricate all O-rings fitted to solenoid valves and valve cartridges using a suitable mineral oil or grease compatible with AK-
ROS oil.
Contamination of lubricating fluid must be no higher than level 18/15, as specified in ISO 4406.
For further information on contamination, refer to SAME specification 92349
Containers of lubricating fluids must be closed and fitted with the specific dispensing nozzle.
The use of open containers or brushes is not permissible.
3. Screw the solenoid valves and cartridge valves into the relative seats by hand, engaging at least one turn of the thread.
Power drivers must not be used at this stage.
4. Complete the tightening operation, applying torques as specified in the table of headings 3 and 4.

0.5.2 - Solenoid valve tightening torques

Table 21
Type of solenoid valve Threads p/n Tightening torque
A (Nm) B (Nm)
7/8”-14 UNF 2.3719.750.0/XX 15-20 5-8
2.3729.410.0/XX
2.3729.610.0/XX

Fig. 5
7/8”-14 UNF 2.3729.250.0/XX 15-20 5±0.5
2.3729.270.0/XX
2.3729.290.0/XX
2.3729.300.0/XX
2.3729.697.0/XX
2.3729.600.0/XX 15-20 5-8
M18X1.5 2.3729.330.0/XX 15-20 5±0.5
2.3729.340.0/XX
2.3729.400.0/XX
Fig. 6
7/8”-14 UNF 2.3729.310.0/XX 15-20 5±0.5
2.3729.698.0/XX
2.3729.718.0/XX

Fig. 7
3/4”-16 UNF 2.3719.510.0/XX 15-20 20-25

Fig. 8

0-24
Introduction
Type of solenoid valve Threads p/n Tightening torque
A (Nm) B (Nm)
M33X2 2.3729.709.0/XX 45-50 5-8

Fig. 9

0.5.3 - Cartridge valve tightening torques

Table 22
Type of valve Threads p/n Tightening torque
A (Nm)
M18X1.5 2.3729.686.0/XX 35-40
2.3719.760.0/XX

Fig. 10
3/4”-16 UNF 2.3729.691.0/XX 35-40

Fig. 11
M22X1.5 2.3729.692.0/XX 45-50
M18X1.5 2.3719.630.0/XX 35-40

Fig. 12
7/8”-14 UNF 0.006.6161.4/XX 45-50
0.015.5426.4/XX 45-50

Fig. 13

0-25
 Introduction
0.6 - Installation of quick couplers
0.6.1 - Table of tightening torques
Table 23
Type of quick coupler Threads p/n Tightening
torque A (Nm)
M22X1.5 0.010.8473.0/XX 60-66

Fig. 14
M22X1.5 0.010.9832.0/XX 60-66

Fig. 15

0-26
10 - Technical
characteristics

10-1
 Technical characteristics
10.1 - Engine
10.1.1 - Motor description - construction type
Engine type
These instructions concern the following engine types:
l TCD 3.6 L4
l TCD3.6 L4
Table 24
TCD
T Turbocharger
C Charge air cooler
D Diesel
Table 25
3.6
3.6 Capacity in litres
Table 26
L4
L in series
4 Number of cylinders
Exhaust gas emission regulation
DANGER
The engine and the respective EAT system (Exhaust After Treatment) are combined together and connected recipro-
cally by suitable electronic control. They are certified by the competent authorities and are able to comply with the
permitted exhaust gas emission limits only if provided in this combination. The engine may not be operated with other
EAT systems
The engines described in this operating manual are compliant with the following exhaust emissions regulations
Table 27
TCD 3.6 >56 kW with exhaust gas after-treatment system
USA EPA Tier 4i
UE Level IIIB
Table 28
TCD 3.6 >56 kW with exhaust gas after-treatment system
USA EPA Tier 4 final
UE Tier IV
Table 29
Without exhaust gas after-treatment systems
The precise certification is stamped on the engine’s identification plate or is located on a separate plate for the concerned markets.
DANGER
The engines for this user manual may only be operated with the exhaust gas after treatment system functioning (if
included in the DEUTZ supply)

10-2
Technical characteristics
Model plate

Fig. 16
The engine type A, the engine number B and the data concerning the power are engraved on the plate
Each spare part order must include the engine type and number.
Location of the model plate
Plate C is fixed on the cylinder head cowling or on the crankcase.

10-3
 Technical characteristics

Fig. 17

10-4
Technical characteristics

XXX XXX X

Fig. 18

Engine number
The engine number D is punched on the crankcase (arrow) and on the model plate.

10-5
 Technical characteristics

1 2

Fig. 19

Serial numbers for the exhaust gas after treatment components

1. Data plate for diesel oxidation catalytic converter
2. Diesel particulate filter data plate
The serial numbers for the exhaust gas after treatment system components are stamped on the data plates

10-6
Technical characteristics

1 2

Fig. 20

10-7
 Technical characteristics
Cylinder numbering

Fig. 21
Cylinder layout
The cylinders are numbered progressively from (1) from the flywheel side.
Direction of rotation
View from flywheel side.
Left hand rotation: Anticlockwise.
Engine sides
View from flywheel side.

10-8
Technical characteristics
10.1.2 - Engine description - Views of engine

6 2

5 3

Fig. 22 - TCD 3.6 L4

Industrial engine - Right side view (example)
l 1 - Lubricant oil filler cap
l 2 - V-belt
l 3 - Coolant inlet
l 4 - Lubricant oil drain screw
l 5 - Lubricant oil cartridge filter
l 6 - Lubricant oil dipstick
l 7 - Coolant outlet

10-9
 Technical characteristics

2
1

6
3

Fig. 23 - TCD 3.6 L4

Industrial engine - Left side view (example)
l 1 - Combustion air intake
l 2 - Crankcase breather
l 3 - Exhaust gas outlet
l 4 - Lubricant oil dipstick, Optional
l 5 - Lubricant oil cartridge filter, Optional
l 6 - Diesel oxidation catalytic converter

10-10
Technical characteristics

2
9

8 3

7 4

Fig. 24 - TCD 3.6 L4

Industrial engine - Right side view (example)
l 1 - Crankcase breather
l 2 - Throttle valve
l 3 - Belt tensioner roller
l 4 - Ribbed V-belt
l 5 - Coolant inlet
l 6 - Lubricant oil drain screw
l 7 - Lubricant oil cartridge filter
l 8 - Lubricant oil dipstick
l 9 - Coolant outlet

10-11
 Technical characteristics

1
7

Fig. 25 - TCD 3.6 L4

Industrial engine - Left side view (example)
l 1 - Combustion air intake
l 2 - Exhaust gas outlet
l 3 - Diesel particulate filter
l 4 - Diesel oxidation catalytic converter
l 5 - Lubricant oil dipstick, Optional
l 6 - Lubricant oil cartridge filter, Optional
l 7 - Lubricant oil filler cap

10-12
Technical characteristics
10.1.3 - Engine description - Lubricant oil diagram

15 14 13 12 11

5 4

10 9 7 6 3 2 1

Fig. 26 - Lubrication oil system

(Example)
l 1 - Lubricant oil sump
l 2 - Lubricant oil pump
l 3 - Pressure cut-off valve
l 4 - Lubricant oil radiator
l 5 - Bypass valve
l 6 - Pressure regulator valve
l 7 - Lubricant oil filter
l 8 - Primary lubricant oil channel
l 9 - Primary lubricant oil channel
l 10 - Crankshaft bearing
l 11 - Piston cooling nozzle
l 12 - Rocker
l 13 - Hydraulic tappet
l 14 - Turbocharger
l 14 - Air compressor, Optional

10-13
 Technical characteristics
10.1.4 - Engine description - Fuel circuit diagram

12 8 9 10

1 2 3 4 5 6 11

Fig. 27 - Fuel circuit diagram

(Example)
l 1 - Fuel tank
l 2 - Fuel pre-filter
l 3 - Fuel delivery pump (electric),
l 4 - Fuel cartridge filter
l 5 - Fuel pressure transducer
l 6 - High pressure pump, with FCU (Fuel Control Unit)
l 7 - Rail
l 8 - Injector
l 9 - Check valve
l 10 - Return line
l 11 - Fuel return to tank
l 12 - Engine control unit

10-14
Technical characteristics
10.1.5 - Engine description - Coolant diagram

6 7 8 9 10

x1 x2

T
x2

1 2 3 4

x3 x1

5 4 3 2 1 11

Fig. 28 - Coolant diagram

(Example)
l 1 - Coolant pump
l 2 - Lubricant oil radiator
l 3 - Air compressor, Optional
l 4 - Coolant feed line for cooling engine
l 5 - Cylinder sleeve/head cooling
l 6 - Recirculated exhaust gas radiator
l 7 - Temperature sender
l 8 - Thermostat
l 9 - Radiator
l 10 - Compensation container
l 11 - Fitting for cab heater

10-15
 Technical characteristics
10.1.6 - Engine description - Exhaust gas recovery

8 7 6

3 2 1 4 5

Fig. 29
External exhaust gas recirculation
l 1 - Recirculated portion of exhaust gas (not cooled)
l 2 - Adjuster (electrically actuated)
l 3 - Coolant line leading to EGR radiator
l 4 - Recirculated exhaust gas radiator
l 5 - Coolant return
l 6 - Recirculated portion of cooled exhaust gas
l 7 - Mixer pipe
l 8 - Throttle valve

10-16
Technical characteristics
10.1.7 - Engine description - Exhaust gas after-treatment

8 7

Fig. 30 - Exhaust after-treatment system

Example:
l 1 - Separator line
l 2 - Differential pressure sensor
l 3 - Exhaust gas temperature sensor
l 4 - Diesel oxidation catalytic converter
l 5 - Diesel particulate filter, Optional
l 6 - Differential pressure sensor
l 7 - Exhaust gas outlet
l 8 - Throttle valve

10-17
 Technical characteristics
10.1.8 - Engine description - Electrical/electronic system

1 2 3 4

12/24 V 10

11

12

13

14

15

16

17

18

9 8 7 6 5 19

Fig. 31 - Electronic engine governor system

l Engine side
l 1 - Rail pressure sensor
l 2 - Intake air pressure transducer, intake air temperature transducer
l 3 - Coolant temperature sensor
l 4 - Engine control unit
l 5 - Camshaft speed sensor
l 6 - Crankshaft speed sensor
l 7 - Fuel pressure transducer
l 8 - Lubricant oil pressure sensor transducer (on opposite side)
l 9 - Central connector (engine control)
l From the side of the device
l 10 - Electric power feed (battery)
l 11 - Signal outputs (e.g. for indicator lamps, rpm signal, engine run signal etc.)
l 12 - Inputs (e.g. override button)
l 13 - Accelerator
l 14 - Hand throttle
l 15 - Optional function converter, e.g. P curve, governor type, ceiling curve, fixed engine speed
l 16 - Key operated start/stop switch
l 17 - Diagnostics key
l 18 - Error warning light
l 19 - CAN bus diagnostic interface

10-18
Technical characteristics
Recommendations for the engine electronics
This engine is equipped with an electronic control device.
The equipment for each system depends on the functions required and the type of engine use.
The resulting wiring with the respective configuration of the connectors can be seen on the corresponding connection diagram.
Also, the assembly instructions from DEUTZ AG must be followed.
Precautionary measures
DANGER
The control unit pin connections are dust and water resistant only when the counter piece is inserted (IP69K class of
protection)! The control unit must be protected against spraying water and humidity until the counter piece is installed!
Switching polarity can cause damage to the control unit. To avoid damaging the control unit, before welding remove
the pin connections from the control unit. Any work on the electrical system that is not carried out in compliance with
DEUTZ directives or by non-qualified personnel may damage the engine electronics in the long term, which is a condi-
tion not covered by the manufacturer’s warranty.
DANGER
The following is strictly prohibited: a) Making changes or connections to the electric control unit wiring or the data
transmission line (CAN lines). b) Switching the control devices. Otherwise, the warranty rights shall be void! Diagnosis
and maintenance may only be performed by authorised personnel using the tools and devices permitted by DEUTZ.
Assembly instructions
The control devices are calibrated based on the respective engine and marked with a specific engine number. Each engine may only
be operated with the respective control device.
To operate the device, connect the nominal value transducers (pedal transducers) to the wiring of the device and calibrate them using
the DEUTZ SERDIA (SERvice DIAgnose) diagnostics program. The connection and installation of the device wiring are shown in the
connection diagram in the DEUTZ assembly instructions.
Supply voltage
l 12 Volts
l 24 Volts
A sufficient battery charge level must be guaranteed. Interrupting the supply voltage to the engine while it is operating may damage
the electrical or electronic system. A drop in the supply voltage stops the engine.
Voltages above 32 Volt destroy the control device.
Diagnostics
The DEUTZ control devices are equipped with a self-diagnostics system. The active and passive error conditions are recorded in the
error memory. Active errors are indicated by the fault indicator/diagnostic lamp.
See para. 10.1.26 - Malfunctions - Malfunc... - page 10-64
The diagnostics can be carried out using:
l Error warning light (flashing code)
l CAN BUS
l DEUTZ electronic display
l diagnostics socket (SERDIA).
Device wiring
Follow the DEUTZ AG assembly instructions. In particular, crimp the connector contacts correctly with commercially available tools.
If necessary, the inserted contacts must be removed from their housings only using the specific tools.

10-19
 Technical characteristics
10.1.9 - Use - Environmental conditions
Low ambient temperatures

Fig. 32
Lubricant oil
l Select the viscosity of the lubricant oil based on the ambient temperature.
l In the case of frequent cold starts, reduce the oil change times by half.
Fuel
l With a temperature below 0°C use winter fuel.
See para. 10.1.16 - Operating materials - ... - page 10-37
Battery
l A sufficient battery charge state is necessary to start the engine.
See para. 10.1.24 - Care and maintenance w... - page 10-58
l Heating the battery to approx. 20 °C improves the engine start behaviour.
(Disassembly and storage of the battery in a warm room).
Accessories for cold starting
l The engines described in this manual are fitted with glow plugs.
See para. 10.1.11 - Usage - Starting proce... - page 10-25
Coolant

10-20
Technical characteristics
l Observe the mixture ratio between antifreeze/cooling water.
See para. 10.1.17 - Operating materials - ... - page 10-38
High ambient temperatures, high altitudes
Note
This engine is equipped with an electronic control device. For the operating conditions mentioned below, the fuel
quantity is reduced automatically by the electronic control device.

l Usage at high altitute

l Usage at high ambient temperatures
Reason: as the altitude or ambient temperature increases, the air density decreases. As a result, the quantity of oxygen contained in
the air aspirated by the engine also reduces, and the fuel/air mixture produced would be excessively rich unless the quantity of fuel
injected is also reduced.
The consequences would be:
l black smoke in the exhaust gas
l high engine temperature
l reduction in engine power
l possible impairment of starting behaviour
If there are additional questions, contact your DEUTZ partner or equipment supplier.
10.1.10 - Use - First start-up
Preparations for the first start-up
(Maintenance program E 10)
l Eliminate the engine storage treatment.
l Remove any transport devices still present.
l Check the battery and cable connections and fit them if necessary.
l Check the belt tension.
See para. 10.1.23 - Care and maintenance w... - page 10-55
l Have authorised personnel check engine monitoring and the alarm system.
l Check the engine mount.
l Check that all flexible pipe connections and the clamps are correctly in their seat.
When performing a general overhaul on an engine, the following operations are also necessary:
l Check and if necessary replace the fuel prefilter and the main filter.
l Intake air filter (if installed, perform the maintenance based on the relative indicator).
l Drain the lubricant oil from the turbocharging air radiator and the condensate water.
l Add the engine lubricant oil.
l Fill the coolant system.
See para. 10.1.30 - Technical data - Engin... - page 10-74

10-21
 Technical characteristics
Add the engine lubricant oil

Fig. 33

Note
An too low or too high level of lubricant oil could damage the engine.

Note
In general, engines are delivered with no lubricant oil. Before filling it, select the quality and viscosity of the lubricant
oil. Order DEUTZ lubricant oils from your DEUTZ partner.

l Pour the lubricant oil into the engine through the filler.
l Pay attention to the lubricant oil filler cap.
See para. 10.1.30 - Technical data - Engin... - page 10-74

10-22
Technical characteristics
Load the fuel

Fig. 34

Note
Only refuel when the engine is stopped. Ensure maximum cleanliness. Do not scatter the fuel. It is necessary to bleed
the fuel system again by carrying out a test cycle for 5 minutes at idle speed or at a reduced load

l The fuel low pressure system must be bled after filling with the manual delivery pump after the 1st start-up.
Use only commercially available, clean diesel fuel. Pay attention to fuel quality.
See para. 10.1.16 - Operating materials - ... - page 10-37
Use summer or winter fuel depending on the external temperature.

10-23
 Technical characteristics
Fill the coolant system

2 1

Fig. 35

NOTE
The coolant must have the required concentration of the cooling system protective action! Never use the engine with-
out the coolant, not even briefly!

CAUTION
The cooling system protective agents must be ordered from your DEUTZ partner.

l Connect the coolant outlet (2) and the coolant inlet (1) to the cooling system. Connect the delivery line between the compensa-
tion container and the coolant pump or the coolant inlet line (3).
l Connect the engine’s breather lines and if necessary the radiator lines to the compensation container.
l Fill the cooling system through the compensation container.
l Close the compensation container with the valve.
l Start the engine and heat it until the thermostat opens (line 2 heats up).
l Engine cycle with the thermostat open 2 - 3 minutes.
l Check the coolant level, top up if necessary

10-24
Technical characteristics
DANGER
Risk of scalding caused by contact with very hot coolant. The cooling system is pressurised! Open the plug only after
it has cooled down. When handling coolant observe the safety directives and specific local regulations.

l Repeat the cycle with the engine started if necessary.

l Fill the coolant up to the MAX notch on the compensation container and close the cooling system cover.
l Turn on the heating if present and set it to the maximum level so the heating circuit fills up and bleeds.
l Pay attention to the filling quantity in the cooling system.
See para. 10.1.30 - Technical data - Engin... - page 10-74
Operating test
NOTE
It is necessary to bleed the fuel system again by carrying out a test cycle for 5 minutes at idle speed or at a reduced
load.

After preparations, perform a brief test cycle up to the operating temperature (approx. 90 °C).
If possible, do not load the engine during the test.
Work with the engine stationary:
l check the engine tightness.
l Check the engine lubricant oil level and top up if necessary.
l Check the coolant level and top up if necessary.
Work during the test cycle:
l check the engine tightness.

10.1.11 - Usage - Starting procedure

DANGER
Before starting the engine, make sure no one is located too near the engine or the machine. After the repair work:
make sure all the protective devices have been refit and no tool has been forgotten on the engine. If starting is per-
formed wth flame glow plugs, pin-type glow plugs or a heater, do not use any other accessories for cold starting start-
ing (e.g. Startpilot). Danger of accidents!
NOTE
If the engine fails to start and the fault indicator lamp flashes, this indicates that the electronic control system has
inhibited starting to protect the engine. The starter block is eliminated by deactivating the system with the ignition key
for approx. 30 s. Run the starter motor for no longer than 20 seconds at a time. If the engine does not start, wait one
minute before repeating the starting manoeuvre. If the engine does not start after two attempts, identify the cause of
the problem by referring to the table. When the engine is still cold, avoid revving immediately to high engine speeds
either under load or with no engine load.
See para. 10.1.25 - Care and maintenance w... - page 10-62
NOTE
If possible separate the engine by decoupling the device lines.

10-25
 Technical characteristics
With the starter device cold

P 0
1
2

Fig. 36
l Insert the key
m Position 0 = no operating voltage.

l Turn the key to the right.

m Position 1 = operating voltage.
m The engine is ready to operate.

l At temperatures below the value set in the electronic engine control unit, preheating starts automatically when the ignition is
switched on.
l The electronic engine control unit activates and regulates the power fed to the glow plugs in relation to coolant temperature.
l Press the key and turn it again to the right, pushing it against the spring.
m Position 2 = start.

l As soon as the engine starts, release the key

m The warning lights turn off.

If the starter motor is checked by an electronic regulator relay from the engine:
l the maximum duration is limited.
l pause is made between two starting attempts
m The starting procedure continues therefore automatically

l another start is prevented with the engine running.

10-26
Technical characteristics
If the pulse starting function is programmed, a single start signal is sufficient with the ignition key in position 2, or if present, with the
starter button.
10.1.12 - Usage - Monitoring engine operation
Electronic engine governor system
The statuses are signalled by the error warning light:
The system controls its own status and the engine status.
l Operation check
m With the ignition active, the error warning light will flash for approx. 2 seconds.
m If there is no reaction during ignition, check the error warning light.

l The warning light does not turn on

m After the lamp test, a warning light that is off signals a possible condition that is correct and without errors during the

checks that can be carried out.

l Permanent light
m System error.
m Operation continues with certain limitations.
m Have a check performed by a DEUTZ service partner.
m If the light is fixed, this means that a controlled unit of measure (e.g. the coolant temperature, the lubricant oil pressure)

exceeded the permitted interval.

Depending on the type of problem, the electronic engine regulator can reduce the engine power to protect the engine.
l Flashing
m Serious system error.
m Deactivation request for the operator. Note: Failure to respect this causes the warranty to be voided!
m The switching off condition for the engine was not reached.
m To cool the engine, forced operation with power reduced, if necessary with automatic switching off.
m Switching off process.
m After the engine has stopped, there may be a starter block.
m The starter block is eliminated by deactivating the system with the ignition key for approx. 30 s.
m Other control warning lights may turn on, e.g. for oil pressure or temperature.
m With the optional override key on the instrument panel for avoiding critical situations, power reduction can be excluded,

automatic deactivation can be delayed or a starter block can be excluded. This brief deactivation of the engine protec-
tion functions is recorded in the control unit.
The overload cutout is established together with the manufacturer and DEUTZ consultants and can be fixed in a customised manner.
Therefore it is absolutely necessary to follow what is indicated in the user manual provided by the system manufacturer.

10-27
 Technical characteristics
Signalling instrument

Fig. 37
Possible warning lights:
l Colour scale
m Operating status warning light with coloured sectors:
m Green = normal operating status.
m Red = critical operating.

Adopt suitable measures.

l Measurement value scale
m The effective value can be read directly. The nominal value can be obtained form the technical data.

See para. 10.1.30 - Technical data - Engin... - page 10-74

10-28
Technical characteristics
Instruments and symbols
Table 30
Instruments/symbols Designation Possible warning lights Measurement
Lubricant oil pressure warning Lubricant oil pressure in the red stop the engine
light zone

Coolant temperature Coolant temperature too high stop the engine

Lubricant oil temperature Lubricant oil temperature too stop the engine
high

Lubricant oil pressure warning If the warning lamp lights after stop the engine
lamp starting the engine or while the
engine is running, the lubricant
oil pressure is too low

Lubricant oil level If the control warning light turns Add the lubricant oil
on after engine ignition or while
the engine is running, the lubri-
cant oil level is too low

10-29
 Technical characteristics
Instruments/symbols Designation Possible warning lights Measurement
Coolant level If the control warning light turns Turn off the engine, let it cool
on after engine ignition or while and top up the coolant
the engine is running, the lubri-
cant oil level is too low

Operating counter Indicates current total of engine Comply with the maintenance
operating hours intervals

Acoustic signal In case of an acoustic signal See fault table.

10-62

DPF operating warning light Flashing Check the AdBlue® filling level
Idle regeneration cycle for die- 10-32
sel particulate filter necessary

Engine warning light Permanent light Activate idle regeneration cycle

In addition to the DPF function 10-32
lamp, the system also indicates
that a idle regeneration cycle
is necessary but has not been
confirmed yet

10-30
Technical characteristics
DEUTZ Electronic Display

Fig. 38
A CAN display may be integrated into the driver’s instrument cluster to view the parameters and error signals relative to the EMR
control system.
The following data can be displayed if they are transmitted by the control unit.
l Engine speed
l Engine torque (current)
l Coolant temperature
l Intake air temperature
l Exhaust gas temperature
l Lubricant oil pressure
l Coolant pressure
l Supply air pressure
l Fuel pressure
l Status of the diesel particulate filter regeneration
l Diesel particulate filter function check
l Errors in the exhaust gas after-treatment system
l Battery voltage
l Accelerator pedal position
l Fuel consumption

10-31
 Technical characteristics
l Operating hours
The error messages are signalled by a text and acoustically, the control device error memory can be read.
A detailed description is provided in the instruction manual provided with the DEUTZ Electronic Display.
10.1.13 - Use - exhaust gas after-treatment systems
Diesel oxidation catalytic converter
The diesel oxidation catalytic converter has a catalytic surface, through which the harmful substances that are contained in the
exhaust gas are transformed into a harmless substance. This causes the carbon monoxide and unburned hydrocarbons to react with
oxygen and are transformed into carbon dioxide and water. Furthermore, nitric oxide is transformed into nitrogen dioxide.
For better performance, temperatures of > 250 °C are required.
Diesel particulate filter
When diesel fuel is burnt, soot is produced, which is separated in the diesel particulate filter. When the load of soot increases, it must
be regenerated. This means that the soot is burnt in the diesel particulate filter.
Regeneration is a continuous process, which is activated as soon as the exhaust gas temperature at the inlet side of the exhaust gas
after-treatment system exceeds 250 °C. The load of the soot filter is monitored permanently by the engine control unit.
Normal operation
Under normal operating conditions (exhaust gas temperature > 250 °C) the load of the filter with soot remains within a permitted
interval and no further actions are required.
The regeneration warning light turns off.
Support mode
If engine operating conditions do not permit passive regeneration, soot will continue to build up in the particulate diesel filter.
If the necessary conditions for passive regeneration are not met during normal operation, a butterfly valve in the combustion air
inlet and controlled by the engine control unit is used to increase the exhaust gas temperature and permit regeneration of the diesel
particulate filter.
This may be the case when:
l The engine has only operates for brief periods.
l Low engine demand.
This process is activated automatically by the engine control unit, no interventions are required by the user.
The regeneration warning light turns off.
Regeneration when stationary
When the support mode does not reach a sufficient reduction in the soot load, the filter will be loaded again with soot and a new
regeneration when stationary will be necessary.
CAUTION
During regeneration, temperatures close to 600°C are created at the end of the exhaust pipe. During regeneration
when stationary, a special engine operation status is activated and it is not possible to use the machine during active
regeneration when stationary. Burn hazard!
This is signalled by a flashing regeneration warning light.
Regeneration when stationary must be started manually by the operator.
It is advisable to perform the necessary idle regeneration cycle as soon as possible, as soot will otherwise continue to accumulate
in the diesel particulate filter.
If the idle regeneration cycle is not performed, the engine control unit will implement engine protection strategies in relation to the
degree of clogging of the diesel particulate filter.
Carrying out regeneration when stationary
The engine must be brought to a “safe state” for regeneration:
l Stop the engine on an empty terrain at a safe distance from inflammable objects.
l Idle the engine.
l The engine control unit now requires a signal indicating that the machine is parked safely (stationary signal).
This takes place based on the application, for example by:
m Activating the parking brake.
m Engaging a defined ratio in the gearbox.

10-32
Technical characteristics
l Confirming with the authorisation key.
Position based on the application, see the device manual.
During the regeneration phase, the regeneration warning light remains on constantly.
On average, regeneration lasts 30 minutes.
Once regeneration has been completed correctly, the regeneration warning light turns off.
Instead of performing an idle regeneration cycle, the engine may be operated for a given period of time at higher load. If the filter
regeneration state returns within the normal operating range, the engine control unit resets the alarm.
Replacing the diesel particulate filter
The soot indicator lamp indicates that diesel particulate filter is permanently clogged and cannot be regenerated within the system.
The soot indicator lamp lights.
Contact your DEUTZ partner.
DEUTZ will remove and retain the clogged diesel particulate filter, and replace it with a clean unit
Regeneration control warning light
The warning light and monitoring of the exhaust gas after-treatment system can consist, depending on the engine version, or a con-
trol warning light or a CAN interface with a corresponding display.
Table 31
Instruments/symbols Power reduction Regeneration
Regeneration warn- Engine warning light Ash warning light
ing light

off off off Normal operation

off off off Support mode
Flashing off off Regeneration when sta-
tionary
Operator authorisation
quick flashing Permanent light off -30 % Regeneration when sta-
tionary
Operator authorisation
quick flashing Flashing off -30 % Regeneration when sta-
tionary
+ limitation of engine Authorisation only by the
speed 1200 rpm DEUTZ partner
quick flashing Flashing Permanent light -30 % No regeneration possible
Ash load 100 % + limitation of engine
speed 1200 rpm

10-33
 Technical characteristics
10.1.14 - Use - Stop procedure
Stop

P 0
1
2

Fig. 39

NOTE
It should be avoided to stop from operating at full speed (coking/clogging with residuals of lubricant oil in the turbo-
charger bearing body). This inhibits the supply of turbocharger lubricant oil! This compromises the useful duration of
the turbocharger. After the discharge, let the engine run at a low speed for approx. one minute.
Turn the key to position 0.
l P = switching level: park
l 0 = switching level: stop the engine
l 1 = switching level: Ignition activated
l 2 = switching level: start the engine

10-34
Technical characteristics
Inertia time
NOTE
The control device remains active for another 40 seconds to store the system data (inertia) and then is deactivated
automatically.

10.1.15 - Operating materials - lubricant oil

In general
Modern diesel engines require lubricant oils with very high performance requisites. The continuous increase in the specific perfor-
mance of diesel engines in recent years has led to an increase in the thermal stress oil sustained by the oil. Furthermore, reduced oil
consumption and longer oil change intervals have meant that the lubricant oil itself is subject to greater contamination. For this reason
it is necessary to comply with what is described in this user manual and observe the recommendations in order not to compromise
engine duration.
Lubricant oils always consists of a base oil and a mixture of additives. The primary functions of a lubricant oil (e.g. protection against
wear and corrosion, neutralising acids produced during combustion, preventing carbon coke and soot encrustation on engine com-
ponents) are performed by these additives. The characteristics of the lubricant oil are equally a decisive index of product quality, with
regard to thermal load, for example.
Substantially, all engine oils with the same specifications can be mixed together. However, it is advisable not to mix engine oils con-
sidering that the worst characteristics in the mix will always predominate.
The lubricant oils authorised by DEUTZ have been thoroughly tested with every engine type. The additives they contain have been
combined together with great care. Therefore, it is not permitted to use other additives for lubricant oils in DEUTZ engines.
The quality of the lubricant oil has great influence on the duration, performance and therefore also the economic aspect of the engine.
Substantially, the following applies: a better lubricant oil quality means that these characteristics are better.
The viscosity of the lubricant oil describes the sliding behaviour of the lubricant oil based on temperature. The viscosity of the lubri-
cant oil has a limited influence and repercussions on the quality of the lubricant oil.
Synthetic lubricant oils are used more and offer specific advantages. These oils are more temperature and oxidant resistant, and
have a relatively low viscosity at low temperatures. As some procedures are important for determining the lubricant oil change inter-
vals and depend substantially on the quality of the lubricant oil (for example, outflow of soot and other impurities), the lubricant oil
change interval must not be increased beyond what is indicated in the lubricant oil change intervals even if you are using synthetic
lubricant oils.
Biodegradable lubricant oils can be used with DEUTZ engines if they satisfy the requirements of this manual.
Quality
The lubricant oils are divided by DEUTZ based on their performance and their quality class (DQC: DEUTZ Quality Class). Substan-
tially, the following applies: in higher quality classes (DQC I, II, III, IV) the lubricant oils have higher performance and characteristics.
The DQC quality classes are integrated with the DQC-LA categories, which include the modern low ash content lubricant oils (LA =
Low Ash).
Lubricants compliant with other equivalent standards may also be used, provided that they meet DEUTZ specifications. If no products
meeting the requisites are available, contact your DEUTZ partner.
Or see the website www.deutz.com
Table 32
http://www.deutz.com
de \SERVICE \Betriebsstoffe und Additive\Deutz Quality Class\
DQC-Freigabeliste
en \SERVICE \Operating Liquids and Additives\Deutz Quality Class\
DQC Release List
The selection of the lubricant oil depends basically on the exhaust gas after-treatment system.
For the engines in this user manual, the following lubricant oils may be used:
Table 33
Reliable quality classes
DEUTZ Other
Engines with exhaust after-treatment system

10-35
 Technical characteristics
Reliable quality classes
DEUTZ Other
DQC III LA Contact your DEUTZ partner
DQC IV LA
Engines without exhaust after-treatment system
DQC III Contact your DEUTZ partner
DQC III LA
DQC IV
DQC IV LA
For low ash content engine oils, authorised according to the DQC system, a list of authorised oils is provided.
Table 34
Lubricant oils
DEUTZ DQC III TLX - 10W40 FE
Not with DPF
Drums Order code:
5 litre container 0101 6335
20 litre container 0101 6336
209 litre drum 0101 6337
Table 35
DEUTZ DQC III LA low ash content lubricant oils
DEUTZ Oil Rodon 10W40 Low SAPS
Drums Order code:
20 litre container 0101 7976
209 litre drum 0101 7977
Table 36
DEUTZ DQC IV synthetic lubricant oils
DQC IV - 5W30-UHP
Not with DPF
Drums Order code:
20 litre container 0101 7849
209 litre drum 0101 7850
Lubricant oil change intervals
l The intervals depend on:
m Lubricant oil quality
m Sulphur content in the fuel
m Type of engine use

l The lubricant oil change interval must be reduced by half if at least one of the following conditions occurs:
m Permanent ambient temperatures below -10 °C (14 °F) or lubricant oil temperature below 60 °C (84 °F).
m Sulphur content in the Diesel fuel >0.5 of the % in weight.

l If the oil change intervals are not reached within one year, the oil change must be carried out at least 1 time a year.
Viscosity
The ambient temperature in the installation site (where the engine is used) plays a crucial role in determining the correct viscosity
grade. Too high viscosity can lead to ignition difficulties, too low viscosity can place the lubricating effect at risk and cause elevated
consumption of the lubricant oil. In the case of ambient temperatures of below -40 °C the lubricant oil must be preheated (e.g. if the
vehicle or work machine is parked in a shed).
Viscosity is classified according to SAE. Substantially, polyvalent lubricant oils must be used. In closed and heated environments
where the temperature is above >5 °C monovalent lubricants can also be used.
NOTE
When selecting the viscosity class, it is essential to comply with the prescribed lubricant oil quality.

Based on the ambient temperature, we recommend the following customary viscosity classes:

10-36
Technical characteristics

Fig. 40

10.1.16 - Operating materials - Fuel

Homologated fuels
In order to comply with standards regarding emissions, diesel engines equipped with an exhaust gas after-treatment system can only
run on sulphur-free fuels.
The operating safety as well as the durability of individual exhaust gas after-treatment systems cannot be guaranteed if this instruc-
tion is ignored.

10-37
 Technical characteristics
Table 37
Exhaust gas after-treatment systems:
DPF Diesel particulate filter
DOC Diesel oxidation catalyst
Fuels that meet the following specifications are permitted:
Diesel fuels
l EN 590
Sulphur <10 mg/kg
l ASTM D 975 Grade 1-D S15
l ASTM D 975 Grade 2-D S15
Sulphur <15 mg/kg
Light fuel oils
l EN 590 quality
Sulphur <10 mg/kg
The use of other fuels that do not meet the requirements stipulated in this manual will void the warranty.
Measurements for the purposes of certification of compliance with the legal emission limits are made using legally-defined test fuels.
These fuels correspond to those described in this manual and refer to the standards EN 590 and ASTM D 975. For other fuels men-
tioned in this manual, the emission values cannot be guaranteed.
To ensure compliance with national emissions requirements, use the fuels prescribed by law (e.g. sulphur free fuels).
Contact your DEUTZ partner.
Table 38
http://www.deutz.com
de \SERVICE\Betriebsstoffe und Additive\ Kraftstoffe
en \SERVICE\Operating Liquids and Additives\ Fuels
Winter operation with diesel fuel
Special demands are made on the cold behavior of fuel (temperature limit value of filterability) for winter operation. During winter,
suitable fuels are made available at service stations.
NOTE
For engines with DEUTZ Common-Rail DCR® injection the addition of petrol or other additives to ensure the fluidity
of the fuel is not permitted.

At low ambient temperatures, the precipitation of paraffin solids in diesel fuel can cause clogging of the fuel system and consequent
operating anomalies. When the external temperature falls below 0 °C (down to -20 °C) winter fuel should be used (which can be
purchased at filling stations from the beginning of the cold season).
l Special diesel fuels are available for arctic climate zones for use in temperatures down to -44 °C.

10.1.17 - Operating materials - Coolant

In general
DANGER
Never use the engine without the coolant, not even briefly!

In the case of water cooled engines, coolant must be prepared and controlled, otherwise damage may be caused to the engine due
to:
l corrosion
l cavitation
l freezing
l overheating

10-38
Technical characteristics
Water quality
The correct water quality is fundamental when treating the coolant. Basically, clean water that does not lie outside the following
analysis values must be used:
Table 39
Analysis values min max ASTM
pH value 6.5 8.5 D 1293
Chlorine (Cl) [mg/l] - 100 D 512
D 4327
Sulphate (SO4) [mg/l] - 100 D 516
Total hardness (CaCO3) [mmol/l] 3.56 D 1126
[mg/l] 356
[°dGH] 20.0 -
[°e] 25.0
[°fH] 35.6
The water quality data is provided by local supply companies.
In the case of differences from the analysis values, the water must be treated.
l pH value too low
Add caustic soda or diluted caustic potash. It is recommended to make small test mixtures.
l Overall hardness too high:
mix with softened water (pH neutral condensate or water softened by means of ion exchangers).
l Chloride and/or sulphates too high:
mix with softened water (pH neutral condensate or water softened by means of ion exchangers).
Cooling system protective agent
DANGER
If mixing nitrite based agents that protect the cooling system with amine based products, nitrosamines are formed that
are harmful to health!

NOTE
The cooling system protective agents must be disposed of in an environmentally friendly manner. Follow the instruc-
tions on the safety data sheet.

The coolant for compact liquid cooled DEUTZ engines is treated by mixing an antifreeze with ethylene glycol and water based cor-
rosion inhibitors.
Table 40
DEUTZ cooling system protective product
Drums Order code:
5 litre container 0101 1490
20 litre container 0101 4616
210 litre drum 1221 1500
This cooling system protective agent does not contain nitrites, ammonia, phosphates and is suitable for the materials in our engines.
It can be ordered from your DEUTZ partner.
If you do not have a DEUTZ cooling system protective agent available, please contact your DEUTZ partner.
Or see the website www.deutz.com
Table 41
http://www.deutz.com
de \SERVICE\Betriebsstoffe und Additive\ Kühlsystemschutz
en \SERVICE\Operating Liquids and Additives\ Cooling System
Conditioner
The cooling system must be checked periodically. This includes, in addition to checking the coolant level, also checking the concen-
tration of the cooling system protective agent.
The check of the cooling system protective agent concentration can be done using a commercial test (for example refractometer).

10-39
 Technical characteristics
Table 42
Percentage of the cooling system Water percentage Protection from cold up to
protective agent
min. 35 % 65 % -22 °C
40 % 60 % -28 °C
45 % 55 % -35 °C
max. 50 % 50 % -41°C
In the case of temperatures below -41 °C contact your DEUTZ support service.
The use of other cooling system protective agents (e.g. chemical anti-corrosive agents) is permitted in exceptional cases. Contact
your DEUTZ partner.
10.1.18 - Maintenance - Maintenance schedule
Associating service levels with service intervals
Table 43
Regular maintenance schedule, TD/TCD 3.6 L4
Stage Activity To be performed by Maintenance interval
every ..... Operating hours
(o.d.e)
E10 First start-up Authorised technical personnel When commissioning new or
overhauled engines
E20 Daily check Operator Once per day, or every 10 oper-
ating hours in case of continu-
ous operation
E30 Maintenance Specialised personnel 500 1) 2) 3)
E40 Extended maintenance I 1.000 3)
E50 Extended maintenance II Authorised technical personnel 2.000 3)
E70 General overhaul 5.000 3) 4)
Table 44
Comments
1) Based on use case, the stress on the lubricant oil may be high. In
this case, halve the oil change interval
See para. 10.1.15 - Operating materials - ... - page 10-35
2) Lubricant oil change intervals in reference to DQC III quality.
3) The manufacturer of the machine must equip the machine with an
operating hour measurement and indication system. The operat-
ing hours are recorded by the ECU. The parameter is is queried
via the CAN bus and the value is represented on a display or
indicated/recorded by an electromechanical hour meter.
Table 45
General overhaul
4) The optimum time for performing a general overhaul depends
substantially on load, operating conditions, environmental condi-
tions and on engine care and maintenance during operation
Your DEUTZ partner will be happy to advise you on defining the
optimum time for performing a general overhaul.
Maintenance operations
Table 46
Stage Activity Measurement Document
E10 The operations are described in 10-21
chapter 3.

10-40
Technical characteristics
Stage Activity Measurement Document
E20 Check Livello dell’olio lubrificante (top 10-42
up if necessary)
Coolant level (top up if neces- 10-21
sary)
Engine seal tightness (visual in-
spection for leaks)
Seal tightness of exhaust sys- 10-15
tem complete with exhaust gas
after-treatment system
Intake air filter/dry air filter (if 10-55
installed, perform the mainte-
nance based on the relative in-
dicator)
Draining water collector bowl on 10-46
fuel pre-filter
E30 Renewal Lubricant oil. The DEUTZ oil 10-35
diagnosis system may be used 10-42
to determine the ideal oil usage
and change interval strategy for
the specific engine application.
For this purpose, contact your
DEUTZ partner.
Lubricant oil filter cartridge (at 10-42
each oil change)
Check Coolant (concentration of addi- 10-51
tive)
Check for damage to intake air [LNK]
ducts
Toothed belt 10-58
Clean Fuel pre-filter / fuel pre-filter 10-46
(replace filter cartridge if neces-
sary)
E40 Check Charge air cooler intake surface
(drain lubricant oil/condensa-
tion)
Battery and cable connections 10-62
With the starter device cold [LNK]
Engine mount (tighten it if nec-
essary, replace if damaged)
Fasteners, hose connections /
clamps (replace if damaged)
V-belt, ribbed V-belt and belt 10-58
tensioner roller
Renewal Fuel filter cartridge 10-46
Fuel pre-filter cartridge Drain 10-46
the water separator bowl imme-
diately if the relative alarm is ac-
tivated (warning lamp/buzzer).
Dry air filter 10-55
Toothed belt 10-46
E50 Renewal Ribbed V-belt and belt tensioner 10-58
roller
Annual Check Engine monitoring, horn. Main-
tenance must only be carried
out by authorised service per-
sonnel!
Renewal Fuel pre-filter 10-46

10-41
 Technical characteristics
Stage Activity Measurement Document
Every 2 years Renewal Dry air filter 10-55
Coolant 10-38
10-51
Based on the status Renew/change Diesel particulate filter - de- 10-32
pending on engine version, the
soot indicator lamp or electronic
display indicates when replace-
ment is necessary (see DEUTZ
replacment schedule).

Service procedures not attributed to service levels

*Drain the fuel pre-filter water separator bowl immediately if the relative water level alarm is activated (warning lamp/buzzer).
Maintenance diagram
A self-adhesive maintenance diagram is provided with each engine. It must be stuck in a visible position on the engine or on the
machine.
Order code: 0312 3911 (TD/TCD 3.6 L4)
10.1.19 - Care and maintenance work - Lubricant oil system
Directives for work on lubricant oil systems
DANGER
Never perform the work while the engine is running! Smoking and open flames prohibited! Pay attention in the case
of hot lubricant oil. Burn hazard!

NOTE
Maximum cleanliness is essential when working on the lubricating oil system. Thoroughly clean the area around the
components to be worked on. Dry any wet areas with a compressed air jet. When handling lubricating oils, observe
safety standards and all applicable local regulations. Dispose of the exiting lubricant oil and the filter elements in
compliance with law. Do not let the exhausted lubricant oil permeate the ground. Perform a test cycle after each inter-
vention. At the same time, guarantee the seal and pressure of the lubricant oil and then check the lubricant oil level.

10-42
Technical characteristics
Check the lubricant oil level

Fig. 41

NOTE
An too low or too high level of lubricant oil could damage the engine. The oil level can only be checked with the engine
horizontal and stationary. Once it is hot, stop the engine and check the oil level after 5 minutes. If the engine is cold,
the check can be made immediately.
DANGER
Pay attention in the case of hot lubricant oil. Burn hazard! Do not remove the dipstick while the engine is running. Risk
of injury!

l Remove the dipstick and clean it with a clean cloth that does not leave fibres.
l Insert the lubricant oil dipstick to the stop.
l Remove the dipstick and read the level of the lubricant oil.
l The lubricant oil level must always be between the MIN and MAX notches! Top up to the MAX notch if necessary.

10-43
 Technical characteristics
Lubricant oil change:
l Heat the engine (lubricant oil temperature > 80 °C).
l Position the engine or vehicle on a horizontal surface.
l Stop the engine.
l Position the collector bowl under the lubricant oil drain screw.
l Unscrew the lubricant oil discharge auger, drain the lubricant oil.
l Fit and tighten the drain hole screw, fitted with a new seal (tightening torque 55 Nm).
l Add the lubricant oil.
m Quality/viscosity data

See para. 10.1.15 - Operating materials - ... - page 10-35

m Fill capacity

See para. 10.1.30 - Technical data - Engin... - page 10-74

l Heat the engine (lubricant oil temperature > 80 °C).
l Position the engine or vehicle on a horizontal surface.
l Check the engine lubricant oil level and top up if necessary.
Replace the lubricant oil cartridge filter

Fig. 42

10-44
Technical characteristics
NOTE
The filter cartridge must never be pre-loaded. Risk of fouling!

l If the anti-twist safety is installed, remove the tightening clamps (optional).

l With the tool (order no.: 170050) loosen and tighten the filter cartridge.
l Collect any exiting lubricant oil.
l Clean the filter holder sealing surface with a clean cloth that does not leave fibres.

Fig. 43
l Lightly oil the seal on the new cartridge for the original DEUTZ filter.
l Manually screw in the new filter until it is sealed and tighten to a torque of: 15-17 Nm
l Tighten the tightening clamps of the anti-twist safety (optional).

10-45
 Technical characteristics

Fig. 44

10.1.20 - Care and maintenance work - Fuel distribution system

Directives for work on the fuel system
DANGER
The engine must be stationary! Smoking and open flames prohibited! In general, the injection lines/high pressure lines
must not be disconnected while the engine is running. Pay attention to hot fuel! During refuelling and while working on
the fuel distribution system always maintain conditions of the maximum cleanliness. Thoroughly clean the area around
the components to be worked on. Dry any wet areas with a compressed air jet. When handling fuel observe the safety
directives and specific local regulations. Dispose of the exiting fuel and the filter elements in accordance with law. Do
not permit the fuel to permeate the ground. After performing all the work on the fuel distribution system, it must be bled,
subjected to a test cycle and its tightness must be checked. In the case of a new start-up, after the maintenance work
or after empting the fuel tank, the fuel system must be bleed.
NOTE
It is necessary to bleed the fuel system again by carrying out a test cycle for 5 minutes at idle speed or at a reduced
load. In consideration of the high precision production of the system, ensure maximum cleanliness! The fuel system
must be watertight and closed. Visually inspect for system leaks/damage.

10-46
Technical characteristics
NOTE
Before starting work, fully clean and dry the engine and the engine compartment. Cover areas of the engine compart-
ment from which dirt may separate using a new clean film. Work on the fuel distribution system may only be carried
out in a completely clean environment. Avoid impurities in the air, such as dirt, dust, humidity, etc.
Change fuel filter element

Fig. 45

NOTE
The filter cartridge must never be pre-loaded. Risk of fouling!

l If the anti-twist safety is installed, remove the tightening clamps (optional).

l With the tool (order no.: 170050) loosen and tighten the filter cartridge.
l Collect any fuel that escaped.
l Clean the filter holder sealing surface with a clean cloth that does not leave fibres.

10-47
 Technical characteristics

Fig. 46
l Lightly oil the seal on the new cartridge for the original DEUTZ filter.
l Manually screw in the new filter until it is sealed and tighten to a torque of: 10-12 Nm
l Tighten the tightening clamps of the anti-twist safety (optional).
l Bleed the fuel distribution system.

10-48
Technical characteristics

Fig. 47

10-49
 Technical characteristics
Cleaning/replacing/bleeding the filter cartridge

9 1

2
8
3
7
4

6 5

Fig. 48
Deutz Common Rail (DCR)
l 1 - Bleed screw
l 2 - Pump fuel supply
l 3 - Fuel return from the fuel control unit (FCU)
l 4 - Fuel delivery pump
l 5 - Electric connection for the water level sensor
l 6 – Drain plug
l 7 - Filter cartridge
l 8 - Fuel tank inlet
l 9 - Fuel return to tank
Emptying the water collector bowl
l Stop the engine.
l Position a suitable collector bowl.
l Electrical connection
m Disconnect the cable connections.

l Loosen the discharge auger

l Drain the fluid until pure diesel fuel starts to exit

10-50
Technical characteristics
l Fit the drain plug (tightening torque 1.6 ± 0.3 Nm)
l Electrical connection
m Connect the cable connections.

Replacing the fuel filter cartridge

l Stop the engine.
l Block the feed of fuel to the engine (if the tank is positioned at the top).
l Position a suitable collector bowl.
l Electrical connection
m Disconnect the cable connections.

l Loosen the drain plug and release the fluid.

l Disassemble the filter element.
l Clean any dirt from the sealing surface of the new filter cartridge and the side opposite the filter head.
l Slightly moisten the sealing surface of the filter cartridge with fuel and screw the filter head back on in a clockwise direction
(17-18 Nm).
l Fit the drain plug (torque 1.6 ± 0.3 Nm).
l Electrical connection
m Connect the cable connections.

l Open the fuel shut-off valve and bleed the system (see “Bleeding the fuel system”).
Bleed the fuel distribution system
l Loosen the bleed screw.
l Release the bayonet closure on the fuel delivery pump by pressing and at the same time turning it anticlockwise. The pump
piston is now pushed out by the spring.
l Pump until no more air comes out of the bleed screw.
l Fully tighten the bleed screw (torque 6.5 ± 1.3 Nm).
l Block the bayonet closure on the fuel delivery pump by pressing and at the same time turning it clockwise.
l Start the engine for approx. 5 minutes at idle speed or with a reduced load. Check the prefilter seal.

10.1.21 - Care and maintenance work - Cooling system

Directives for work on the cooling system
CAUTION
Danger of burns due to very hot coolant! The cooling system is pressurised! Open the plug only after it has cooled
down. The coolant must have the required concentration of the cooling system protective action! When handling cool-
ant observe the safety directives and specific local regulations. In the case of an external radiator, proceed following
the manufacturer’s instructions. Dispose of the exiting coolant in compliance with the relative regulations and do not
permit it to penetrate the ground. The cooling system protective agents must be ordered from your DEUTZ partner.
Never use the engine without the coolant, not even briefly!
Check the coolant level, if engine is equipped with external radiator
l Add new coolant and bleed the system following the instructions of the cooling system manufacturer.
l Carefully open the cooling system plug.
l The lubricant oil level must always be between the MIN and MAX notches! Top up to the MAX notch if necessary.

10-51
 Technical characteristics
Check the coolant additive concentration

Fig. 49
l Carefully open the cooling system plug.
l Using a commercially available antifreeze tester (1) (e.g. hydrometer, refractometer) check the coolant additive - the concen-
tration in the radiator/compensation container (2).
l Concentration of the coolant additive in proportion to the coolant mixture.
See para. 10.1.17 - Operating materials - ... - page 10-38
The specific tester may be ordered from your DEUTZ partner with part number 1824.

10-52
Technical characteristics
Empty the cooling system

Fig. 50
l Carefully open the radiator cap.
l Position a suitable collector bowl.
l Remove the crankcase hole blanking screw (1).
l Add the coolant.
l If the screw plug is not accessible, the coolant may be drained from the coolant line on the engine oil radiator.
l Refit the screw with sealant.
l Replace the radiator cap.

10-53
 Technical characteristics
Filling and bleeding the cooling system

Fig. 51

CAUTION
Danger of burns due to very hot coolant! The cooling system is pressurised! Open the plug only after it has cooled
down.

l Carefully open the cooling system plug (1).

l Loosen any coolant bleed screws.
l Top up the coolant up to the maximum notch or to the filling limit.
l Turn on the heating if present and set it to the maximum level so the heating circuit fills up and bleeds.
l Replace the radiator cap.
l Heat the engine up to the operating temperature (thermostat opening temperature).
l Stop the engine.
l Check the coolant level with a cold engine. If necessary, top up to the MAX marking or to the fill limit of the header tank.

10-54
Technical characteristics
10.1.22 - Care and maintenance work - Engine cleaning
Cleaning operations
NOTE
For all cleaning work, pay attention to not damage the components (e.g. deformed radiator honeycomb, etc.). For
engine cleaning, cover the electric/electronic components and connections (e.g. control devices, alternator, solenoid
valves, etc.). Do not use a direct water/steam jet for cleaning. Then heat the engine.
DANGER
Clean the engine only when the engine is stationary. Remove the engine cover, the cooling air cover if present and
refit it after cleaning.

General information
The following causes of dirt make it necessary to clean the engine:
l high concentration of dust in the air
l chaff and straw in the engine area
l coolant leaks
l lubricant oil leaks
l fuel leaks
As operating conditions vary from application to application, clean as necessary in relation to degree of dirt and contamination
Cleaning with compressed air
l Remove the dirt with compressed air. Blow the air on the radiator and the cooling fins always from the exhaust air side towards
the clean air side.
Clean with cold detergent
l Spray the engine with cold detergent and leave it on for approx. 10 minutes.
l Clean the engine with a strong jet of water.
l Rotate the engine until it heats up to evaporate the residual water.
Clean with a high pressure device
l Clean the engine with a jet of steam (maximum pressure 60 bar, maximum steam temperature 90°C, min. distance 1m).
l Rotate the engine until it heats up to evaporate the residual water.
l Clean the radiator and the cooling fins always from the exhaust air side towards the clean air side.

10.1.23 - Care and maintenance work - Intake system

Directives for work on the intake system
DANGER
Never perform the work while the engine is running!

NOTE
Maximum cleanliness is essential when working on the intake system. Close the intake openings if necessary. Used
filter elements must be disposed of in compliance with law.

10-55
 Technical characteristics
Service the dry air filter

Fig. 52

DANGER
Do not clean the filter element (3) with petrol or hot liquids! Replace damaged filter elements.

l Service the filtering element (3) based on the maintenance plan interval.
l Open the retaining bracket (1).
l Remove the filter cover (2) and withdraw the filter element (3).
l Filter element (3):
m in the case of a low amount of contamination, blow dry compressed air on it from the inside towards the outside (max.

5 bar);
m replace in the case of a large amount of contamination.

10-56
Technical characteristics
Replace the dry air filter safety cartridge
NOTE
Never clean the safety cartridge (4).

l Replace the safety cartridge (4) based on the maintenance plan interval.
l For this purpose:
m Unscrew the hexagonal nut (5), withdraw the safety cartridge (4).
m Insert a new safety cartridge, tighten the hexagonal nut.

l Insert the filter element (3), fit the cover (2) and fasten with the tightening bracket (1).
Maintenance warning light for the dry air filter

Fig. 53
l Dry air filter maintenance is carried out based on the maintenance indicator or switch.
l Filter maintenance is necessary when:
m the yellow maintenance switch control warning light turns on while the engine is running.
m the red service field (1) of the maintenance indicator is completely visible.

l After performing the maintenance, press the maintenance indicator reset button. The maintenance indicator is again ready
for use.

10-57
 Technical characteristics
Clean the dry air filter dust exhaust valve

Fig. 54
l Empty the dust exhaust valve (1) by pressing the exhaust slot.
l Any dust incrustations inside the device can be removed by squeezing the upper part of the device with your fingers.
l Clean the exhaust slot.

10.1.24 - Care and maintenance work - Belt transmissions

Check the belt transmission
DANGER
Perform work on the belt transmission only when the engine is stationary! After the repair work: make sure all the
protective devices have been refit and no tool has been forgotten on the engine.

l Visually inspect the entire belt transmission for damage.

l Replace damaged parts.
l Refit the protections if necessary!
l In new belts are used, check the correct position; check the tension after 15 min. of operation.

10-58
Technical characteristics
Replacing the ribbed V-belt

Fig. 55
l 1 - Belt tensioner roller
l 2 - Sealing pin
l 3 - Assembly hole
l Push the belt tensioner roller with the box spanner in the direction of the arrow until it is possible to fit a sealing pin in the as-
sembly hole. Now the ribbed V-belt is tension free.
l First withdraw the ribbed V-belt from the smaller roller and from the belt tensioner roller.
l Fit the new ribbed V-belt.
l Retain the belt tensioner roller using a box spanner and remove the sealing pin.
l Retighten the ribbed V-belt using the belt tensioner and the box spanner. Check that the ribbed V-belt is resting correctly in
its guide.

10-59
 Technical characteristics
Check the belt tension

5 4 3 2

Fig. 56
l Lower the indicator arm (1) in the tester.
l Place the guide (3) between the two pulleys on the V-belt (2). For this reason, the stop must be lateral.
l Uniformly press the button (4) in the right corner with respect to the V-belt (2) until you can hear the spring release.
l Delicately lift the tester without changing the position of the indicator arm (1).
l Read the value measured on the intersection point (arrow), indicator scale (5) and arm (1).
l Correct the tension if necessary and repeat the measurement.
Tool
The belt tension tester (part number: 8115) may be ordered from your DEUTZ partner.

10-60
Technical characteristics
Replacing the belt

4
B A
3

Fig. 57
l 1 – Screw
l 2 – Screw
l 3 – Screw
l 4 - Adjustment wrench
l Unscrew the screw and check nut.
l Move the alternator above the adjustment wrench towards (B) until the belt loosens.
l Remove the belts and fit the new ones.
l Move the alternator above the adjustment wrench towards (A) until the belt is correctly tensioned.
l Check the belt tension.
See para. 10.1.30 - Technical data - Engin... - page 10-74
l Retighten the screw and check nut (torque 30 Nm).

10-61
 Technical characteristics
10.1.25 - Care and maintenance work - Electrical system
Directives for work on the electrical system
DANGER
Never touch live parts; immediately replace defective control warning lights.

NOTE
Make sure the polarity of the connections is correct. For engine cleaning, cover the electric/electronic components and
connections (e.g. control devices, alternator, solenoid valves, etc.). Do not use a direct water/steam jet for cleaning.
Then heat the engine. Do not check the presence of voltage by tapping against ground. If it is necessary to perform
electric welding work, the ground clamp of the welder must be directly connected to the part to be welded. Three-
phase current alternator: Do not interrupt the connection between the battery, alternator and regulator while the engine
is running.
Battery
NOTE
Disconnecting the battery from the terminals could cause electronically stored data to be lost. Keep the battery clean
and dry. Make sure that the battery is positioned correctly and safely. Dispose of depleted batteries in an environmen-
tally friendly manner.
DANGER
Risk of explosion! The gas released from the battery is explosive! Flames, sparks, smoke and bare lights prohibited!
Risk of corrosion! Wear safety footwear and protective goggles! Avoid contact with skin and clothes! Risk of short
circuit! Do not place metal tools on the battery!
Check the voltage
l Test the battery voltage with a common voltmeter. The voltage provides information about the state of charge.
Table 47
Battery Charge status (Volt)
12 Volts 12-14.4
24 Volts 24-28.4
Check the acid level
l Unscrew the plugs.
l Follow the manufacturer instructions regarding the level of the fluid. The fluid should normally be 1015 mm above the upper
edge of the plate or the control device if present.
l Only use distilled water for topping up.
l Tighten the plug.

10-62
Technical characteristics
Check the acid density

Fig. 58
l Unscrew the plugs.
l Using a common densimeter to measure the density of the electrolyte in each battery element. The measured values can be
used to find the battery charge. During the process it should correspond to 20°C.
l Before charging, the acid level must be tested.
l Tighten the plug.
Table 48
Acid density [kg/ l] Charge status Measurement
Normal Tropical
1.28 1.23 good None
1.20 1.12 half charge
1.12 1.08 return charge

10-63
 Technical characteristics
Remove the battery
l To disconnect, always disconnect the negative pole first. Otherwise there is a risk of short circuit!
l Remove the fastening element and the battery.
Charging the battery
l Unscrew the plugs.
l Charge the battery using a normal battery charger. Observe the manufacturer data!
l Tighten the plug.
Fitting the battery
l Use a new or charged battery and apply the retainers.
l Clean the connection terminals and the battery poles with fine sandpaper.
l For the connection, first connect the positive pole and then the negative one. Otherwise, risk of short circuit!
Make sure that the terminal contact is correct. Tighten them manually.
l Apply acid-free and acid-resistant grease on the complete terminals.

10.1.26 - Malfunctions - Malfunction table

Malfunctions and solutions
Table 49
Malfunctions Causes Action
The engine does not start or starts with dif- The clutch did not uncouple (if possible) Check the clutch
ficulty Empty fuel tank Empty fuel tank
Fuel intake line blocked Check
Limit temperature for start-up not reached Check
With the starter device cold Check/replace
Incorrect engine oil SAE viscosity class Lubricant oil change:
The fuel quality does not comply with the Changing the fuel
instruction manual
The battery is defective or discharged Check the battery
Starter cable connections loose or oxidised Check the cable connections
Starter faulty or the pinion does not engage Check the starter
Dirty air filter/faulty turbocharger Check/replace
Air in the fuel system Bleed the fuel distribution system
Compression value too low Compression test
Exhaust gas counterpressure too high Check
Injection pipe not airtight Check the injection pipe
The engine does not start and the diagnos- The engine electronics prevent start-up Identify the fault from the error code and
tics warning light flashes rectify the fault if necessary
The engine starts, however operates ir- Exhaust back-pressure Check
regularly or loses strokes Compression value too low Compression test
With the starter device cold Check/replace
Air in the fuel system Bleed
Fuel pre-filter dirty Renew/change
The fuel quality does not comply with the Changing the fuel
instruction manual
Faulty injector Renew/change
Injection pipe not airtight Check the injection pipe
There may be a change in the number of The electronic engine control system has Identify the fault from the error code and
revolutions and the diagnostics warning identified an error and implemented a sub- rectify the fault if necessary
light may turn on stitute engine speed value

10-64
Technical characteristics
Table 50
Malfunctions Causes Action
The engine overheats. The temperature Breather pipe clogged Clean
alarm trips Incorrect engine oil SAE viscosity class Lubricant oil change:
Faulty lubricant oil radiator Check/replace
Oil filter fouled on air side and/or lubricant Renew/change
oil line side
Lubricant oil level too high Check the engine lubricant oil level and
drain if necessary
Lubricant oil level too low Add the lubricant oil
Faulty injector Renew/change
Coolant heat exchanger dirty Clean
Coolant pump failure (toothed V-belt bro- Check if torn or loosened
ken or loose)
Insufficient coolant Top up
Resistance in the cooling system too high/ Check the cooling system
flow rate too low
Cooling fan or exhaust gas thermostat fail- Check/replace/tighten
ure, V-belts snapped or loose
The turbocharging air pipe leaks Check the turbocharging air pipe
Turbocharging air radiator dirty Check/clean
Dirty air filter/faulty turbocharger Check/replace
Air filter maintenance switch/indicator Check/replace
faulty
Exhaust gas counterpressure too high Check
Coolant fan defective/belt broken or loose Check/replace the fan/V-belt if necessary
The engine does not develop enough pow- Lubricant oil level too high Check the engine lubricant oil level and
er drain if necessary
Lubricant oil radiator blades dirty Clean
Oxygen intake temperature too high Check system
The fuel quality does not comply with the Changing the fuel
instruction manual
Dirty air filter/faulty turbocharger Check/replace
Air filter maintenance switch/indicator Check/replace
faulty
Coolant fan defective/belt broken or loose Check/replace the fan/V-belt if necessary
The turbocharging air pipe leaks Check the turbocharging air pipe
Turbocharging air radiator dirty Clean
Resistance in the cooling system too high/ Check the cooling system
flow rate too low
Injection pipe not airtight Check the injection pipe
Faulty injector Renew/change
The engine provides low power and the di- The engine electronics reduce the power Contact your DEUTZ partner.
agnostics warning light turns on
The engine does not operate all cylinders Injection pipe not airtight Check the injection pipe
Faulty injector Renew/change
The turbocharging air pipe leaks Check the turbocharging air pipe
Lubricant oil level too high Check the engine lubricant oil level and
drain if necessary

10-65
 Technical characteristics
Table 51
Malfunctions Causes Action
The engine oil pressure is too low or it is Lubricant oil level too low Add the lubricant oil
depressurised The engine position is too sloped Check the engine mount
/reduce the slope
Incorrect engine oil SAE viscosity class Lubricant oil change:
The engine consumes too much lubricant Lubricant oil level too high Check the engine lubricant oil level and
oil drain if necessary
The engine position is too sloped Check the engine mount/reduce the slope
Crankcase breather Check/replace
Lubricant oil in the exhaust gas system Engine running continuously at excessively Check the load factor
low load (<20-30%)
The engine smoke is blue Lubricant oil level too high Check the engine lubricant oil level and
drain if necessary
The engine position is too sloped Check the engine mount/reduce the slope
The engine smoke is white Temperature limit for starting reached Check
With the starter device cold Check/replace
The fuel quality does not comply with the Changing the fuel
instruction manual
Faulty injector Renew/change
The engine smoke is black Dirty air filter/faulty turbocharger Check/replace
Air filter maintenance switch/indicator Check/replace
faulty
The turbocharging air pipe leaks Check the turbocharging air pipe
Faulty injector Renew/change
Regeneration indicator lamp flashing The diesel particulate filter is loaded with Engage regeneration when stationary
soot and must be regenerated See para. 10.1.13 - Use - exhaust gas
afte... - page 10-32
Regeneration indicator lamp flashing rap- The diesel particulate filter is loaded with Engage regeneration when stationary
idly soot and must be regenerated See para. 10.1.13 - Use - exhaust gas
Engine alarm warning lamp lights Regeneration while station was not autho- afte... - page 10-32
rised
The regeneration washing light flashes The diesel particulate filter is clogged with Have the idle regeneration cycle peformed
quickly. The engine alarm washing light soot and must be regenerated. Regenera- by your DEUTZ partner
flashes. Power reduction tion while station was not authorised

10-66
Technical characteristics
10.1.27 - Faults - Engine management
Engine protection strategy of electronic engine management system

Fig. 59
l 1 - Diagnostics key
l 2 - Error warning light
l 3 - Electronic engine regulation (EMR)
NOTE
The warning light turns off as soon as all faults are eliminated. In the case of some anomalies, it is necessary to deac-
tivate the ignition, wait 30 s and only then reactivate the ignition. If a sensor is faulty, all the corresponding monitoring
functions are deactivated. Only the sensor fault is documented in the error memory.
Depending on the monitoring function instruments, electronic engine regulation could protect the engine in some error situations
from possible damage by monitoring compliance with the important limit values during operation and checking correct operation of
the system components.
Depending on the seriousness of a detected anomaly, the engine can continue to operate with certain limits, with the error warning
light remaining on, or the error light flashes, indicating a serious system error. In this case, the engine must be stopped as soon as
it is possible to do so safely.

10-67
 Technical characteristics
Error warning light
The error warning light is located near the driver’s seat in the vehicle.
The error warning light could issue the following signals:
l Operation check
m With the ignition active, the error warning light will flash for approx. 2 seconds.
m If there is no reaction during ignition, check the error warning light.

l The warning light does not turn on

m After the lamp test, a warning light that is off signals a possible condition that is correct and without errors during the

checks that can be carried out.

l Permanent light
System error
m Operation continues with certain limitations.
m Have a check performed by a DEUTZ service partner.
m If the light is fixed, this means that a controlled unit of measure (e.g. the coolant temperature, the lubricant oil pressure)

exceeded the permitted interval.

m Depending on the type of problem, the electronic engine regulator can reduce the engine power to protect the engine.

l Flashing
Serious system error.
m Deactivation request for the operator. Note: Failure to respect this causes the warranty to be voided!
m The switching off condition for the engine was not reached.
m To cool the engine, forced operation with power reduced, if necessary with automatic switching off.
m Switching off process.
m After the engine has stopped, there may be a starter block.
m The starter block is eliminated by deactivating the system with the ignition key for approx. 30 s.
m With the optional override key on the instrument panel for avoiding critical situations, power reduction can be excluded,

automatic deactivation can be delayed or a starter block can be excluded. This brief deactivation of the engine protec-
tion functions is recorded in the control unit.
In the case of operating anomalies and the need for spare parts, contact one of our competent support service dealers
. In the case of a fault, our qualified personnel can make any repair in a quick and appropriate manner using original DEUTZ spare
parts.
Diagnostics key
The diagnostics key is used to display the errors currently present in the electronic engine regulation error memory, in the form of
flashing codes.
The flashing codes offer:
l The present errors can be classified.
l a univocal signal of the error in the form of an optical signal.
m The flashing codes can only be interpreted by a DEUTZ service partner.

Using the diagnostic key

The flashing code signals all the errors present in the error memory, meaning active and passive errors.
To start the request, turn off the control unit (ignition off). Then press and hold the diagnostic butting while switching the ignition on
for approximately 1 s.
Press the diagnostic button again to view the next error (next error stored in error memory). If the last error present is displayed,
pushing the diagnostic key again the first error will be displayed.
After emitting the flashing error code, the error warning light will turn off for five seconds.

10-68
Technical characteristics
Displaying a system error via a flashing code

2s 2s
0,8 s
0,4 s
0,4 s

0,4 s
0,8 s

1 2 0,4 s 8

Fig. 60
Example:
Flashing code 1-2-8
l 1 x brief flash
l 2 x long flashes
l 8 x short flashes
This flashing code signals damage or a short circuit in the supply air temperature sensor cables. The time sequence of the flashing
signals is indicated in the figure.
The flashing codes can only be interpreted by a DEUTZ service partner.

10-69
 Technical characteristics
10.1.28 - Transport and storage - Transport
Suspension device

Fig. 61

DANGER
The transport devices fit on this engine are calibrated based on the engine weight. If you want to transport the engine
with additional components, the transport devices must be reconfigured.

l Only use the correct suspension device to transport the engine.

l It must be possible to adjust the suspension device (1) based on the engine barycentre.
l After transport/before start-up of the engine: Remove the transport eyelets (2).

10-70
Technical characteristics

Fig. 62

DANGER
Danger of death! If errors are made when implementing the suspension, the engine could overturn or fall!

l The fastening device may not be fastened securely to the barycentre (1).
l The fastening material could slip and the engine could overturn (1).
l A fastening device that is too short could cause the transport device (2) to bend, damaging it.

10.1.29 - Transport and storage - Engine protection treatment

In general
All engines receive the following protection treatments:
l Internal protection treatment
l External protection treatment
NOTE
DEUTZ partners have the following types of suitable protection products available.

10-71
 Technical characteristics
After placing the engine out of service, the following protection treatments satisfy the requirements for protecting for a 12 month
period.
The following procedures for applying protective treatment must only be performed by qualified personnel who has been adequately
informed of the risks involved.
Failure to comply with the instructions and exposing the engine or any parts treated with wax to any unfavourable conditions (placing
outside or storage in humid and non-ventilated areas) or if there is any damage to the layer of the protective material, a shorter pro-
tection and treatment period must be considered for the device.
The engine’s protective treatment must be checked approx. every 3 months by opening the covers. If traces of corrosion are found,
a new treatment is necessary
To prevent the protective product from being removed from bearings, bushes and the cylinder sleeves, do not rotate the crankshaft
after applying the protective treatment.
Before starting up a treated engine, remove the protective wax.
Internal protection treatment
l The internal protective treatment is done by wetting the interior walls with the protective product, using an engine treatment
cycle.
l The treatment cycle may be carried out once to protect the various systems:
Fuel distribution system
NOTE
Close the fuel line leading from the tank to the engine to protect the system from contamination with dirt or dust. Pro-
tect the electronics from humidity/corrosion.

l Fill the fuel tank with a mixture of:

m 90% fuel distillate.
m 10% protective lubricant oil.

l Carry out the protection cycle with the engine not loaded, minimum cycle duration 5 minutes.
Lubrication oil system
l Drain the lubricant oil with the engine hot.
l Use diesel fuel or detergent to thoroughly clean the lubricant oil sump, the cylinder head with rockers, the valves and the valve
springs.
l Fill the engine with TITAN EM 2020 DEUTZ(SAE 20W-20) protective oil for running-in, then perform the treatment cycle
(together with the fuel system treatment cycle) by warming the engine to approximately 60°C for at least minutes to coat all
the components of the oil lubrication system. Otherwise, wet all accessible components with protective oil for running-in, and
use a separate pump to circulate protective oil for running-in, heated to 60°C, throughout the engine until all the bearings and
bushes are coated.
Cooling system
l Depending on the series, the engines are equipped with air, oil or coolant (cooling water with a cooling system protective
agent) based cooling systems.
l Cooling air system, see the External protection treatment section.
l For oil cooled engines, the lubricating oil in circulation also is used for cooling. In this way the cooling compartments are au-
tomatically treated with the oil lubrication system.
l If a protective product that has preserving characteristics is added to the cooling system for liquid cooled engines, once
drained no other measures are required.
l Otherwise, the coolant must be drained and in order to create a protective layer on the inner surfaces of the cooling system,
carry out a protective treatment with a mixture consisting of:
m 95 % treated water
m 5 % anti-corrosive agent

l The duration of the protective treatment cycle and the concentration of the anti-corrosive product must be decided based on
the data provided by the anti-corrosive agent manufacturer.
l Then drain the coolant.

10-72
Technical characteristics
Intake air lines
l After performing the protective treatment cycle, remove the cylinder head cover and injection valves. Bring the respective
pistons to TDC.
l Using a spray wand, spray protective oil for running-in through the aperture to wet the accessible area of the cylinder sleeve
with oil.
l Srpay protective oil for running-in into the air intake duct.
External protection treatment
l Before carrying out the external protection treatment, the engine must be cleaned thoroughly with detergent. Eliminate any
signs of corrosion or paint damage.
Glossy parts and external surfaces
l All glossy metal external surfaces and parts (e.g. flywheel, flange surfaces) must be painted or sprayed with the protective
product.
Rubber parts
l Unpainted rubber parts (e.g. sleeves) are rubbed with talcum powder.
Belt transmissions
l Disassemble the belts and the ribbed V-belt and store them packaged.
l Spray anti-corrosive liquid on the V-belt pulleys and on the belt tensioner rollers.
Engine openings
l To delay the evaporation of the protective substances, air and water tight covers must be placed on all engine openings.
l With the air compressor installed, close the intake and pressure connector with a plug.
l Block the air inlet again to avoid engine ventilation (chimney effect).
Storage and packaging
l After applying the protective treatment, store the engine in a dry, well ventilated building under adequate cover.
l This cover must be placed on the engine with a certain clearance so that air can circulate around it and condensate water
cannot form. Use a drier if necessary.
Dewaxing
l Before starting, the engine must be dewaxed.
l The packaging and all covers on the closed openings must be removed.
l Eliminate any signs of corrosion or paint damage.
Fuel distribution system
Drain the tank if it contains a mixture of diesel fuel and protective oil.
l Connect the fuel tank line to the engine. Ensure maximum cleanliness.
l Fill the fuel tank and system with the specified fuel.
Fuel distribution system
l Unscrew the lubricant oil discharge auger, drain the lubricant oil.
l Pour the lubricant oil into the engine through the filler.
Coolant system
l In the case of compatibility between the preserving agent with the protective product for the cooling system, this can be added
directly to the coolant system based on the requirements.
l If you are not perfectly certain of compatibility between the anti-corrosive product to be used with the protective product for the
cooling system, before adding it first perform a washing cycle with clean water for approx. 15 minutes.
Dewaxing the external parts
l Wash all the surfaces and components covered with the preserving protect with fuel distillate or a suitable detergent.
l If necessary wash the toothed belt pulley grooves.
l Fit the belts and V-belts based on the instructions.
l Top up the coolant.

10-73
 Technical characteristics
Preserving/cleaning products
For information about reference products to be used for protecting or cleaning that comply with DEUTZ requirements, contact your
DEUTZ partner.
Or see the website www.deutz.com
Table 52
http://www.deutz.it
de \SERVICE \Betriebsstoffe und Additive\ Motor
en \SERVICE\Operating Liquids and Additives\ Engine Corrosion
Protection

10.1.30 - Technical data - Engine data and adjustment data

Main technical data
Table 53
Engine type Dimensions TCD 4.1 L4 TCD 6.1 L6
Operating mode 4-stroke diesel engine
Turbocharging Turbocharger Turbocharger with supply air
cooling
Type of cooling water cooled
Cylinder layout in series
Number of cylinders 4
Bore/stroke [mm] 98/120
Total capacity [cm3] 3621
Combustion system Direct injection
Injection system Common Rail
Exhaust gas recirculation Externally cooled
Exhaust gas after-treatment DOC diesel oxidation catalyst and/or DPF diesel particulate filter
Valves per cylinder 2
Engine firing order 1-3-4-2
Direction of rotation viewed on the left
from the flywheel
Engine power according to ISO [kW] See the engine identification plate
3046 standard
Number of revs (nominal num- [rpm] See the engine identification plate
ber or revs)
start of delivery [°BTDC] See the engine identification plate
Coolant quantity (only con- [l] 4.6/4.6
tained in the engine without the
radiator/pipes and lines)
Industrial engines/agricultural
technology
Permitted constant temperature [°C] max. 110
of the coolant
Temperature difference be- [°C] 8
tween coolant inlet/outlet
Start of thermostat opening [°C] 88
Thermostat completely open [°C] 95
*The lubricant oil quan-
tities indicated are for
standard versions. For
engines with non-stan-
dard configurations, such
as other oil sump/dipstick
variants and/or special
installations in inclined
positions, the quantity of
oil may vary. Always refer
to what is indicated on the
notch of the lubricant oil
dipstick.

10-74
Technical characteristics
Engine type Dimensions TCD 4.1 L4 TCD 6.1 L6
Quantity of spare lubricant oil  [l] 8*
(with filter)
Maximum temperature of the [°C] 125
lubricant oil in the lubricant oil
sump
Minimum lubricant oil pressure [kPa/bar] 80/0.8
(low number of revs, hot engine)
Maximum temperature permit- [°C] 50
ted for the combustive air after
the turbocharging air radiator
V-belt tension pretension/tension correction
V-belt AVX 13 (width: 13 mm) [N] 650±50/400±50
Ribbed V-belt tension Spring belt tensioner with automatic tension
Weight without the cooling sys-  [kg] 350
tem in accordance with DIN
70020-A
*The lubricant oil quan-
tities indicated are for
standard versions. For
engines with non-stan-
dard configurations, such
as other oil sump/dipstick
variants and/or special
installations in inclined
positions, the quantity of
oil may vary. Always refer
to what is indicated on the
notch of the lubricant oil
dipstick.

10.1.31 - Technical data - Tools

Tool order
The special tools described in this chapter can be purchased at:
Contact your DEUTZ partner.

10-75
 Technical characteristics
Special wrench for loosening the cartridge filters

Fig. 63
Order code: 170050
For loosening the cartridge filters.

10-76
Technical characteristics
Refractometer

Fig. 64
Order code: 0293 7499
This test device can be used to evaluate the following operating materials:
l Coolant
l Battery acidity
l AdBlue®
The test equipment may be ordered from your DEUTZ partner.

10-77
 Technical characteristics
10.2 - Transmission
10.2.1 - Transmission (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)
Mechanical layout of transmission
Transmission section

Fig. 65
l 1. Clutch
l 2. Gearbox input shaft
l 3. Reverse drive gear pair
l 4. Forward drive gear pair
l 5. Primary gearbox shaft
l 6. Secondary gearbox shaft
l 7. Rear PTO clutch
l 8. Rear PTO reduction gear
l 9. Pinion
l 10. 2 range reduction gearbox
l 11. HI-LO unit
l 12. 4WD engagement device
l 13. Mechanical parking brake

10-78
Technical characteristics
Detail of 4 range reduction gearbox

Fig. 66

10.2.2 - Transmission (5110 C -> ZKDY440200TD10001)

Mechanical layout of transmission
Transmission section

Fig. 67

10-79
 Technical characteristics
l 1. Clutch
l 2. Gearbox input shaft
l 3. Reverse drive gear pair
l 4. Forward drive gear pair
l 5. Primary gearbox shaft
l 6. Secondary gearbox shaft
l 7. Rear PTO clutch
l 8. Rear PTO reduction gear
l 9. Pinion
l 10. 4 range reduction gearbox
l 11. HI-LO unit
l 12. 4WD engagement device
l 13. Mechanical parking brake
Detail of 2 range reduction gearbox

Fig. 68

10-80
Technical characteristics
10.2.3 - Transmission (5100 C -> ZKDY480200TD10001)
Mechanical layout of transmission
Transmission section

Fig. 69
l 1. Torsional spring plate
l 2. Hydraulic reverse shuttle unit
l 3. Gearbox input shaft
l 4. Primary shaft
l 5. Secondary gearbox shaft
l 6. Rear PTO clutch
l 7. Rear PTO reduction gear
l 8. Pinion
l 9. 4 range reduction gearbox
l 10. HI-LO unit
l 11. 4WD engagement device
l 12. Mechanical parking brake

10-81
 Technical characteristics
Detail of 2 range reduction gearbox

Fig. 70

10.2.4 - Transmission (5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

Mechanical layout of transmission
Transmission section

Fig. 71
l 1. Torsional spring plate
l 2. Hydraulic reverse shuttle unit
l 3. Gearbox input shaft

10-82
Technical characteristics

Fig. 71
l 4. Primary gearbox shaft
l 5. Secondary gearbox shaft
l 6. Rear PTO clutch
l 7. Rear PTO reduction gear
l 8. Pinion
l 9. 4 range reduction gearbox
l 10. HI-LO unit
l 11. 4WD engagement device
l 12. Mechanical parking brake

10-83
 Technical characteristics
Detail of 2 range reduction gearbox

Fig. 73

10-84
Technical characteristics
10.2.5 - Hydraulic reverse shuttle (5100 C -> ZKDY480200TD10001)
9
8
10

11

12

2 3 4 5 6 7

Fig. 74
l 1. Flywheel
l 2. Torsional spring plate
l 3. Forward drive piston
l 4. Forward drive clutch
l 5. Reverse drive clutch
l 6. Reverse piston
l 7. Support
l 8. Forward drive shaft
l 9. Reverse drive shaft
l 10. Rear PTO drive shaft
l 11. Shuttle speed sensor
l 12. Tone wheel

10-85
 Technical characteristics
Forward drive clutch

7 6 1

14

5
13

11

12

10

Fig. 75
l 1. Screw
l 2. Disc
l 3. Pin
l 4. Corrugated spring
l 5. Friction disc
l 6. Steel disc, 3 mm
l 7. Steel disc, 6.5 mm
l 8. Hub
l 9. Belleville washer

10-86
Technical characteristics
l 10. Bearing
l 11. Piston
l 12. O-Ring
l 13. O-Ring
l 14. Clutch housing
Reverse drive clutch
3
4

10

5
8

6 7

13

15
16
12

11

2 14

Fig. 76
l 1. Corrugated spring
l 2. Friction disc
l 3. Steel disc, 3 mm

10-87
 Technical characteristics
l 4. Steel disc, 6.5 mm
l 5. Hub
l 6. Bearing
l 7. Support
l 8. Piston
l 9. O-Ring
l 10. O-Ring
l 11. Circlip
l 12. Circlip
l 13. Circlip
l 14. Clutch housing
l 15. Bearing
l 16. O-rings

10.2.6 - Hydraulic reverse shuttle (5110 C -> ZKDY520200TD10001, 5120 C -> ZK-
DY560200TD10001)

9
8
10

11

12

2 3 4 5 6 7

Fig. 77

10-88
Technical characteristics
1. Flywheel
2. Torsional spring plate
3. Forward drive piston
4. Forward drive clutch
5. Reverse drive clutch
6. Reverse drive piston
7. Support
8. Forward drive shaft
9. Reverse drive shaft
10. Rear PTO drive shaft
11. Shuttle speed sensor
12. Tone wheel

10-89
 Technical characteristics
Forward drive clutch

2
7 6
1

14 4

13
5

11

8
12

10

Fig. 78
1. Screw
2. Disc
3. Pin
4. Corrugated spring
5. Friction disc
6. Steel disc, 3 mm
7. Steel disc, 6.5 mm

10-90
Technical characteristics
8. Hub
9. Belleville washer
10. Bearing
11. Piston
12. O-Ring
13. O-Ring
14. Clutch housing
Reverse drive clutch

3 3
4

10

5
9

6 7

15 16

13

11

12 14

Fig. 79

10-91
 Technical characteristics
1. Corrugated spring
2. Friction disc
3. Steel disc, 3 mm
4. Steel disc, 6.5 mm
5. Hub
6. Bearing
7. Support
8. Piston
9. O-Ring
10. O-Ring
11. Circlip
12. Circlip
13. Circlip
14. Clutch housing
15. Bearing
16. Seal rings

10-92
Technical characteristics
10.2.7 - Rear PTO (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)
Layout of one-speed PTO

1 2

4
3

from Engine

REAR PTO

Fig. 80
l 1. PTO output shaft
l 2. Driving gear
l 3. 540 driving gear
l 4. Engagement sleeve
l 5. PTO output flange shaft (version with fitted flange shaft)

10-93
 Technical characteristics
Layout of two-speed PTO

1 2

3 5
6

from Engine

REAR PTO

Fig. 81
l 1. PTO output shaft
l 2. Dual driving gear
l 3. 540 driving gear
l 4. Engagement sleeve
l 5. 750 driving gear
l 6. PTO output flange shaft (version with fitted flange shaft)

10-94
Technical characteristics
Layout of four-speed PTO

1 2 3 4

9
7
5 6

STD

from Engine

ECO

REAR PTO

Fig. 82
l 1. PTO output shaft
l 2. ECO/Normal PTO mode selector sleeve
l 3. Dual driving gear
l 4. ECO PTO drive gear
l 5. 540 driving gear
l 6. PTO 540/1000 selector shaft
l 7. PTO 1000/ECO PTO driving gear
l 8. PTO output shaft
l 9. Ground speed PTO output shaft

10-95
 Technical characteristics
Four disc PTO engagement clutch

8 10
7 9 28
6
17
27
19

1
18

1
12 20
13 21
25
11
14 30
29 23
15 24
22

26

Fig. 83
l 1. Accumulator
l 7. Calibrated shims
l 6. PTO clutch disc retainer circlip
l 8. Steel thrust ring
l 9. Friction discs
l 10. Steel discs
l 11. PTO clutch hub
l 12. Shim
l 13. Circlip
l 14. Spring thrust washer
l 15. PTO clutch spring
l 17. PTO brake cover
l 18. PTO brake friction disc
l 19. PTO brake steel disc
l 20. Circlip
l 21.Thrust washer
l 22. PTO clutch body
l 23. PTO brake piston
l 24. PTO brake piston O-ring
l 25. PTO brake piston O-ring
l 26. PTO clutch housing
l 27. PTO clutch piston
l 28. PTO clutch piston O-ring
l 29. PTO clutch piston O-ring
l 30. “Vespel” seal rings

10-96
Technical characteristics
10.2.8 - Rear PTO (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110
C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Layout of two-speed PTO

Fig. 84

10-97
 Technical characteristics
Layout of four-speed PTO

Fig. 85

10-98
Technical characteristics
Four disc PTO engagement clutch

8 10
7 9 28
6
17
27
19

1
18

1
12 20
13 21
25
11
14 30
29 23
15 24
22

26

Fig. 86
1. Accumulator
6. PTO clutch disc retainer circlip
7. Calibrated shims
8. Steel thrust ring
9. Friction discs
10. Steel discs
11. PTO clutch hub
12. Shim
13. Circlip
14. Spring thrust washer
15. PTO clutch spring
17. PTO brake cover
18. PTO brake friction disc
19. PTO brake steel disc
20. Circlip
21. Thrust ring
22. PTO clutch body
23. PTO brake piston
24. PTO brake piston O-ring
25. PTO brake piston O-ring
26. PTO clutch housing
27. PTO clutch piston

10-99
 Technical characteristics
28. PTO clutch piston O-ring
29. PTO clutch piston O-ring
30. “Vespel” seal rings
10.2.9 - Views of transmission
View of transmission from right hand side
3
4
1
2

5 6 7

Fig. 87

1. Shuttle output speed sensor,

2. Gear engagement / selector lever,
3. Range gearbox selector lever
4. Range gearbox selector device,
5. Oil pump intake line filter,
6. Wheels speed sensor,
7. HML speed sensor.
View of transmission from left hand side

1 2 3 4

Fig. 88

1. Cover for HI-LO / HML hydraulic actuator unions,

2. Parking brake lever,
3. Ground speed PTO selector lever,
4. Ground speed PTO final flange shaft,
5. Rear PTO final flange shaft,
6. PTO speed selector lever.

10-100
Technical characteristics
Top view of transmission

2 3
1

6
4

Fig. 89

1. Gear engagement / selector lever,

2. Range gearbox selector lever,
3. Rear PTO clutch,
4. Power steering pump mounting flange,
5. 60L ECI pump mounting flange,
6. Drive shaft for transfer / ancillary pumps.

10-101
 Technical characteristics
Rear view of transmission

3
1

Fig. 90

1. Ground speed PTO final flange shaft,

2. Rear PTO final flange shaft,
3. Draft sensor.

10.2.10 - HI-LO unit (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)

LO clutch active

6 5

2 7

Fig. 91
In this condition, the LO clutch (1), the housing of which is mated to the shaft (2), mechanically constrains the planetary gear carrier
(3) with the sun gear (4).
Drive from the secondary shaft (5) is transmitted via the sun gear (6) to the planetary gear carrier (3), but as the planetary gear carrier
(3) is mechanically constrained with the sun gear (4), there is no demultiplication effect and the HI-LO output shaft (7) turns at exactly
the same speed as the secondary shaft (5).
In this condition, it is as if there were no HI-LO unit.

10-102
Technical characteristics
HI clutch active

9
3

5 7

4 6

Fig. 92
In this condition, the planetary gear carrier (3) is mechanically constrained with the HI-LO casing by the HI clutch (8), and is therefore
locked.
Drive from the secondary shaft (5) is transmitted via the sun gear (6) to the planetary reduction gearbox, where it is transmitted throu-
gh the planet gears (9) and reaches the HI-LO output shaft (7), at multiplied speed, via the sun gear (4)

10-103
 Technical characteristics
10.2.11 - HI-LO unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
HI clutch active

6 5

2 7

Fig. 93
In this condition, the HI clutch (1), the housing of which is mated to the shaft (2), mechanically constrains the planetary gear carrier
(3) with the sun gear (4).
Drive from the secondary shaft (5) is transmitted via the sun gear (6) to the planetary gear carrier (3), but as the planetary gear carrier
(3) is mechanically constrained with the sun gear (4), there is no demultiplication effect and the HI-LO output shaft (7) turns at exactly
the same speed as the secondary shaft (5).
In this condition, it is as if there were no HI-LO unit.

10-104
Technical characteristics
LO clutch active

9
3

5 7

4 6

Fig. 94
In this condition, the planetary gear carrier (3) is mechanically constrained with the HI-LO casing by the LO clutch (8), and is therefore
locked.
Drive from the secondary shaft (5) is transmitted via the sun gear (6) to the planetary reduction gearbox, where it is transmitted throu-
gh the planet gears (9) and reaches the HI-LO output shaft (7), at demultiplied speed, via the sun gear (4)

10-105
 Technical characteristics
10.2.12 - HML unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001)
L clutch active

1 7 3 6

Fig. 95
In this condition, the sun gear (1) is mechanically constrained with the HML casing by the L clutch (2), and is therefore locked.
Drive from the secondary shaft (3) is transmitted via the crown wheel (4) to the planetary reduction gearbox, where it is transmitted
through the planet gears (5) and reaches the HML output shaft (6), via the planetary gear carrier (7)

10-106
Technical characteristics
M clutch active

5
10

6
8 9 7
1
3

Fig. 96
In this condition, the shaft (8) carrying the sun gear (9), is mechanically constrained with the HML casing by the M clutch (10), whe-
reas the sun gear (1) is constrained with the idler gear.
The sun gear (9) has a different number of teeth than the sun gear (1) constituting the intermediate gear.
Drive from the secondary shaft (3) is transmitted via the crown wheel (4) to the planetary reduction gearbox, where it is transmitted
through the planet gears (5) and reaches the HML output shaft (6), via the planetary gear carrier (7).

10-107
 Technical characteristics
H clutch active

9
11

6
8 7
3

Fig. 97
In this condition, the H clutch (11), the housing of which is mated to the shaft (8), mechanically constrains the planetary gear carrier
(7) with the sun gear (9).
Drive from the secondary shaft (3) is transmitted via the crown wheel (4) to the planetary reduction gearbox, but as the planetary gear
carrier (7) is mechanically constrained with the sun gear (9), there is no demultiplication effect and the HML output shaft (6) turns at
exactly the same speed as the secondary shaft (3).
In this condition, it is as if there were no HML unit.

10-108
Technical characteristics
10.3 - Rear axle
10.3.1 - Rear differential

1
6
2

8
7
9

10

8 9
11

13 12

Fig. 98
l 1. Rings with calibrated thickness for adjusting pinion - crown wheel backlash
l 2. Pinion bearing
l 3. Pinion
l 4. Differential lock engage fork
l 5. Differential lock engagement piston
l 6. Right hand axle shaft
l 7. Right hand differential carrier flange
l 8. Rings with calibrated thickness for adjusting axial differential position
l 9. Differential bearing
l 10. Differential lock engage sleeve
l 11. Differential
l 12. Left hand differential carrier flange
l 13. Left hand axle shaft

10-109
 Technical characteristics

4
5

6
9

8
7

Fig. 99
l 1. Planet gear pin
l 2. Planetary gear pin
l 3. Sun gear
l 4. Thrust ring
l 5. Planetary gear carrier
l 6. Differential lock engage sleeve
l 7. Planetary gear unit
l 8. Concave thrust ring
l 9. Crown wheel

10-110
Technical characteristics
10.3.2 - Rear axle (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110
C -> ZKDY440200TD10001)

Fig. 100

10.3.3 - Rear axle (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001)

Fig. 101

10-111
 Technical characteristics
10.4 - Front axle
10.4.1 - Front axle
Steering angle “A”

Fig. 102

10-112
Technical characteristics
Final reduction gear

Fig. 103

1. Planetary gear carrier hub

2. O-ring
3. Ring gear
4. Brake disc
5. Steering knuckle housing
6. Upper kingpin
7. Gasket
8. Top bearing
9. Axle shaft
10. Roller bearing cage
11. O-ring
12. Lower bearing
13. Gasket
14. Lower kingpin
15. Brake piston
16. Steel disc
17. Friction disc
18. Bearing
19. Cover
20. Cover disc
21. Planetary gear unit
22. Pin

10-113
 Technical characteristics
Pinion, differential and differential lock

Fig. 104
1. Axle body
2. Crown wheel
3. Planet gear
4. Side gear
5. Differential carrier mount
6. Differential lock
7. Axle shaft
8. Bearing
9. Bearing
10. Shim
11. Bearing
12. Seal ring
13. Bush
14. Lock ring
15. Pinion
16. Differential carrier
17. Bearing
18. Side gear
19. Differential carrier mount
20. Piston
21. Shock absorber spring

10-114
Technical characteristics
22. Return spring
23. Differential lock engagement lever
24. Shoe

10-115
 Technical characteristics
10.5 - Bodywork - Cab - Platform
10.5.1 - A/C system - Version with standard roof

2
close 15 bar
open 11 bar
A
2,45 bar B
28 bar
C

10
4

1a

3 1

9
D0040780

Fig. 105 - Operating diagram

KEY
1. Compressor with electromagnetic clutch
2. Condenser
3. Dehydrator tank - filter
4. 3-stage pressure switch for engaging/disengaging compressor clutch and activating condenser cooling fans.
5. Expansion valve
6. Evaporator
7. Electronic minimum evaporator temperature sensor
8. Cab ventilation fans
9. Air shroud
10. Condenser cooling fan.
l A: Low pressure gas section
l B: High pressure gas section
l S: High pressure liquid section

10-116
Technical characteristics
TECHNICAL DATA
l Minimum safe pressure: 2.45 bar Maximum safe pressure: 28 Bar
Refrigerant: R134a
Quantity of refrigerant: 1,350 g.
Total quantity of antifreeze oil when originally filled: 210 g.
Oil type: SUN-OIL COMPANY SP20
Operation
The compressor (1) receives drive directly from the crankshaft via a belt, and is turned by a pulley with an electromagnetic clutch
(1a) controlled from a switch on the control panel. To protect the system against damage, a safety pressure switch is included in the
system which:
l prevents engagement of the electromagnetic clutch (1a) if the pressure in the system is below the minimum limit 2.45 bar due
an inadequate quantity of coolant in the system or coolant leakage.
disengages the clutch (1a) and therefore stop the compressor if the pressure exceeds the maximum limit of 28 bar (406 psi)
(generally due to overheating).
Another switch controls engagement and disengagement of the fan (10) for cooling the condenser (2), to maintain an operating pres-
sure within the normal range of 11-15 bar. The refrigerant (in gas phase) is aspirated by the compressor, where it is compressed and,
as a result, increases in temperature. This compressed gas is sent to the condenser (2), where it is cooled by the air flow produced
by the fan (10) to its condensation point, causing it to change to a high pressure liquid state. The refrigerant now passes through the
filter - dehydrator unit (3), which performs three functions: removing contaminants, absorbing any moisture contained in the circuit
and acting as a reserve reservoir. The refrigerant in liquid state is sent to the evaporator (6) via an expansion valve (5), which conti-
nuously meters the quantity of fluid delivered to maintain optimum evaporation conditions. In the evaporator, the refrigerant expands
to reach its critical evaporation point and cool to approximately – 8°C (17.6°F). As the temperature of the ambient air passed through
the evaporator (6) by the fans (8) is significantly higher than – 8°C (17.6°F), the heat released to the refrigerant by the air causes the
refrigerant to boil and evaporate completely. At the outlet of the evaporator (6), the refrigerant is aspirated again by the compressor
(1), initiating a new cycle. As heat is extracted from the ambient air by the evaporator, the water vapour carried in the air condenses,
producing a dehumidifying effect. This condensation forms on the fins of the evaporator which, if a temperature above 0°C (32°F) is
not maintained, ice forms, compromising the function of the evaporator. A temperature sensor (7) ensures that the temperature of the
evaporator is maintained above 0°C (32°F), while still remaining within the optimum range for effective heat exchange. This tempe-
rature sensor disengages the clutch (1a) of the compressor (1) when the lower temperature limit is reached and engages the clutch
(1a) when the evaporator temperature reaches the upper limit in the range. The condensation formed on the fins of the evaporator
(6) also contains dust, pollen and other particles normally carried in the air. The continuously forming condensation therefore has a
very effective air cleaning action, and is drained away from the system by two pipes. A predetermined quantity of antifreeze oil is also
introduced into the circuit to lubricate all the mechanical components of the system. A percentage of this oil circulates continuously
throughout the entire system as a mist, lubricating the compressor (pistons and bearings) and the expansion valve.
Emptying, flushing and recharging
1. DANGER
Before emptying, flushing and recharging the A/C system, check for leakage with a leak detector.

2. To perform maintenance on the system, an A/C system service station must be used that is capable of the following functions:
m Aspirate refrigerant from the circuit.
m Produce a hard vacuum to flush the circuit completely.
m Filter the refrigerant collected from the system.
m Separate the antifreeze/lubricant oil from the refrigerant and determine the volume and weight of each.
m Refill the circuit with exactly the same amount of refrigerant and oil recovered.
m Measure the pressure in both the fluid delivery circuit and the low pressure return circuit.

Emptying the system

1. DANGER
Remove the ignition key.

2. Connect the service station to the high pressure union (1) and follow the specific instructions provided with the station for
emptying the system.

10-117
 Technical characteristics
3. Disconnect the component to be repaired or replaced as soon as the service station stops. Plug all the circuit connection lines
as quickly as possible.
Flushing and recharging the system
1. Before recharging the system, the system itself must be flushed to eliminate any air, moisture and contamination (oxidation or
sludge). The flush process is performed by creating a hard vacuum that evaporates any moisture and aspirates the resulting
vapour, which carries with it the contaminants contained in the system.
m To perform the flushing and recharge cycles, the service station must be connected to the high (1) and low (2) pressure

unions.
DANGER
The “maximum vacuum” state must be maintained for at least 10 minutes.

2. After flushing, the antifreeze oil removed during the emptying cycle must be returned to the system, followed by the refrigerant.
m Quantity of refrigerant (R134a): 1350 g / Quantity of oil: see quantity recovered.

DANGER
If the system is emptied or flushed to permit replacement of a component of the system itself, measure the
quantity of oil contained in the removed part and add the same quantity of new oil to the circuit in addition to
the quantity of oil recovered with the refrigerant.
DANGER
Refer to the instructions for the service station for the procedures for filling the system with oil and refrigerant.

10-118
Technical characteristics
10.5.2 - A/C system - High visibility version
2
15 bar
A
20 bar
2,45 bar B
28 bar
C

10
4

1a

3 1

9
D0040790

Fig. 106 - Operating diagram

KEY
1. Compressor with electromagnetic clutch
2. Condenser
3. Dehydrator tank - filter
4. 4-stage pressure switch for engaging/disengaging compressor clutch and activating condenser cooling fans.
5. Expansion valve
6. Evaporator
7. Electronic minimum evaporator temperature sensor
8. Cab ventilation fans
9. Air shroud
10. Condenser cooling fans.
l A: Low pressure gas section
l B: High pressure gas section
l S: High pressure liquid section
TECHNICAL DATA

10-119
 Technical characteristics
l Minimum safe pressure: 2.45 bar Maximum safe pressure: 28 Bar
Refrigerant: R134a
Quantity of refrigerant: 1,350 g.
Total quantity of antifreeze oil when originally filled: 210 g.
Oil type: SUN-OIL COMPANY SP20
Operation
The compressor (1) receives drive directly from the crankshaft via a belt, and is turned by a pulley with an electromagnetic clutch
(1a) controlled from a switch on the control panel. To protect the system against damage, a safety pressure switch is included in the
system which:
l prevents engagement of the electromagnetic clutch (1a) if the pressure in the system is below the minimum limit 2.45 bar due
an inadequate quantity of coolant in the system or coolant leakage.
disengages the clutch (1a) and therefore stop the compressor if the pressure exceeds the maximum limit of 28 bar (406 psi)
(generally due to overheating).
Another switch controls engagement and disengagement of the fans (10) for cooling the condenser (2), to maintain an operating
pressure within the normal range of 15–20 bar. The refrigerant (in gas phase) is aspirated by the compressor, where it is compressed
and, as a result, increases in temperature. This compressed gas is sent to the condenser (2), where it is cooled by the air flow produ-
ced by the helical fans (10) to its condensation point, causing it to change to a high pressure liquid state. The refrigerant now passes
through the filter - dehydrator unit (3), which performs three functions: removing contaminants, absorbing any moisture contained in
the circuit and acting as a reserve reservoir. The refrigerant in liquid state is sent to the evaporator (6) via an expansion valve (5),
which continuously meters the quantity of fluid delivered to maintain optimum evaporation conditions. In the evaporator, the refrige-
rant expands to reach its critical evaporation point and cool to approximately – 8°C (17.6°F). As the temperature of the ambient air
passed through the evaporator (6) by the fans (8) is significantly higher than – 8°C (17.6°F), the heat released to the refrigerant by
the air causes the refrigerant to boil and evaporate completely. At the outlet of the evaporator (6), the refrigerant is aspirated again
by the compressor (1), initiating a new cycle. As heat is extracted from the ambient air by the evaporator, the water vapour carried in
the air condenses, producing a dehumidifying effect. This condensation forms on the fins of the evaporator which, if a temperature
above 0°C (32°F) is not maintained, ice forms, compromising the function of the evaporator. A temperature sensor (7) ensures that
the temperature of the evaporator is maintained above 0°C (32°F), while still remaining within the optimum range for effective heat
exchange. This temperature sensor disengages the clutch (1a) of the compressor (1) when the lower temperature limit is reached and
engages the clutch (1a) when the evaporator temperature reaches the upper limit in the range. The condensation formed on the fins
of the evaporator (6) also contains dust, pollen and other particles normally carried in the air. The continuously forming condensation
therefore has a very effective air cleaning action, and is drained away from the system by two pipes. A predetermined quantity of
antifreeze oil is also introduced into the circuit to lubricate all the mechanical components of the system. A percentage of this oil circu-
lates continuously throughout the entire system as a mist, lubricating the compressor (pistons and bearings) and the expansion valve.
Emptying, flushing and recharging
1. DANGER
Before emptying, flushing and recharging the A/C system, check for leakage with a leak detector.

2. To perform maintenance on the system, an A/C system service station must be used that is capable of the following functions:
m Aspirate refrigerant from the circuit.
m Produce a hard vacuum to flush the circuit completely.
m Filter the refrigerant collected from the system.
m Separate the antifreeze/lubricant oil from the refrigerant and determine the volume and weight of each.
m Refill the circuit with exactly the same amount of refrigerant and oil recovered.
m Measure the pressure in both the fluid delivery circuit and the low pressure return circuit.

Emptying the system

1. DANGER
Remove the ignition key.

2. Connect the service station to the high pressure union (1) and follow the specific instructions provided with the station for
emptying the system.
3. Disconnect the component to be repaired or replaced as soon as the service station stops. Plug all the circuit connection lines
as quickly as possible.

10-120
Technical characteristics
Flushing and recharging the system
1. Before recharging the system, the system itself must be flushed to eliminate any air, moisture and contamination (oxidation or
sludge). The flush process is performed by creating a hard vacuum that evaporates any moisture and aspirates the resulting
vapour, which carries with it the contaminants contained in the system.
m To perform the flushing and recharge cycles, the service station must be connected to the high (1) and low (2) pressure

unions.
DANGER
The “maximum vacuum” state must be maintained for at least 10 minutes.

2. After flushing, the antifreeze oil removed during the emptying cycle must be returned to the system, followed by the refrigerant.
m Quantity of refrigerant (R134a): 1350 g / Quantity of oil: see quantity recovered.

DANGER
If the system is emptied or flushed to permit replacement of a component of the system itself, measure the
quantity of oil contained in the removed part and add the same quantity of new oil to the circuit in addition to
the quantity of oil recovered with the refrigerant.
DANGER
Refer to the instructions for the service station for the procedures for filling the system with oil and refrigerant.

10-121
 Technical characteristics
10.6 - Hydraulic system
10.6.1 - Distributor hydraulic circuits
Basic hydraulic circuit with 4-way distributors and electronic SAC

Fig. 107
l 1. Oil suction line filter
l 2. Pressure switch (0.5 bar absolute pressure)
l 3. 22.5 cc oil pump
l 4. 4-way distributor
l 5. Female oil quick connector
l 6. EHR5-OC distributor
l 7. Hitch cylinder
l 8. Antishock valve
l 9. Rear gearbox
l 10. Oil to steering circuit
l 11. SAC casing
l 12. Bevel gear set lubrication
l 13. PTO output shaft lubrication
l 14. Brake discs lubrication
l 15. PTO bearing lubrication

10-122
Technical characteristics
Hydraulic circuit, versions with trailer braking (France version), 6-way distributor, supplementary
cylinders and electronic SAC

Fig. 108
l 1. Oil suction line filter
l 2. Pressure switch (0.5 bar absolute pressure)
l 3. 22.5 cc oil pump
l 4. 6-way distributor
l 5. Female oil quick connector
l 6. EHR5-OC distributor
l 7. Hitch cylinder
l 8. Supplementary cylinders
l 9. Trailer braking valve
l 10. Oil quick connector for trailer braking
l 11. Antishock valve
l 12. Oil from brake system
l 13. Oil to steering circuit
l 14. Rear gearbox
l 15. SAC casing
l 16. Bevel gear set lubrication
l 17. PTO output shaft lubrication
l 18. Brake discs lubrication
l 19. PTO bearing lubrication

10-123
 Technical characteristics
Hydraulic circuit, versions with 6+2-way distributor, 60l ECO pump system, electronic SAC with auxil-
iary cylinders, trailer braking (Italy version), front hitch and 60l ECO unit

Fig. 109
l 1. Oil suction line filter
l 2. Pressure switch (0.5 bar absolute pressure)
l 3. 22.5 cc oil pump
l 4. 14 cc oil pump
l 5. Trailer braking valve
l 6. Oil pressure switch (11 Bar)
l 7. 2-way auxiliary distributor
l 8. Oil quick connector
l 9. 60L/ECO valve block
l 10. Check valve
l 11. Flow control valve
l 12. 6-way distributor
l 13. Oil quick connector
l 14. EHR5-OC distributor
l 15. Hitch cylinder
l 16. Antishock valve
l 17. Supplementary cylinders
l 18. Cut-off valve
l 19. Flow compensator valve
l 20. Antishock valve body
l 21. Pressure cut-off valve (70 bar)
l 22. Accumulator
l 23. Front hitch cylinders
l 24. Oil from brake circuit
l 25. Oil to transmission circuit
l 26. Rear gearbox
l 27. SAC casing
l 28. Bevel gear set lubrication
l 29. PTO output shaft lubrication
l 30. Brake discs lubrication

10-124
Technical characteristics

Fig. 109
l 31. PTO bearing lubrication

10-125
 Technical characteristics
10.6.2 - Transmission hydraulic circuits (5090 C -> ZKDY360200TD10001)
Basic hydraulic circuit, 2 wheel driver versions

Fig. 111
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 4. Steering cylinder, 2-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (4 discs)
l 10. Utilities valve block
l 11. Solenoid valve cutoff plug
l 12. Rear gearbox
l 13. Oil to auxiliary distributor/SAC
l 14. Secondary shaft lubrication
l 15. Pump Drive lubrication
l 16. PTO and shuttle shaft lubrication
l 17. PTO brake
l 18. PTO clutch (4 discs)
l 19. Rear differential lock actuator

10-126
Technical characteristics
Hydraulic circuit, versions with 4 wheel drive, HI-LO, electrohydraulic DT and front PTO

Fig. 112
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (4 discs)
l 10. Utilities valve block
l 11. HI-LO
l 12. Composite valve
l 13. Front PTO valve block
l 14. Front PTO ON/OFF 4/2 solenoid valve
l 15. 4 cc transfer pump
l 16. Restrictor valve
l 17. Rear gearbox
l 18. Oil to auxiliary distributor/SAC
l 19. Secondary shaft lubrication
l 20. Pump Drive lubrication
l 21. PTO and shuttle shaft lubrication
l 22. PTO brake
l 23. PTO clutch (4 discs)
l 24. Front differential lock actuator
l 25. Rear differential lock actuator
l 26. Front PTO lubrication
l 27. Dual traction engagement
l 28. Feed pressure outlet (21 Bar)
l 29. Radiator bypass pressure outlet (12 Bar)
Right side overview

10-127
 Technical characteristics

Fig. 113
l 5. Filter unit (50 bar)
l 7. Oil cooler heat exchanger
l 9. Rear PTO (4 discs)
l 10. Utilities valve block
l 13. Front PTO valve block
Left side overview

10-128
Technical characteristics

Fig. 114
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 11. HI-LO
l 18. Oil to auxiliary distributor/SAC
Detail of utility valves

10-129
 Technical characteristics

Fig. 115
l 6. Pressure regulator valve unit
l 8. Pressure switch (11 Bar)
l 10. Utilities valve block
l 25. Rear differential lock actuator
l 27. Dual traction engagement
l 28. Feed pressure outlet (21 Bar)
l 29. Radiator bypass pressure outlet (12 Bar)

10-130
Technical characteristics
View from underside

Fig. 116
l 4. Steering cylinder, 4-wheel drive axle
l 24. Front differential lock actuator

10-131
 Technical characteristics
10.6.3 - Transmission hydraulic circuits (5100 C -> ZKDY400200TD10001)
Hydraulic circuit, versions with 4 wheel drive, HI-LO, electrohydraulic DT and front PTO

Fig. 117
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (4 discs)
l 10. Utilities valve block
l 11. HI-LO
l 12. Composite valve
l 13. Front PTO valve block
l 14. Front PTO ON/OFF 4/2 solenoid valve
l 15. 4 cc transfer pump
l 16. Restrictor valve
l 17. Rear gearbox
l 18. Oil to auxiliary distributor/SAC
l 19. Secondary shaft lubrication
l 20. Pump Drive lubrication
l 21. PTO and shuttle shaft lubrication
l 22. PTO brake
l 23. PTO clutch (4 discs)
l 24. Front differential lock actuator
l 25. Rear differential lock actuator
l 26. Front PTO lubrication
l 27. Dual traction engagement
l 28. Feed pressure outlet (21 Bar)
l 29. Radiator bypass pressure outlet (12 Bar)

10-132
Technical characteristics
Right side overview

Fig. 118
l 5. Filter unit (50 bar)
l 7. Oil cooler heat exchanger
l 9. Rear PTO (4 discs)
l 10. Utilities valve block
l 13. Front PTO valve block

10-133
 Technical characteristics
Left side overview

Fig. 119
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 11. HI-LO
l 18. Oil to auxiliary distributor/SAC

10-134
Technical characteristics
Detail of utility valves

Fig. 120
l 6. Pressure regulator valve unit
l 8. Pressure switch (11 Bar)
l 10. Utilities valve block
l 25. Rear differential lock actuator
l 27. Dual traction engagement
l 28. Feed pressure outlet (21 Bar)
l 29. Radiator bypass pressure outlet (12 Bar)

10-135
 Technical characteristics
View from underside

Fig. 121
l 4. Steering cylinder, 4-wheel drive axle
l 24. Front differential lock actuator

10-136
Technical characteristics
10.6.4 - Transmission hydraulic circuits (5110 C -> ZKDY440200TD10001)
Basic hydraulic circuit, 2 wheel driver versions

Fig. 122
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 4. Steering cylinder, 2-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (5 discs)
l 10. Utilities valve block
l 11. Solenoid valve cutoff plug
l 12. Rear gearbox
l 13. Oil to auxiliary distributor/SAC
l 14. Secondary shaft lubrication
l 15. Pump Drive lubrication
l 16. PTO and shuttle shaft lubrication
l 17. PTO brake
l 18. PTO clutch (5 discs)
l 19. Rear differential lock actuator

10-137
 Technical characteristics
Hydraulic circuit, versions with 4 wheel drive, HI-LO, DT and SDD, and front PTO

Fig. 123
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. S.D.D. power steering
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (5 discs)
l 10. Utilities valve block
l 11. HI-LO
l 12. Composite valve
l 13. Front PTO valve block
l 14. Front PTO ON/OFF 4/2 solenoid valve
l 15. 4 cc transfer pump
l 16. Restrictor valve
l 17. Rear gearbox
l 18. Oil to auxiliary distributor/SAC
l 19. Secondary shaft lubrication
l 20. Pump Drive lubrication
l 21. PTO and shuttle shaft lubrication
l 22. PTO brake
l 23. PTO clutch (5 discs)
l 24. Front differential lock actuator
l 25. Rear differential lock actuator
l 26. Front PTO lubrication
l 27. Dual traction engagement
l 28. Feed pressure outlet (21 Bar)
l 29. Radiator bypass pressure outlet (12 Bar)
Right side overview

10-138
Technical characteristics

Fig. 124
l 5. Filter unit (50 bar)
l 7. Oil cooler heat exchanger
l 9. Rear PTO (5 discs)
l 10. Utilities valve block
l 13. Front PTO valve block
Left side overview

10-139
 Technical characteristics

Fig. 125
l 1. Pump (14 cc)
l 2. Acoustic filter (pressure damper)
l 3. Rotary distributor (power steering)
l 11. HI-LO
l 18. Oil to auxiliary distributor/SAC
Detail of utility valves

10-140
Technical characteristics

Fig. 126
l 6. Pressure regulator valve unit
l 8. Pressure switch (11 Bar)
l 10. Utilities valve block
l 25. Rear differential lock actuator
l 27. Dual traction engagement
l 28. Feed pressure outlet (21 Bar)
l 29. Radiator bypass pressure outlet (12 Bar)

10-141
 Technical characteristics
View from underside

Fig. 127
l 4. Steering cylinders, 4-wheel drive axle
l 24. Front differential lock actuator

10-142
Technical characteristics
10.6.5 - Transmission hydraulic circuits (5100 C -> ZKDY480200TD10001)
Hydraulic circuit, versions with 4 wheel drive, HI-LO and electrohydraulic DT

Fig. 128
l 1. Pump (16 cc)
l 2. Acoustic filter (pressure damper)
l 3. Power steering valve
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (5 discs)
l 10. Accumulator
l 11. Shuttle valves block
l 12. Temperature sensor
l 13. Proportional solenoid valve
l 14. Pressure switch (4 Bar)
l 15. Oil transfer pump
l 16. Protection filter
l 17. Utilities valve block
l 18. ON/OFF solenoid valve 4/3 EDH 12
l 19. 6-disc hydraulic reverse shuttle
l 20. ON/OFF solenoid valve 3/2 EDH 044/32
l 21. ON/OFF solenoid valve 4/2 EDH 044/42
l 22. Oil to auxiliary distributor/SAC
l 23. Rear gearbox
l 24. Front gearbox housing
l 25. Hydraulic reverse shuttle lubrication
l 26. Secondary shaft lubrication
l 27. Pump Drive lubrication
l 28. PTO and shuttle shaft lubrication
l 29. PTO brake

10-143
 Technical characteristics

Fig. 128
l 30. PTO clutch (5 discs)
l 31. Front differential lock actuator
l 32. Rear differential lock actuator
l 33. Dual traction engagement

10-144
Technical characteristics
Hydraulic circuit, versions with 4 wheel drive, HI-LO, electrohydraulic DT, front PTO and Park Brake

Fig. 130
l 1. Pump (16 cc)
l 2. Acoustic filter (pressure damper)
l 3. Power steering valve
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (5 discs)
l 10. Accumulator
l 11. Shuttle valves block
l 12. Temperature sensor
l 13. Proportional solenoid valve
l 14. Pressure switch (4 Bar)
l 15. Oil transfer pump
l 16. Protection filter
l 17. Utilities valve block
l 18. ON/OFF solenoid valve 4/3 EDH 064/43
l 19. 4-disc hydraulic reverse shuttle
l 20. ON/OFF solenoid valve 3/2 EDH 044/32
l 21. ON/OFF solenoid valve 3/2 EDH 044/42
l 22. Front PTO 4 cc oil transfer pump
l 23. Front PTO valve block
l 24. HI-LO
l 25. Composite valve
l 26. Restrictor valve
l 27. Front gearbox housing
l 28. Rear gearbox
l 29. Oil to auxiliary distributor/SAC
l 30. Front differential lock actuator
l 31. Rear differential lock actuator

10-145
 Technical characteristics

Fig. 130
l 32. Dual traction engagement
l 33. Hydraulic reverse shuttle lubrication
l 34. Secondary shaft lubrication
l 35. Pump Drive lubrication
l 36. Front PTO brake PTO and shuttle shaft lubrication
l 37. PTO brake
l 38. PTO clutch (5 discs)
l 39. Front PTO lubrication
l 40. Front PTO clutch
l 41. Front PTO brake

10-146
Technical characteristics
Hydraulic circuit, versions with 4 wheel drive, HML, DT and SDD, front PTO and Park Brake

Fig. 132
l 1. Oil suction line filter
l 2. Pressure switch (0.5 bar absolute pressure)
l 3. 22.5 cc oil pump
l 4. Trailer braking valve
l 5. Oil pressure switch (11 Bar)
l 6. 2-way auxiliary distributor
l 7. Oil quick connector
l 8. 6-way distributor
l 9. Oil quick connector
l 10. EHR5-OC distributor
l 11. Lift cylinder
l 12. Antishock valve
l 13. Supplementary cylinders
l 14. SC valve
l 15. Antishock valve unit
l 16. Accumulator
l 17. Front lift cylinders
l 18. Valve
l 19. Oil quick connector for trailer braking
l 20. Oil from brake system
l 21. Brake ON/OFF control
l 22. Oil to transmission circuit
l 23. Rear gearbox
l 24. SAC casing
l 25. Bevel gear set lubrication
l 26. PTO output shaft lubrication
l 27. Brake discs lubrication
l 28. PTO bearing lubrication

10-147
 Technical characteristics
10.6.6 - Transmission hydraulic circuits (5110 C -> ZKDY520200TD10001, 5120 C -> ZK-
DY560200TD10001)
Basic hydraulic circuit, 2 wheel driver versions

Fig. 133
l 1. Pump (16 cc)
l 2. Acoustic filter (pressure damper)
l 3. Power steering valve
l 4. Steering cylinder, 2-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (5 discs)
l 10. Accumulator
l 11. Shuttle valves block
l 12. Temperature sensor
l 13. Proportional solenoid valve
l 14. Pressure switch 4 Bar
l 15. Transfer pump
l 16. Protection filter
l 17. Utilities valve block
l 18. ON/OFF solenoid valve 4/3 EDH 12
l 19. 6-disc hydraulic reverse shuttle
l 20. Solenoid valve cutoff plug
l 21. ON/OFF solenoid valve 3/2 EDH 044/32
l 22. ON/OFF solenoid valve 4/2 EDH 044/42
l 23. Oil to auxiliary distributor/SAC
l 24. Rear gearbox
l 25. Front gearbox housing
l 26. Hydraulic reverse shuttle lubrication
l 27. Secondary shaft lubrication
l 28. Pump Drive lubrication

10-148
Technical characteristics

Fig. 133
l 29. PTO and shuttle shaft lubrication
l 30. PTO brake
l 31. PTO clutch (5 discs)
l 32. Rear differential lock actuator

10-149
 Technical characteristics
Hydraulic circuit, versions with 4 wheel drive, HI-LO and electrohydraulic DT

Fig. 135
l 1. Pump (16 cc)
l 2. Acoustic filter (pressure damper)
l 3. Power steering valve
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Pressure switch (11 Bar)
l 9. Rear PTO (5 discs)
l 10. Accumulator
l 11. Shuttle valves block
l 12. Temperature sensor
l 13. Proportional solenoid valve
l 14. Pressure switch (4 Bar)
l 15. Oil transfer pump
l 16. Protection filter
l 17. Utilities valve block
l 18. ON/OFF solenoid valve 4/3 EDH 12
l 19. 6-disc hydraulic reverse shuttle
l 20. ON/OFF solenoid valve 3/2 EDH 044/32
l 21. ON/OFF solenoid valve 4/2 EDH 044/42
l 22. HI-LO
l 23. Composite valve
l 24. Oil to auxiliary distributor/SAC
l 25. Rear gearbox
l 26. Front gearbox housing
l 27. Hydraulic reverse shuttle lubrication
l 28. Secondary shaft lubrication
l 29. Pump Drive lubrication
l 30. PTO and shuttle shaft lubrication
l 31. PTO brake

10-150
Technical characteristics

Fig. 135
l 32. PTO clutch (5 discs)
l 33. Front differential lock actuator
l 34. Rear differential lock actuator
l 35. Dual traction engagement

10-151
 Technical characteristics
Hydraulic circuit, versions with 4 wheel drive, HML, DT and SDD, front PTO and Park Brake

Fig. 137
l 1. Pump (16 cc)
l 2. Acoustic filter (pressure damper)
l 3. Power steering with SDD
l 4. Steering cylinders, 4-wheel drive axle
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 7. Oil cooler heat exchanger
l 8. Park Brake check valve block
l 9. Check valve (0.5 Bar)
l 10. Accumulator
l 11. Utilities valve block
l 12. ON/OFF solenoid valve 4/2 EDH
l 13. ON/OFF solenoid valve 3/2 EDH
l 14. Pressure switch (11 Bar)
l 15. Rear PTO (5 discs)
l 16. Shuttle valves block
l 17. Temperature sensor
l 18. Proportional solenoid valve
l 19. Pressure switch (4 Bar)
l 20. ON/OFF solenoid valve 4/3 EDH 12/43
l 21. 6-disc hydraulic reverse shuttle
l 22. Oil transfer pump
l 23. Protection filter
l 24. Front axle brake valve
l 25. Trailer brake block
l 26. Single stage brake pump
l 27. Brake pressure sensor
l 28. Front brake circuit oil reservoir
l 29. Park brake lever valve
l 30. Pressure switch (15 Bar)
l 31. Complete Park Brake

10-152
Technical characteristics

Fig. 137
l 32. 4 cc oil transfer pump
l 33. Front PTO valve block
l 34. HML valve block
l 35. HML clutch unit
l 36. Restrictor valve
l 37. Oil to pneumatic trailer braking valve
l 38. Oil to trailer braking valve
l 39. Oil to auxiliary distributor/SAC
l 40. Rear gearbox
l 41. Front gearbox housing
l 42. Front left hand brake
l 43. Front right hand brake
l 44. Hydraulic reverse shuttle lubrication
l 45. Secondary shaft lubrication
l 46. Pump Drive lubrication
l 47. PTO lubrication
l 48. HML lubrication
l 49. PTO brake
l 50. PTO clutch (5 discs)
l 51. Front PTO lubrication
l 52. Front differential lock actuator
l 53. Rear differential lock actuator
l 54. Dual traction engagement
l 55. Park brake pressure outlet (21 Bar)
l 56. Radiator bypass pressure outlet (12 Bar)
l 57. Feed pressure outlet (21 Bar)
l 58. Forward drive pressure outlet
l 59. Reverse pressure outlet
l 60. Shuttle lubrication pressure outlet
l 61. H clutch pressure outlet (21 bar)
l 62. M clutch pressure outlet (21 bar)
l 63. L clutch pressure outlet (21 bar)

10-153
 Technical characteristics
Right side overview

Fig. 139
l 7. Oil cooler heat exchanger
l 24. Front axle brake valve
l 26. Single stage brake pump
l 29. Park brake lever valve
l 30. Pressure switch (15 Bar)
l 31. Complete Park Brake
l 33. Front PTO valve block
l 42. Front left hand brake
l 43. Front right hand brake

10-154
Technical characteristics
Left side overview

Fig. 140
l 1. Pump (16 cc)
l 2. Acoustic filter (pressure damper)
l 3. Power steering with SDD
l 22. Oil transfer pump
l 23. Protection filter
l 34. HML valve block
l 39. Oil to auxiliary distributor/SAC
l 61. H clutch pressure outlet (21 bar)
l 62. M clutch pressure outlet (21 bar)
l 63. L clutch pressure outlet (21 bar)

10-155
 Technical characteristics
Detail of utility valves

Fig. 141
l 5. Filter unit (50 bar)
l 6. Pressure regulator valve unit
l 8. Park Brake check valve block
l 11. Utilities valve block
l 14. Pressure switch (11 Bar)
l 15. Rear PTO (5 discs)
l 16. Shuttle valves block
l 18. Proportional solenoid valve
l 20. ON/OFF solenoid valve 4/3 EDH 12/43
l 25. Trailer brake block
l 53. Rear differential lock actuator
l 54. Dual traction engagement
l 55. Park brake pressure outlet (21 Bar)
l 56. Radiator bypass pressure outlet (12 Bar)
l 57. Feed pressure outlet (21 Bar)
l 58. Forward drive pressure outlet
l 59. Reverse pressure outlet
l 60. Shuttle lubrication pressure outlet

10-156
Technical characteristics
View from underside

Fig. 142
l 4. Steering cylinders, 4-wheel drive axle
l 52. Front differential lock actuator

10.6.7 - STEERING/TRANSMISSION pump (14 cm³) (5090 C -> ZKDY360200TD10001, 5100

C -> ZKDY400200TD10001)
Steering circuit gear pump

10-157
 Technical characteristics

Fig. 143 - Steering circuit gear pump

(Versions with and without HML)
Technical characteristics:
Displacement: 14 cm³/rev
Maximum operating pressure: 150 bar
Minimum flow rate: 11.3 l/min at 750 rpm
Maximum flow rate: 33.3 l/min at 2200 rpm
Direction of rotation: Left

10-158
Technical characteristics
10.6.8 - Power steering 160 cc

L R

P T

Fig. 144 - Power steering 160 cc

l Displacement: 160 cc/rev
l Oil viscosity: 10 Min - 1,000 Max mm²/s
l Max pressure relief valve calibration at flow rate of 25 l/min: 150 bar
l Anti-cavitation valves: Included
l One-way valve, port “B”: Included
l Normal steering wheel torque: 1-3 Nm
l Steering wheel torque with manual steering: 120 Nm
l Peak steering wheel torque: 240 Nm
l Steering wheel turns (from fully right to fully left) 3.5

10-159
 Technical characteristics
10.6.9 - Power steering SDD 125-250cc

L R

P T

Fig. 145 - Power steering SDD 125-250cc

l Displacement: 125/250 cc/rev
l Oil viscosity: 10 Min - 420 Max mm²/s
l Max pressure relief vale calibration at flow rate of 25 l/min: 150 bar
l Maximum pressure in return line: 35 bar
l Anti-cavitation valves: Included
l One-way valve, port “B”: Included
l Normal steering wheel torque: 1-3 Nm
l Steering wheel torque with manual steering: 120 Nm
l Peak steering wheel torque: 240 Nm
l Steering wheel turns with SDD disabled (from fully right to fully left): 4.5
l Steering wheel turns with SDD enabled (from fully right to fully left): 2.2

10-160
Technical characteristics
SDD system function

Fig. 146
l 1 - SDD Solenoid valve
l 2 - Proximity sensor
The power steering pump with SDD has a dual rotor allowing it possible to operate with 2 different displacements 125 and 250 cc.
These are selected electrically from a button in the cab, which controls a solenoid valve (2) installed directly on the power steering
pump.
With the “OFF” solenoid valve (2) state, the smaller pump displacement (125cc) is enabled for road driving and emergency mano-
euvres (engine off).
With the “ON” solenoid valve (2) state selected from the button in the cab, the larger pump displacement (250cc) is enabled, which
reduces the number of steering wheel turns necessary for manoeuvring. This function is used for working in the field and with the
front loader. The ratio is fixed and independent of the steering wheel turn speed.
For safety reasons, once a speed limit of 13 kph is exceeded and with the steering wheel turned straight ahead, the electronic control
unit switches the solenoid valve to “OFF”. A proximity sensor (1) mounted directly on the power steering pump verifies congruence
between the logical state of the solenoid valve and the physical state of the hydraulic components to ensure the safety of the system.

10-161
 Technical characteristics
Hydraulic function of SDD system

L R

P T
Fig. 147 - Neutral Mode

10-162
Technical characteristics

L R

P T
Fig. 148 - Steering right mode, single rotor displacement (125cc)
l 1 - Single rotor displacement enabled

10-163
 Technical characteristics

L R

4
1

P T
Fig. 149 - Steering right mode, dual rotor displacement (250cc)
l 1 - Single rotor displacement enabled
l 2 - Double rotor displacement enabled
l 3 - SDD Proximity sensor
l 4 - SDD Solenoid valve active

10-164
Technical characteristics
10.6.10 - Rear PTO
1 2

Fig. 150
l 1. Rear PTO engagement clutch
l 2. Rear PTO feed line
l 3. Rear PTO brake feed line
l 4. Rear PTO clutch engagement solenoid valve

10-165
 Technical characteristics
Rear PTO engage

Fig. 151
Activating the rear PTO energises the PTO engagement solenoid valve (1). The oil enters the chamber (2) passing from the solenoid
valve (1) and then arriving in the damper chamber (3) to modulate engagement. At the same time, the oil flows into the chamber (4)
which causes the piston (5) to move to the left, engaging the clutch. The oil in the chamber (6) flows to the return line via the solenoid
valve (1).

10-166
Technical characteristics
Rear PTO disengagement

7
2

3 6

Fig. 152
When deactivating the rear PTO, the PTO engagement solenoid valve (1) is de-energised and the oil contained in the chamber (2)
returns through the solenoid valve due to the effect of the spring (3) that pushes the piston (4), at the same time the oil arriving from
the maintaining valve (7) passing through the solenoid valve (1) enters the chamber (5) pushing the piston (6) of the PTO brake,
blocking the PTO flange shaft.

10-167
 Technical characteristics
10.6.11 - Shuttle control unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)

3
2

Fig. 153
l 1. Reverse solenoid valve
l 2. Proportional solenoid valve
l 3. Forward drive solenoid valve
l 4. Pressure switch 4 Bar
l 5. Shuttle unit accumulator
l 6. Oil temperature sensor

10-168
Technical characteristics

Fig. 154
l 1. Forward drive pressure outlet (21 bar)
l 2. Reverse pressure outlet (21 bar)
l 3. Lubrication pressure outlet (5 bar)

10-169
 Technical characteristics
10.6.12 - 60 l/min. ECO AUX block
The “60 ECO” hydraulic system makes it possible to reach the maximum capacity of the distributors (60l/min) at an engine speed of
just 1,600 rpm. This system is ideal for front loader applications, where hydraulic power is needed at low engine speeds.
This system (enabled and disabled by the operator from a button) consists of a dual pump (22.5 + 14 cc) and functions in relation to
engine speed. When the system is enabled, the secondary pump (14 cc) activates progressively in relation to engine speed, and the
output flow rate of this pump is added to the flow rate of the main pump.

Fig. 155

1. Proportional flow control solenoid valve

2. Bypass ON/OFF solenoid valve
The proportional flow control solenoid valve (1) is used to control the proportion of the output flow rate of the secondary pump added
to the auxiliary circuit. The flow rate delivered is proportional to the current powering the solenoid valve and is independent of ope-
rating pressure.
When the bypass solenoid valve (2) is in “OFF” status the 14 CC secondary pump oil is bypassed, sending the oil to the return and
reducing energy dissipation in neutral. With the solenoid valve in “ON” status, therefore energised, the system sums the capacity of
the two hydraulic pumps.

10-170
Technical characteristics

% Secondary pump
Oil flow (l/min.)

Engine speed (rpm)

A
B
C
Fig. 156
l A - % secondary pump usage
l B - Flow rate with ECO function off
l C - Flow rate with ECO function on

10-171
 Technical characteristics

B C
Fig. 157
l A - oil going to return
l B - oil from the pump
l C - oil going to the distributor

10-172
Technical characteristics

2
C

B
Fig. 158
l A - oil going to return
l B - oil from the pump
l C - oil going to the distributor
l 1 - Bypass ON/OFF solenoid valve
l 2 - Check valve (0.3 Bar)
l 3 - Solenoid proportional valve

10-173
 Technical characteristics

Fig. 159
l 1 - Power
l 2 - Toward the distributors block
l 3 - Return

10-174
Technical characteristics
10.6.13 - Park Brake (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
1
3

2 5

Fig. 160
l 1 - Park brake return line
l 2 - Accumulator
l 3 - Park Brake Feed Line
l 4 - Park brake pressure outlet 21 Bar
l 5 - Check valve

10-175
 Technical characteristics

3 7

Fig. 161 - Hydraulic circuit diagram

l 1 - Front axle brake valve
l 2 - Front brakes
l 3 - Brake fluid reservoir
l 4 - Master cylinder
l 5 - Check valve 0.5 Bar
l 6 - Accumulator
l 7 - Park Brake valve and lever
l 8 - Park brakes, free play 0.35

10-176
Technical characteristics

Fig. 162
l 1 - Park Brake control lever
l 2 - Manual release pump

10-177
 Technical characteristics
1

1 2 3

Fig. 163
l 1 - Park Brake control lever
l 2 - Manual release pump
l 3 - Park brake indicator lamp switch
l 4 - Seat for 15 Bar NC pressure switch

10-178
Technical characteristics
Operation

1 0

3 2 4

Fig. 164 - Park Brake engaged

Acting on the lever (1) taking it from position 0 to position 1 the pressure is removed. The Belleville washer (3) pushes on the piston
(2) which presses on piston (4) applying force on the brakes (5) and the reaction disc (6), thereby generating the braking force.

10-179
 Technical characteristics
1 0

2 PB 3

Fig. 165 - Park Brake disengaged

Acting on the lever (1) taking it from position 1 to position 0 pressure is sent into the chamber (PB) moving piston (2) to the left. Due
to this the force applied on the piston (3) is removed so the brake discs (4) can turn freely

10-180
Technical characteristics

PF 2 4

PB 3

Fig. 166 - Braking with pedals

With the handbrake deactivated the oil coming from the gearbox enters the chamber (PB) and overcomes the force of the Belleville
washer, freeing the brake discs. Acting on the brake pedals the master cylinder (1) creates pressure in the chamber (PF) that acts
on piston 4, moving it to the right and forcing the brake discs (3) against the reaction disc (4), thereby generating the braking force
proportional to the brake pedal travel.
10.6.14 - Suction pump filter
This range of tractors can mount two different types of suction filters depending on the installed configuration:
l with single pump: 2.4419.484.0 - Ø 40
l with dual pump: 2.4419.795.0 - Ø 45

10-181
 Technical characteristics

Fig. 167

10-182
Technical characteristics

Fig. 168

10-183
 Technical characteristics
10.6.15 - HYDAC delivery line filter

A B

Fig. 169

10-184
Technical characteristics

Fig. 170 - Position

l Maximum operating pressure: 50 bar
l Burst pressure: >180 Bar
l Bypass valve calibration: 3.5 +0.5 Bar
l Filtration rating: 15 microns
l Operating temperature (°C): -30 to +100
l Pressure chamber volume: 1.12 L

10.6.16 - Transfer pump

Rotation: right
Delivery:
l/min. = 9.8 at 825 RPM
l/min. = 26 at 2200 RPM

10-185
 Technical characteristics
Pump location

Fig. 171
l A - Transfer pump
Components of transfer pump

4
1

2 3

Fig. 172
l 1 - Flange
l 2 - Internal gear
l 3 – Ring gear

10-186
Technical characteristics

4
1

2 3

Fig. 172
l 4 - Pump body

10.6.17 - Hydraulic pumps unit

22.5 cm³ pump
Rotation: right
Flow rate:
l/min. = 21.8 at 825 RPM
l/min. = 56.5 at 2200 RPM

10-187
 Technical characteristics

Fig. 174

14 cm³ pump

Fig. 175
Rotation: right
Flow rate:
l/min. = 13.5 at 825 RPM
l/min. = 32.5 at 2,200 RPM

10-188
Technical characteristics
Pumps positioning

Fig. 176
l A - 22.5 cm³ hitch pump
l B - 14 cm³ hitch pump

10.6.18 - Power steering pump (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
16 cm³ pump

Fig. 177
Rotation: Left
Flow rate:

10-189
 Technical characteristics
l/min. = 15.1 at 825 RPM
l/min. = 40.1 at 2200 RPM
Pump location

Fig. 178
A - Power steering pump

10-190
Technical characteristics
10.6.19 - Distributor unit
Distributors unit configurations
4-way distributor (USA)

2 2

Fig. 179
l 1. Pressure relief valve 190 Bar
l 2. Kick out + float 145 bar

10-191
 Technical characteristics
4-way distributor

Fig. 180
l 1. Pressure relief valve 190 Bar
l 2. Detend
l 3. Spring
l 4. Dual/single action conversion screw

10-192
Technical characteristics
6-way control valve with flow divider

3 4 5

Fig. 181
l 1. Flow regulator (from 7 to 47 l/min)
l 2. Pressure relief valve 190 Bar
l 3. Kick out 145 Bar
l 4. Detend
l 5. Float
l 6. Dual/single action conversion screws

10-193
 Technical characteristics
6-way distributor, with front hitch

2 2 2

Fig. 182
l 1. Pressure relief valve 190 Bar
l 2. Float

10-194
Technical characteristics
6-way distributor (USA)

2 2 2

Fig. 183
l 1. Pressure relief valve 190 Bar
l 2. Kick out + Float

10-195
 Technical characteristics
Rear coupling configuration, 6-way distributors

Fig. 184
l 1. Feed to distributors
l 2. Rear hitch feed

10-196
Technical characteristics
10.6.20 - Pressure regulator valve unit

2 1

5
3

Fig. 185

10-197
 Technical characteristics

5 6

C1 L

21 bar 12 bar 5 bar

P1

H
1
T
2 3 4

Fig. 186

1. Check valve
2. Feed pressure regulator valve 21 Bar
3. Radiator bypass valve 12 Bar
4. Lubrication pressure regulator valve 5 Bar
5. Feed pressure outlet 21 Bar
6. Radiator bypass pressure outlet 12 Bar

10-198
Technical characteristics
10.6.21 - Services command unit

2
1 3

7
5

Fig. 187

1. Four-wheel drive solenoid valve

2. PTO solenoid valve
3. Differential solenoid valve
4. Pressure outlet for Park Brake: 21 bar
5. Park Brake accumulator
6. Check valve
7. Services pressure switch

10-199
 Technical characteristics
10.6.22 - HML control block (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)

2
3

Fig. 188

1. “H” range
2. “M” range
3. “L” range

10-200
Technical characteristics

6 5
4

Fig. 189

1. “L” range - Pressure: 21 bar

2. “M” range - Pressure: 21 bar
3. “H” range - Pressure: 21 bar

10-201
 Technical characteristics
10.6.23 - Braking system

Fig. 190

1. Stop/go sensor
2. SAFIM valve
NOTE
For the basic version tractor, the front brake system uses gearbox oil, whereas the rear brake system uses conven-
tional SDF BRAKE OIL fluid.

10-202
Technical characteristics

R N

1 2

B1 B2

Fig. 191
l 1 - Oil going to RH rear brake
l 2 - Oil going to LH rear brake
l 3 - Oil going to front brakes
l 4 - SAFIM valve bleed screw

10-203
 Technical characteristics

PAGE LEFT INTENTIONALLY BLANK

10-204
20 - Calibrations and
electronic diagnosis

20-1
 Calibrations and electronic
diagnosis
20.1 - Diagnostic tools
20.1.1 - SDF Analyser
SDF Analyser
Description
The SDF Analyser instrument lets the technician troubleshoot and commission the tractor correctly, and test the functions of the
electric components of the tractor’s on-board systems and engine.
Data is exchanged between the instrument and the electronic control units on the tractor via a diagnostic socket installed on the
tractor wiring harness.
The SDF Analyser lets the technician perform the following:
l View data received from the different electronic control units (e.g. sensor, button and potentiometer states etc.) managing the
tractor systems.
l Test the functions of the electric components installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.)
l Perform the operations necessary for commissioning the tractor, calibrating the hydraulic reverse shuttle and calibrating sen-
sors.
l View errors (faults).
-
Advantages
Using the SDF Analyser offers a number of significant advantages because:
l It has a screen refresh rate two time faster than previous diagnostic systems.
l It is compatible with all laptop operating systems in use today. It is faster than the ART® (All Round Tester).
l It functions as an active interface, with its own microprocessor and flash memory. New software updates are easily installable
with a guided menu.
l It may be used on both old and new tractors, using the specific adapter cables included following the instructions given in the
relative training and workshop manuals.
l May be connected to the laptop either with a USB cable or by Bluetooth connection within a 10 metre range.
-
Description of Kit
The SDF Analyser is delivered to Authorised Service Centres in a case containing the following:
1. Complete SDF Analyser carrier case (P/N 5.9030.997.0) 6 7
2. Analyser tool (P/N 5.9030.997.1) 8
3. Base PC Tester diagnostic cable (P/N 5.9030.997.2)
4. Base EDS diagnostic cable (P/N 5.9030.997.4) 4
5. Bluetooth dongle (P/N 5.9030.997.5)
6. EDS adapter cable, first type (P/N 5.9030.997.6)
7. PC Tester adapter cable for Deutz (P/N 5.9030.997.7)
8. PC Tester adapter cable for Rubin /Iron (P/N 5.9030.997.8)
9. Case containing: 9

m CD-Rom for installing software on laptop and

10
m Multi-language handbook with installation instructions. 3 2
1 5
10. USB connection cable
Fig. 192

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Calibrations and electronic
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Installing the software
The minimum requisites for the laptop for installation of the SDF Analyser base
software and the PC diagnostic software are indicated in the multi-language hand-
book included in the case. The installation procedure is also described in the hand-
book. Installing the SDF Analyser software is simple and only takes a few minutes.
Once the software is installed, the icons for launching the 3 functions of the soft-
ware will be displayed on the desktop of the host laptop.

Fig. 193

-
Functions
The SDF Analyser software consists of 3 functions:
PC Tester
Generally used for connection to electronic control units on tractors with CANBUS network. There are
certain exceptions, however, which are described in detail in the specific training courses.
PCTester

CVT Diag
For connection to “Infocenter” on-board instruments.

CVT Diag

SDF Analyser
For connection to ZF electronic control units on tractors without CANBUS network.

SDF Analyser

-
Connecting tool and launching software
Side: Tool-Tractor
Connect the SDF Analyser to the electronic system of the tractor as follows:
1. Switch the tractor off and remove the ignition key,
2. Connect the SDF Analyser interface to the correct adapter cable (in relation to tractor diagnosed), then connect the cable to
the diagnostic socket on board the tractor,
3. Turn the ignition switch to “On”.
-
Tool-Laptop side
Connect the SDF Analyser to the laptop as follows:
l Use the Bluetooth dongle to connect via Bluetooth, or
l Enable Bluetooth on your laptop (if laptop has integrated Bluetooth module), or
l Connect the SDF Analyser interface to the laptop with the USB connector cable.
-
Launching functions
To launch any of the functions, double-click the respective icon on the desktop.
-

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Basic settings in PC Tester
The user may configure a number of basic settings (e.g. language, COM ports, screen layout etc.) for the PC Tester function before
starting to use the function itself. Proceed as follows:
Double-click the relative icon on the desktop and wait for the start screen.
Select “Tools” and then “Setup” from the option menu.

Fig. 194

-
Menus available:
l “Interface” / Interface,
l “Lines Selection” / Lines Selection,
l “Interface” / Interface.
-
“Interface” / Interface menu
The following may be selected from this menu:
l Interface and COM ports, and
l display language.

Fig. 195

-
“Visual Style” / Visual Style menu
The following may be selected from this menu:
l Background colour of screens,
l Font colour,
l Font type, and
l Enable “Microsoft Word” function
(reproduces PC Tester screens in a Word document.)

Fig. 196

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Calibrations and electronic
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-
“Lines Selection” / Lines Selection menu
The following may be selected from this menu:
l Tractor ECU pin mapping in manual mode.

Fig. 197

-
Base settings in SDF Analyser
The user may configure a number of basic settings for (e.g. language, COM ports, screen layout etc.) for the SDF Analyser function
before starting to use the function itself. Proceed as follows:
Double-click the relative icon on the desktop and wait for the start screen.
Select “Continue” / Continue from the options menu, then select “Configuration” /
Configuration.

Fig. 198

-
“Configuration” / Configuration menu
The following may be selected from this menu:
l Interface,
l Display language,
l COM ports,
l Font type, and
l Window layout.

Fig. 199

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 Calibrations and electronic
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SDF Analyser - Diagnostic socket connection
SDF Analyser - Diagnostic socket connection
Table 54
Component Image FROM: A:
SDF Analyser - -

Fig. 200
Cable for diagnostic socket (p/n SDF Analyser Tractor diagnostic
5.9030.997.2); A = Connection to SDF socket
Analyser; B = Connection to diagnostic
socket

Fig. 201
Tractor diagnostic socket - -

Fig. 202

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Calibrations and electronic
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20.1.2 - Serdia 2010
Serdia
“Serdia 3.5 level III” software
To enable correct analysis of faults, facilitate the procedure of putting the tractor into service and check correct operation of the engi-
ne electrical components, the Technician is provided with a software application called SERDIA (P/N 5.9030.740.4/10), for installation
on a portable computer. With SERDIA, the technician can:
l display errors (faults) that have occurred;
l program the control unit;
l carry out sensor calibration or setting procedures.
Description of the kit
The SERDIA software is supplied to Authorised Workshops in a carrying case with all the basic items needed for operation. The case
contains:

Fig. 203

Table 55
Pos. P/N Description Qty
5.9030.740.4/10 Case, complete 1
1 5.9030.740.0 . Installation disk 1
2 5.9030.740.2 . Level III interface General overhaul 1
3 5.9030.741.0 Adapter cable (not included in kit) 1
Data is exchanged between the SERDIA software and the control units by way of a diagnostic socket incorporated in the tractor
wiring. Accordingly, the SERDIA package is supplied with an interface cable that must be used on the particular model and version
of tractor being serviced.

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DiagnosiS EMR 4 - Serdia 2010
General Informations
l Engines involved: DEUTZ AG type TCD 3.6 L4, TCD 4.1 L4, TCD 6.1 L6
l Part Number: 10002785
l Function group: B0
Description
With the introduction of the new Tier 4i / Stage 3b engines, a new Serdia diagnostic software is required for use with the existing
diagnostic interface. The new software is titled Serdia 2010 and is now available.
This Software will be used in parallel to the existing Software Serdia 2000. This is necessary as Serdia 2010 at present only supports
EMR 3 and 4, therefore Serdia 2000 will remain in service for use on previous EMR1, EMR2, EMR3 engines.
The new Software will be released under a License agreement and an individual license will be required for each single Serdia-
Interface (HS-Light II).
This License is available through our parts departments using the part number 10002785.
License
To order the License it is necessary to specify the Serial Number of the HS-Light II Interface in the order procedure as described
below.
Serial Number of the HS-Light II Interface identification.

Fig. 204

When placing the order, insert the Serial Number of the Serdia Interface HS-Light II wire in the input box “Order-No“.

000-130241

Fig. 205
The License is available within 5 days after placing the order and will require a License data file installation in your computer.
Serdia 2010 Software installation procedure
The Serdia 2010 Software is immediately available to download from the following web link. http://serdia.deutz.com
After using the Link the following page appears:

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Calibrations and electronic
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Serdia 2010 icon:

Fig. 206

- Click the Icon “Serdia 2010”. The download page for Serdia 2010 appears:

7
2
3 1
4

Fig. 207
l 1): Serdia 2010 User Manual - Download
l 2): Serdia 2010 Software - Download for Install
l 3): License data file - this is to be installed after the installation of Serdia 2010. With this file the Interface HS-Light II is acti-
vated in Serdia 2010
l 4): Error code list EMR 4
l 5): Software Update for Serdia 2010 (just needed if Serdia 2010 is already installed)
l 6): License Terms
l 7): Manual for Uninstall Serdia 2010
- Click the file “Serdia 2010 V...” to download it. (N.2) in the installation green box.
- After the successful Download of the Software, refer to the document “Manual_Serdia2010:_EN_Level2_Version100_02052011.
pdf” Chapter 3.3.4.” on how to install the software.
License data file installation procedure
- Go to weblink “http://serdia.deutz.com” to find out if your License has been activated
- Click Serdia 2010 to enter the screen that shows the License box.

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 Calibrations and electronic
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Fig. 208
- Click on the icon “Interface Lis.txt“ to open the document showing the list of Interface serial numbers activated.

Fig. 209

Exemple of list:

Fig. 210

- Scroll the list until you find your Interface serial number.
- If not present, you have to wait more time.
- If present, close the document and click the file named: “Serdia 2010 License.exe” to download it in your computer.

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Calibrations and electronic
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Serdia2010 Licence.

Fig. 211

- Follow the download guided sequence.

- Once completed the installation, the Serdia 2010 Software is ready to work.
Intermediate Wire
A new intermediate wire is also necessary to provide a connection between the Serdia Interface and the Electronic Engine Controller.
The part number of the intermediate wire is 0.020.0441.4 which can also be used with the previous engines systems EMR1, EMR2
and EMR3, this making the old intermediate wire Part No 5.9030.741.0 redundant.
Wire P.N. 0.020.0441.4. 8

10

11

Fig. 212

Layout of the wire:

l 8): Connection to 14 Pin Diagnostic Socket (is always to connect)
l 9): Connection to 19 Pin Can-Bus Socket (Only Maxi Vision Cabin)
l 10): Connection to Serdia Interface for Electronic Engine Control EMR1, EMR2, EMR3.
l 11): Connection to Serdia Interface for Electronic Engine Control EMR4
Please do not hesitate to contact your Technical Advisor for any help to install the new Serdia 2010 Software.
SerDia 2010 updating license file
Document type
Informative note for network
General information
Functional groups and subgroups
B0 00
Description
To ensure that the SerDia 2010 diagnostic software (P.N. 10002785) functions correctly, it must be updated at least twice every
year. To do this, the new license file issued on the DEUTZ AG portal must be installed on the computer used for diagnostics before

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 Calibrations and electronic
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01 February and 01 August of every calender year. This is necessary to ensure complete, trouble-free diagnostic and adjustment
functionality.
The new license file is available from the DEUTZ AG portal at the address: http://serdia.deutz.com/.

Changing the date on the Windows system clock of the computer used will not prevent license deactivation.

Table 56
Updating the license file
Name License file: 1.8.xxx
Publication date From 17/01/2014
Software download http://serdia.deutz.com/

Procedure for installing SerDia 2010 license file update

Install the license file update before the license expiry date, which is viewable in the SerDia 2010 main screen (Figure 1). If the update
is not installed before this date, the software will stop working and request installation of the update.
Figure 1.

01.02.2014

Fig. 213

Access the website http://serdia.deutz.com/ and click SerDia 2010 (Figure 2).
Figure 2.

Fig. 214

A link to the new SerDia2010 license file (License ... .exe) is visible in the window opened (Figure 3).
Figure 3.

Fig. 215

Click the link to download the file, and follow the attached installation instructions. Click “Next” (Figure 4).

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Calibrations and electronic
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Figure 4.

Fig. 216

Click “Next” (Figure 5).

Figure 5.

Fig. 217

Click “Install” (Figure 6).

Figure 6.

Fig. 218

Click “Finish” (Figure 7).

Figure 7.

Fig. 219

At the end of the installation procedure, the following table is displayed. Refer to this table to check if your license is listed and has
been updated correctly. The license code matches the serial number of the interface in your possession (Figures 8 and 9).

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 Calibrations and electronic
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Figure 8 - Identifying interface.

Fig. 220

Figure 9 - Table of active licenses.

Fig. 221

Please contact your Area Technical Inspector for any queries on this subject.

We recommend visiting the “News Service” section of the technical documentation portal daily to check for new docu-
ments and view them as soon as they become available.

Introduction
With the introduction of the new engine generation in the beginning of 2011, which fulfill the new emission standards EU stage III B,
US Tier4i. Therefore Deutz releases a new Version of its diagnostics software SerDia2010 release 2.0.221. All engines fulfilling this
emission standard are equipped with the EMR4 ECU, which allows many new diagnostic features, due to it’s new software concept
and additional interfaces.
SerDia2010 is a must for engine diagnostic purposes at engines according stage III B / Tier4i and higher.
Important
This manual was created for user with SerDia access level 1.

Important
If you use a higher access level with SerDia2010 it is possible, that some functions, which are visible or useable for
you, are not described in this script.

DEUTZ AG
Application Engineering
Safety instructions
WARNING
The use and the application of SerDia2010 can be dangerous!

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Calibrations and electronic
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WARNING
It is critical that you carefully read and follow the instructions and warnings below and in the associated installation
manuals:

WARNING
Serdia2010 enables a user to influence or control the electronic system in a vehicle or machine. SerDia2010 is spe-
cially designed for the exclusive use by personnel, who have special experience and training.

WARNING
Improper use or unskilled application may alter the machine performance or system performance in a manner, that
results in death, serious personal injury or property damage.

Important
Do not use SerDia2010, if you do not have the proper experience and training.

Important
It is recommended, that in-vehicle use of SerDia2010 shall be conducted on enclosed test tracks, or ensured machine
surroundings.

Important
Use of SerDia2010 on a public road should not occur unless the specific calibration and settings have been preciously
tested and verified as safe.

Important
When using SerDia2010 with machine systems, that influence vehicle behaviour and can affect the safe operation
of the machine, you have to ensure, that the machine can be transitioned to a safe condition, if a hazardous incident
should occur.
Important
All legal requirements, including regulations and statutes regarding vehicles and machines must be strictly followed
when using this product.

WARNING
If you fail to follow these instructions, there might be a risk of death, serious injury or property destruction.

Important
Any data acquired through the use of SerDia2010 must be verified for reliability, quality and accuracy prior to use or
distribution. This applies both to calibration and to measurements, that are used as a basis for calibration work.

Important
The DEUTZ AG and it’s representatives, agents and affiliated companies deny any liability for the functional impair-
ment of DEUTZ products in terms of fitness, performance and safety, if non-DEUTZ software, parameter settings or
model components are used with or deployed to access DEUTZ products.
Important
The DEUTZ AG and it’s representatives, agents and affiliated companies will never be liable for any damage or injury
caused by improper use of SerDia2010.

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 Calibrations and electronic
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Important
DEUTZ provides training regarding the proper use of SerDia2010.

Important
Before using SerDia2010 it is required to verify, that the software is up to date and all updates are installed.

Important
The DEUTZ AG and it’s representatives deny any liability for any injury caused by the use of a non up to date software
version of SerDia2010. If necessary the software can be updated from serdia.deutz.com.

Important
It is recommended to make an access to the ECU while engine is running only, if it is guaranteed, that a change of
programming cannot lead to hazardous effects in engine behavior. If this is not ensured, a faulty programming can
cause undefined engine reactions, that results in death,serious personal injury or property damage.
Important
A faulty programming of the ECU can activate a sleep mode of the ECU because of safety reasons. In this case the
ECU is switched off, a communication to the ECU is not possible any more. A repair or reprogramming of the ECU is
not possible. The ECU has to be replaced.
Important
If supply voltage of the ECU is switched off or the connection between the SerDia interface and the ECU is interrupted
while changing parameters of the dataset, a sleep mode of the ECU, because of safety reasons, can be activated. In
this case the ECU is switched off, a communication to the ECU is not possible any more. A repair or reprogramming
of the ECU is not possible. The ECU has to be replaced.
Important
If you cannot agree with these limitations, you are excluded from using SerDia2010.

Important
If you cannot agree with these limitations, you are excluded from using SerDia2010. In this case contact the supplier.
The purchase price and the not used licence fee will be refunded within one month after receipt.

General preferences
Subject of the present documentation is the use of SerDia2010 at DEUTZ engines with electronic injection equipment.
Important
This document shows the functionality of SerDia2010 and it’s use to communicate with and parameterize of DEUTZ
ECU’s. The information contained herein only correspond to the state of the art at the time of setting and are not sub-
ject to an immediate revision service.
Important
In case of problems with SerDia2010 please contact the supplier.

Before contacting please collect information about the individual circumstances of the problem you have, as much as possible. The
following information has to be given as a minimum:
l PC-hardware
l Windows operating system
l SerDia2010 version

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Calibrations and electronic
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l Type of interface
l DEUTZ ECU part number
l Engine number
WARNING
To allow the access to the ECU it is recommended to install a diagnostic socket according DEUTZ wiring diagram for
the respective engine.

WARNING
SerDia2010 will be delivered with access level 2 in general. The access level is not depending on the hardware in-
terface level.

Important
If a different access level is needed, it is necessary to make a request to the supplier. Within 5 working days you will
get an email with a confirmation / negation to your request. If confirmed the licence update has to be downloaded from
serdia.deutz.com and installed on the computer, in order to activate the new level.
WARNING
Following information has to be given in order to get a change of the access level.

l Complete details as name and address of applicant (if different to the licence user).
l Complete details as name, address and qualification of the prospective licence user.
l Detailed description because of the reasons for changing the access level.
WARNING
It is not permitted to resell or transfer the licence and within also the interface for SerDia2010 without knowledge and
agreement of DEUTZ AG! Is a transfer needed, please contact the supplier to get a confirmation. Without a written
confirmation (email feedback) from DEUTZ a resell or transfer is strictly forbidden!
General preferences - Availability
SerDia2010, documentation, updates and information is is available at the following locations:
l Global SIS - portal
l Website: serdia.deutz.com
General preferences - Licence purchasing
To use SerDia2010 it is recommended to purchase a software licence for each interface used. Not before successful registration and
confirmation of the licence (by DEUTZ) for the individual interface serial number, a communication between software, interface and
ECU is possible in order to have a diagnostic access to the new DEUTZ engines.
Second dealer stage:
Responsible for delivery, assistance, maintenance and service of the second dealer distribution net is the service partner or OEM,
who is directly connected to the DEUTZ service network. He is also responsible for classification of his sub dealers regarding access
level. If interfaces are sold via second dealer stage the final user has to be mentioned directly while ordering, respectively, if reselling
is later, it has to be communicated to and confirmed to the supplier.
Order procedure
The licence can only be purchased through the official DEUTZ dealer net respectively the central OEM. Each licence is linked to one
specific interface serial-no. To enable parallel diagnostics for e.g. 5 service technicians, five licence’s will be required. For ordering
please use the DIWI-system only! It is currently not possible to place an order via SAP or file transfer.
A physical dispatch of goods doesn’t take place if no interface hardware is ordered. If only the software SerDia2010 is ordered the
registration / release of the interface serial no. is completed usually within 5 working days. After tis delay the software can be down-
loaded from serdia.deutz.com. You can check the registration easily: All registered serial no. are mentioned in the licence’s overview
file licence.txt also available on the website.
Procedure

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 Calibrations and electronic
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Important
Allways enter the consignee (e.g.2nd dealer stage, OEM dealer, customer)!

Fig. 222 - Ordering in DIWI

Important
Enter PN 1000 2785 (software-licence) and quantity.

Important
Enter interface serial-no.in pop-up window.

Fig. 223 - Entering serial-no.(pop-up window)

Important
Release the order.

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Calibrations and electronic
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Important
Download of actual SerDia2010 – software 5 days after release of the order. Install SerDia2010 on all required PC’s.

General preferences - Access and communication

SerDia2010 (Service-Diagnosis) is a PC software which works together with notebook and interface to communicate with the engine
control unit. For the use of SerDia2010 it is recommended to take a special software training at the training center.
The training center cologne provides such EMR4 training courses.
WARNING
The data of the published and respectively valid technical documents, such as operating instructions, circuit diagrams,
workshop manuals, repair and setting instructions, technical bulletins, service bulletins etc., are exclusively mandatory
for operation, maintenance and repair. We refer especially to the valid edition of the “Installation Manual Electronic”,
which is available from the Application Engineering Dept.
Electronic engine control units (ECU) are state of the art in modern engine technology. Target for these controllers is at first to replace
the functions of mechanical governors (like speed governor) and secondly to increase the ability of new functions. To communicate
with the DEUTZ-ECU’s SerDia2010 is necessary. Furthermore
1. Interface (Dongle with wiring, diagnostic plug, serial number and authorization level).
2. State of the art notebook or personal computer, optionally with printer are needed (see also Hardware).
Overview

Fig. 224 - Basic scheme of modern computer based diagnosis

Introduction
SerDia2010 is working with DEUTZ controller family EMR4. It is possible to use this software to communicate with different ECU’s.
The software can be downloaded via the internet access serdia.deutz.com.
If necessary,a new version of SerDia2010 is launched here. Also updates can be available, which have to be installed per hand by
user. These updates will be included in the next SerDia2010 version, too. Changes in the ECU-software concerning adjustment,
parameterization, calibration or deleting error memory are possible only with SerDia2010. The access to the several functions is
depending on the access level of the user.
SerDia2010 is running with operating systems MS-Windows XP SP2, Windows Vista and Windows 7. Functions are activated by
clicking on command buttons on the screen.

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 Calibrations and electronic
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Minimal equipment
To communicate with a DEUTZ engine controller the following equipment is necessary:
l PC or Notebook
l DeCom or HS light II USB Interface
l Diagnostic plug correctly connected with the controller
Hardware
Software SerDia2010 is able to work with Interface
l HS-Light
l DEUTZ Communicator DeCom
available from DEUTZ AG.
Hs-Light
Important
SerDia2010 is executable with HS-Light II Interface.

WARNING
Once SerDia2010 is compatible to EMR3 ECU’s the compatibility with HS-Light will not be enhanced any more. So
HS-Light will not be provided in the far future any more!

Important
If a new interface is needed for communication with SerDia2010 it is recommended to order a Deutz Communicator
DeCom as soon as available.

HS-light Interface

Fig. 225

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Calibrations and electronic
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The licence for SerDia2010 has to be ordered separately via DIWI (see Licence
purchasing). You can find the HS-Light serial number on the back side of the in-
terface:
Where to find the Seria number?

Fig. 226

DeCom
Important
SerDia2010 is executable with DEUTZ Communicator (DeCom).

WARNING
Once SerDia2010 is compatible to EMR3 ECU’s the compatibility with HS-Light will not be enhanced any more. Be-
ginning at this time, only the DEUTZ Communicator will show full functionality (including compatibility to EMR3 with
SerDia2010)!
Important
If a new interface is needed for communication with SerDia2010, it is recommended to order a Deutz Communicator
DeCom as soon as available.

Features

Fig. 227

l K-Line and L-Line interface according ISO 9141-2 and ISO 14230-4. Baudrate up to 500 Kbaud

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 Calibrations and electronic
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l 2 Full Can with max. 1 Mbit/s adjustable, according CAN-specification 2.0A and 2.0B
l USB 2.0 full-speed
l Galvanic isolation of inputs and to the PC
l Power supply from PC, current max. 250 mA
l LEDs for showing state of interface communication:
Table 57
LED Status 2x CAN
Green USB/device status
Green Ubat
Green CAN communication 2
Green CAN communication 1
Green K-/L-Line communication
Green SAE J1708/J1587 communication
l working temperature range –20°C up to +60°C
l storing temperature range –40°C up to +85°C
l type of protection: IP50
l Deutz standard diagnostic plug, 12 pole
l switchable termination resistor
l 1m wiring length: Interface <=> PC fixed on interface with bend protection and cord grip
l 2m wiring length: Interface <=> ECU fixed on interface with bend protection and cord grip
l power supply from PC
l voltage range: 8-32V
l EMC according DIN ISO 7637-2, DIN EN 61000-4-2, 61000-4-3, 61000-4-4, 61000-4-6, 61000-6-2, 61000-6-4
-
Pin assignment USB type A

Fig. 228

Pin assignment diagnostic plug

Table 58
PIN Signal Description
1 VBUS +5VDC
2 D- Data -
3 D+ Data +
4 GND Ground
-
Standard Plug for Pin Contacts (ITT Cannon Part Number 192922-1270)

Fig. 229

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Calibrations and electronic
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Table 59
Pin Signal (1x Can) Signal (2x Can) Function (1x Can) Norm
A U_bat U_bat Supply Voltage (+8V ... +32V) -
B GND GND Ground -
C not connected not connected - -
D J1708a J1708a J1708a SAE J1708/J1587
E J1708b J1708b J1708b SAE J1708/J1587
F not connected CANL2 - -
G CANL CANL1 CAN Low ISO 11898
H CANH CANH1 CAN High ISO 11898
J not connected not connected - -
K K K K-Line ISO 9141
L L L L-Line ISO 9141
M not connected CANH2 - -
Ordering DeCom
The licence can only be purchased through the official DEUTZ dealer net respectively the central OEM. For ordering please use the
DIWI-system only! It is currently not possible to place an order via SAP or file transfer.
The registration / release of the interface serial no. is completed usually within 5 working days. After tis delay the software can be
downloaded from serdia.deutz.com. You can check the registration easily: All registered serial no. are mentioned in the licences
overview file licence.txt also available on the website.
Procedere
Important
Allways enter the consignee (e.g.2nd dealer stage, OEM dealer, customer)!

Fig. 230 - Ordering in DIWI

Important
Enter PN 1000 xxxx (Hardware incl. software-licence) and quantity of Interfaces.

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 Calibrations and electronic
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Important
Release the order.

Important
Download of actual SerDia2010 – software 5 days after release of the order. Install SerDia2010 on all required PC’s.

PC/Notebook
Minimum hardware
l Notebook or PC (IBM-AT compatible)
l USB interface
l graphic board VGA/SVGA with a resolution of 1024 x 768 Pixel
l frequency = 1,5 GHz
l main memory = 1 MB RAM
l hard disk = 500 MB (free memory)
l CD-driver
l internet access for SerDia2010 updates
l administrator status for installation
Minimum software, operating system
l operating system MS-Windows XP SP2, VISTA, Windows 7 (32bit or 64bit)
Diagnostic plug
A connection plug has to be installed in the machine to connect the engine ECU with the SerDia2010 hardware interface. The plug
has to be easily accessible (for example in cabin). While doing the wiring of the plug and connecting it to the control unit, please use
the right wiring diagram.
The plug purchased via DEUTZ:
l Diagnostic plug TN 0419 9615
l Serial according to ISO 9141 and SAE J1587
-
Diagnostic plug

Fig. 231

Table 60
Signal Function Norm Assignment
CANH CAN High diagnostic CAN - H
CANL CAN Low diagnostic CAN - G
CANH CAN High customer CAN - F
CANL CAN Low customer CAN - M
K K-Line ISO-1941 K
L L-Line ISO-1941 L
J1708a J1708a J1708/J1587 D

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Signal Function Norm Assignment
J1708b J1708b J1708/J1587 E
Ubat Power supply - A
Gnd Ground reference - B
Software installation
Newest SerDia2010 setup files are available at: serdia.deutz.com
Before installation of the software, please download the new Setup data first. The new updates due to the change in control unit
software, program extension and improvements, can always be found at above mentioned website.
Important
Please do not connect the SerDia2010 USB interface to the PC, until program installation is finished!

WARNING
To use SerDia2010 you need a released licence (see chapter Order procedure and Ordering DeCom). Release is
done for each interface separately.

Installation of SerDia2010
Important
For all following actions admin rights are necessary!

Chronological order of installation:

l Download SerDia2010 from serdia.deutz.com or start program-CD.
l Start installation of Setup.exe
l The installation process is running automatically.
l Additionally a JAVA-runtime-system is installed.
l Configuration of the HS-Light driver (if HS-Light interface shall be used).
1. connect HS-Light interfaces to USB
2. Start of “samPDU ConfigurationCenter” in Windows start menu at START => “Programs” => “samtec Diagnostic Tools”
=> “samPDU”
3. Search of the connected interface with activate “Find VCI”

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Fig. 232 - Start screen samPDU

l After installation SerDia2010 can be launched via SerDia2010 icon on the desktop.

Important
For all administrators who configure the PC’s for other users: The path C:\Deutz\SerDia\*.* must be entirely acces-
sible.

Important
Via internet serdia.deutz.com , the so called “Bugfixes” can be provided also. This bug fixes are files the user can
manually copy to SerDia-directory. These data can solve problems as a short time solution in the actual SerDia pro-
gram. In the next SerDia version this will be automatically included.
Access level
WARNING
SerDia2010 will be delivered with access level 2 in general. The access level is not depending on the hardware in-
terface level.

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Important
If a different access level is needed, it is necessary to make a request per email to the supplier. Within 5 working days
you will get an email with confirmation / negation of the request. If confirmed the licence update has to be downloaded
from serdia.deutz.com and installed on the computer, in order to activate the new level.
l For installation the administrator mode is necessary.
l For all others PC-User modes, the path C:\Deutz\SerDia\*.*needs entirely full access.
Table 61
No. Version Application Note
1 Interface Level I (1) Control, regular maintenance work For end customer, only for respec-
according to maintenance schedules tive engine in OEM machine
2 Interface Level II (2) Inspection, test and adjustment Repair work within the scope of war-
work, repair work also within the ranty only with worldwide service
scope of the warranty, engine ex- agreement. For OEM with regional
change (incl.EAT) For OEM without Selfservice
3 Interface Level III (3) working in the scope of the warranty, mechanical reworking of engine
extensive diagnosis, test & adjust- components and major overhaul
ment work on whole engine, major usually provided for OEM by the
overhaul, intermediate overhaul, DEUTZ service organization
mechanical reworking of engine
components
4 Interface Level IV (4) replacement program (only by only for DEUTZ-OEM- or Devel-
DEUTZ) opment-Engineer, Employees of
DEUTZService organization
User level, competence level, interface access right
Table 62
EMR4 1 2 3 4
Operating software
update the operating software (Flashen without pass- 2 2 v v
word)
supported control unit EMR4 (EDC17CV52, CV54, v v v v
CV56)
supported control unit EMR3 (EDC7, EDC16) v v v v
supported control unit EMR2 v v v v
Dataset (L = Read / S = Write)
read and write the dataset (without extra data) without 2 2 L/S L/S
access to parameter
read and write of dataset (without extra data) with ac- 2 2 2 L/S
cess to parameter
overall programming without possibility of change the 2 2 L/S L/S
operation data
overall programming with possibility of change the op- 2 2 2 L/S
eration data
Dataset (L = Read / S = Write)
access to all parameters according to the available 2 L/S L/S L/S
competence level (UseCases)
adjustment of service parameters in form of pre-defined 2 L/S L/S L/S
tasks with running engine
Measured Values (L = Read / S = Write)
showing the selected measured values 2 v v v
showing the internal calculated values for Level IIIa and 2 2 v v
Level IIIaS
CAN-Status 2 v v v
2) only allowed for hardware according to respective engine.
Regardless of the level of competence exists all access for the hardware to the respective engine.

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Table 63
EMR4 1 2 3 4
Error Memory (L = Read / S = Write)
show the errors in error memory 1 including the environ- v v v v
ment data
delete all errors or single error in error memory 1 v v v v
show the errors in error memory 2 including the environ- 2 v v v
ment data
delete all errors or single error in error memory 2 2 2 v v
Extras data (Logistic data, operating data and cus- (L = Read / S = Write)
tomer data)
access to the logistic data 2 L L L/S
read, reset the maintenance counter 2 2 L L/S
access to the load spectrum data 2 2 L/S 2 L/S
read and reset the override memory 2 2 L L/S
Calibration and test functions (L = Read / S = Write)
drive pedal calibration 2 v v v
low idle adjustment 2 v v v
droop calibration 2 v v v
Test the inputs and outputs 2 v v v
Control Unit Functions (L = Read / S = Write)
reset 2 v v v
activate and deactivate a test bench dataset
engine shut off 2 v v v
2) only allowed for hardware according to respective engine.
Regardless of the level of competence exists all access for the hardware to the respective engine.
Program handling - General communication access
By the use of SerDia2010, in order to communicate with a DEUTZ control unit, the following instructions during connection, are
recommended:
l Start the computer
l Connect the interface to the Computer via USB Interface
l Switch on power supply of the control unit
l Connect the interface to the diagnostic plug of control unit
l Start SerDia2010 on the Computer
Now the available interface for SerDia will be searched automatically and the connection will be created.The setting for the hard- and
software of the ECU will be adjusted automatically. During program start the following information window is shown.

Fig. 233 - Information window

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Program handling - Programstart and home screen
After program start the start screen (home) is shown:

Fig. 234 - Start screen

From all screens in program you can go back to home while pressing next icon in the button bar.

Using button “display for supported ECU software” a page with an overview regarding in SerDia2010 implemented software versions
of ECU-software and assisted ECU hardware is shown.

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Fig. 235 - Overview SW-versions

Information’s onto the start screen
On the start screen many information’s give an overview about the system and the ECU. At “logistic data” you will find information
about hard- and software of the ECU. Engine hours, counters, etc. is available at “ECU counters” On the lower body of the screen
there is some information regarding communication ECU <-> User merged.
In detail:
l Serial number of the interface.
This number is the basis for access level and licensing.

Fig. 236

l Visualization of connection status.

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If communication between Notebook and ECU is ok, indicator is green. If com-
munication is not possible or interrupted, indicator is red. If communication is con-
nected, indicator is green.

Fig. 237

l ECU software.
The ECU software of the connected control unit is shown in the lower right window.

Fig. 238

l Engine number.
The engine number, stored in ECU, is shown.

Fig. 239

Program handling - Main menu

For navigation in SerDia2010 a button bar is used called main menu. This main menu is shown at all screens in program.
Table 64
Home Back to start screen

Fig. 240
Error memory Access to memory 1 Access to memory 2

Fig. 241
Data set management Download: new operating SW, com- Upload: complete data set
plete data set, partial data set

Fig. 242

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UseCases Access to several measurement and parameterize functions in order to
manage different

Fig. 243
guided diagnostics not finished yet

Fig. 244
report documents not finished yet

Fig. 245
configuration Adjust: language, access level elevation, setting folders for file storage

Fig. 246
help Information regarding SerDia2010

Fig. 247
program exit exit SerDia2010

Fig. 248
rebuild connection Updates a new connection

Fig. 249

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Program handling - Configuration
Program settings like language, setting folders for file storage and access level elevation can be configured
by pressing the CONFIGURATION icon.

Fig. 250 - configuration, setting

The respective setting configuration can be saved by pressing the SAVE SETTING icon.

Program handling - Error memory

By pressing the ERROR MEMORY icon the error memory 1 can be opened.

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Fig. 251 - Error memory 1

SerDia2010 is collecting all errors and it’s environment data out of the ECU. The errors will be shown together with KWP-code, DTC-
code, number of occurrence and a short error description.
Possible interactions:
Button “Actualize error memory” reads out the error memory out of the ECU.

Button “Clear error memory” delete of all passive errors. Active errors can also be deleted but come up
again directly.

Button “Save as CSV file” list of errors will be saved in a CSV file.

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Button “Error details” shows some details about the chosen error and some hints to solve it (available with
SW ...580..and higher).

Fig. 252 - Additional error information

Button “Error environment” shows important measurements at time of error occurrence.

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Fig. 253 - Error environment

Program handling - Dataset management
Important
This function is only available with access level 2 or higher!

Program handling - Offline Viewer

The Offline Viewer is available after installation of SerDia2010 with its own icon on the desktop Advantage: If only measurements
have to be considered, it is not necessary to start SerDia2010 completely but the Offline Viewer can be loaded very fast.

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Fig. 254 - Start screen Offline Viewer

Possible interactions
Open measurement
Click OPEN icon and select file from hard disk.

Zoom function
If a measurement has been loaded, the screen can be zoomed in and out with the highlighted slider.

Fig. 255 - Slider

Change of background color

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Decouple measurement window.

Change of background color.

Fig. 256

Color palette.

Fig. 257

Program handling - Usecases EMR4

Button USECASES starts screen with the overview of the available use cases. Depending on the actual
access level different use cases can be started here.

For all changes of parameters while using the use cases, the following is obligatory:
WARNING
The user has to check all changes and make plausible all influence and risk of the changes.

WARNING
The user is bearing the responsibility for all expected and unexpected effects because of the parameter changes.

WARNING
After changing parameters the effects regarding functionality of the engine / machine hast to be checked under en-
sured machine surroundings.

Assembly Inspection and Initialisation Tests

After installation and commissioning of a plant inspections of warning lights and simulations of warning limits can be performed on
this site. Parameters can be set to the window for the given values.

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Fig. 258 - Assembly Inspection and Initialization Tests (1/3)

Important
Please note the order of entry!

Important
First enter the relevant value then set the hook otherwise exists danger of uncontrolled engine switch off!

In the input field several values can be entered to check the warning limits. After entering the values the hook will be set next to the
description to confirm the respective value. This value will be shown next to the input field.

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Fig. 259 - Assembly Inspection and Initialization Tests (2/3)

In the lower part of the screen checks for cooling water level switch and water in fuel switch are possible. By setting the hook for the
respective inspection the warning systems can be checked. The engine will be specified in such border states.

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Fig. 260 - Assembly Inspection and Initialization Tests (3/3)

Graphic dipslay
The summary page gives an overview about the available measurements. Several predefined measurements or graphical displays
can be chosen by the user.

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Fig. 261 - Summary page graphic display

Fig. 262 - Running graphic display

Possible interactions

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Scaling y-axis: double click onto the values of the axis. In the shown window will
pop up and a new value can be given.

Fig. 263

Table 65

_mp
Fig. 264
Start of measurement record (before starting measurement a file name for storing data has to be defined).

Fig. 265
Start of measurement.

Fig. 266
Stop of measurement.

Fig. 267
Interrupt measurement (pause).

Fig. 268

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Delete measurement.

Fig. 269
Spreadsheet window separating / docking for placing on the screen

Fig. 270
Switch to bosch acronyms instead of normal parameter labels.

_mp
Fig. 271

Fig. 272 - Spreadsheet window

Measured values:

Fig. 273 - List of values

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Next icon include/delete values for measurements

Fig. 274

Change of background color:

Click at chosen color.

Fig. 275

Color palette.

Fig. 276

BACK BUTTON back to overview screen.

Similarly is the setting for measurements of engine start, measurement configuration of EAT and applications.
Dynamic Reading-Gauge
Using the Dynamic Reading-Gauge in the Use-Case graphic display, allows you to create individual Experiments, regarding your
engine. The possibility of recording up to 20 different engine controller parameters at the same time, SerDia 2010 allows a simple
but effective diagnosis. For example to monitor the fuel injected output, air-mass flow and engine speed, diagnosing wether plausible
values are caused.

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Fig. 277 - Startscreen Use-Case graphic Display

Mouse clicking the Dynamic Reading-Gauge Button (marked green) starts the diagnosis configuration.

Fig. 278 - Startscreen dynamic reading-gauge

The picture above shows which parameters can be recorded (left column) with SerDia 2010. Mouse clicking the green marked button

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selects a single parameter and copies it to the right column (measurement selection).

Fig. 279 - Parameter Selection dynamic reading-gauge

Besides the possibility of creating and configuring individual adapted experiments, SerDia 2010 allows the user to load pre configured
experiments created by the Deutz Service with the *.mwa file-ending. By mouse clicking the blue marked button in the picture shown
above, *.mwa files can be searched on the computer and loaded in to SerDia 2010. Clicking either the red marked or green button,
all parameters of the *.mwa file or an singular parameter of the *.mwa file is copied to the measurement selection.

Fig. 280 - Selected Parameters - creating and saving *.mwa files

Are all parameters loaded in the measurement selection the experiment can be started by clicking the green button on the lower right

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side. By clicking either the red or blue marked button the selected parameters are deleted or saved to HDD as a *.mwa file.

Fig. 281 - Dynamic reading-Gauge in action

Output test
Important
This function is only available with access level 2 or higher!

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Input test

Fig. 282 - Screen: input test

The actual switching status of the ECU inputs are shown as a lamp. The active switching status (depending on the input configura-
tion high or low) is shown as a switched on lamp (yellow). So it is easy to check, if inputs are wired correct and change their state if
hardware switch is actuated.
Analogue speed setpoint
Important
This function is only available with access level 2 or higher!

Constant Speed setpoint

Important
This function is only available with access level 2 or higher!

Low Idle adjustment

Important
This function is only available with access level 2 or higher!

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Droop adjustment
Important
This function is only available with access level 3 or higher!

Set limp home RPM

In case of failure of the accelerator pedal or the CAN-Bus the emergency speed intervene to be in a constant condition.

Fig. 283 - Screen Set limp home RPM

The emergency speed can be pretended in the right text box:
Possible interactions:
l Store emergency speed in ECU by entering:
01101

l Read emergency speed out of the ECU:

01101

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Important
The emergency speed range is limited from low idle up to 1200 rpm!

Trip Recorder
Important
This function is only available with access level 2 or higher!

Sensors
The UseCase sensors provides an overview of various measurements. For 4 of these measurements the upper and lower limits are
displayed in the bar graph with corresponding measured value.

Fig. 284 - Screen sensors

Following values can be viewed if they are sent by ECU:
l Boost pressure
l Ambient pressure
l Fuel delivery pressure
l Engine oil pressure
l Boost temperature
l Ambient temperature
l Cooling temperature
l Battery voltage
l Vehicle velocity
EGR, Throttle
The UseCase for analyze and diagnose exhaust gas recirculation and throttle is only available with engines, who are equipped with
this features.

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Important
This function is only available with access level 2 or higher!

Calibration of injectors (IQA-Code)

Compression test
Important
This function is not available with a level lower than access level 2!

Engine hours
Important
This function is only available with access level 2 or higher!

SCR-Overview
Important
Provided for a correct use of the UseCases is an engine, equipped with a system of SCR exhaust after treatment.

Fig. 285 - SCR-overview

This overview page provides a quick overview about values of different sensors and the whole EAT system.

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Pressing next icon opens the page of measurements for the SCR-System. (see also Measurements).

Fig. 286 - Page of measurement SCR

By pressing the next iconthe user gets to the SCR-test functions (Access only with Level 2 or higher).

Mouse clicking the next icon starts the SCR-End Of Line Test (see description SCR-EOL).

The arrow Button guides back to the SCR overview.

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SCR Test function
Important
This function is only available with access level 3 or higher!

SCR End Of Line test

Main page diesel particulate filter DPF
On the DPF main page, the whole DPF-system is shown graphically in an exemplary situation at the engine.

Fig. 287 - DPF-main page

Besides the entire overview of the DPF-system on the left side, the most important values of the DPF equipment is shown on the
right side. The user switches over to a component specific page by selecting the individual relevant diagnostic components of the
DPF-system using the PC-mouse.
Turn to page diesel particulate filter and burner then click on the filter.

Elemento DOC

DOC element

Fig. 288

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Turn to page supply-module then click on the module.

Fig. 289

Turn to page diesel particulate filter and burner then click on the burner.

Fig. 290

Turn to page air pump then click on the pump.

Fig. 291

Fig. 292 - Activate spark plug then click on the plug

For each single summary page the possibility to turn back to the main page exists. Burner testing is the only exception.

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Button “measuring data acquisition”:

Pushing the button “Measuring Data Acquisition “, the user will be skipped back
to the diagnostic page “Measuring Data Acquisition”, that will allow to record and
trace the measurements of the main page. To verify, that the engine is running, so
that the DPF-System is able to work, therefore the engine speed will be checked.
If the engine doesn’t run, the user is asked to start the engine with the following
message:

Fig. 293

Important values of the DPF-burner system are shown in various labels in the
upper half of the functional area. For example the “combustion chamber tempera-
ture“ at the top, the “burner air mass flow reference value“, the “burner air mass
flow actual value“ in the left labels, such as the secondary fuel injection mass of
the burner in the right label. In the middle the status display of the burner is placed.
Next image shows functional area upper half.

Fig. 294

In the lower half of the functional area important values of the DPF in various la-
bels are shown. These are:
l the “exhaust gas temperature“ at the entry of the diesel oxidation catalyst
(DOC) in the left label
l the “exhaust gas temperature reference value“ and the actual value in the

right label
l In the middle the status display of the DPF is placed

Next image shows functional area lower half.

Fig. 295

In the picture on the upper left hand side the time since last successful regenera-
tion is shown.

Fig. 296

Values DPF

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The overview page for the measurement “Measuring Data Acquisition“ shows the indicated values from the DPF main page as a
graphical tool.

Fig. 297 - Screen: measurement

Demo modus
Within the diagnostic application of the Deutz DPF-system, there is a DEMO-mode integrated, that can be activated, by mouse
clicking the DEMO button in the upper right corner of the system overview, on the DPF main page. In the DEMO-mode a real DPF-
burner system will be simulated. It basically only shows what plausible values of a DPF-burner will be shown.

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Fig. 298 - Screen DPF DEMO-mode

Diesel particulate filter (DPF) and burner
Here the system component “Diesel Particulate Filter (DPF) and burner“ will be shown.

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Fig. 299 - Burner top view

With pushing the button “switch burner on/off” the burner can be switched on and by
pushing it again, it will be switched off.

The button “Measuring Data Acquisition” traces the indicated values from the DPF main page for measure-
ment into a graphical tool.

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Fig. 300 - Screen: measurement

By pushing the button “request regeneration” a regeneration can be started on demand.

The actual status of the burner is shown during regeneration at the status display.

0%

Fig. 301

Click on the symbol to change the burner conditions:

Table 66
Possible burner conditions
state 1 of burner initialization: stand by

Fig. 302

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Possible burner conditions
state 4 of burner: preheating

Fig. 303
state 8 of burner: ignition

Fig. 304
state 16 of burner: ramping

Fig. 305
state 32 of burner: on

Fig. 306
state 64 of burner: glowing off

Fig. 307

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Table 67
For changing DPF-conditions, press onto the symbol:
state 1 DPF: initialization / state 2 DPF: charging/loading

Fig. 308
state 4 DPF: cat-warm up (start burner) / state 8 DPF: warm up phase (HC-injection)

Fig. 309
state 16 DPF: regeneration

Fig. 310

At the same time the temperatures before and after DPF (or DOC), and the DPF differential pressure, can be checked in the lower
half of the screen.

Fig. 311 - Check temperatures before and after DPF (or DOC)
DPF End of Line Test
By pressing EOL Button an EOL-test of the DPF burner system can be started.(only level access 2 or
higher!)

WARNING
The EOL (End of line) Test is available with software P_802_592_XXX or higher.

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Important
The tests are running fully automatic. At the end a result for the complete test is shown (Test successful / not suc-
cessful).

WARNING
The individual test functions can be activated only above a minimum coolant temperature of 70°C.

Fig. 312 - DPF EOL-Test

By clicking on End of line (EOL) Test the test will be started. Depending on the engine temperature this test will take about 15 minutes.
For a successful EOL-test two conditions must be guaranteed, on the hand the coolant-temperature needs to be at least 75 °C and
the engine needs to running, else the test will fail. The button named burner test will start the burner, afterwards SerDia feeds back
wether the burner has started successfully.
Clicking on the button named deflate pipes will vent the pipes concerning the entire DPF-Burner system. It is recommended to vent
the pipes before operating the DPF-burner system for the first time as well as after draining the fuel pipes.
Clicking on the button named Reset ash Load, will reset the maintenance intervals for the ash-load within the ECU. Analogously the
buttons reset soot load and reset ash & soot load.
Important
This is a service function, which is required after each exchange of DPF-filter.

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If a filter regeneration was not possible for an extended period, a service regenera-
tion is required. A click on this button will start the service regeneration.

Fig. 313

If a filter regeneration was not possible for an extended period, a service regeneration is required. A click on this button will start the
service regeneration.
By pressing the shown button the window “Measuring Data Acquisition DPF” will open (see Values DPF).

By pressing next button the screen of the supply module will be opened.

By pressing next button the results of the individual EOL-tests will be stored (with added information about
engine type, machine type, etc.).For documenting the EOL-test results either a unencrypted as well as a
encrypted file will be generated.

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Fig. 314 - Additional information for documentation of DPF EOL-test

Supply Module DPF, burner
The overview page allows to control each valve for fuel injection of the burner and for HC-injection.

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Fig. 315 - Supply Module

On the left side the component view of the supply module is placed, on the right side a simplified representation of the circuit is
shown. Above a functional area is available. It contains control elements, which, if activated, indicate actual values like pressure or
temperatures directly into the simplified representation circuit. Additionally the position of each component will be shown by a color
labeling in the component view.
Important
Further function is only available with access level 3 or higher!

Air pump
The system component air pump is described on the overview page as well.

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Fig. 316 - Air pump

For the air pump functional test, a setpoint can be given manually.
Important
The manual air pump functional test is only available for some versions of the ECU-software.

With the linear regulator an air mass flow can be chosen for setpoint of the air pump. The label above the linear regulator shows the
actual setpoint.
After that the setpoint has to be confirmed by pressing the button “ok”.

For finishing the test the “Stop Button” can be used.

Following values will be shown in the left picture above the air pump:
Table 68
At the top on the left: Air pump rotation speed
At the top in the middle: Air mass flow(reference value)
In the middle: Air mass flow (actual value)
At the bottom on the right: Air pump pressure

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Spark plug

Fig. 317 - Setting the spark plug in ignition-mode via SerDia

Pressing the small spark plug picture next to the red 4, shown in the System Overview in Use-Case mainpage DPF, will let the pic-
ture shown above pop up. Placing the hook in the little Check-Box “activate spark plug” will start the ignition process. Analogously,
unhooking the check box will deactivate the ignition process.
Please notice the trailing time of the system!
WARNING
Be aware of the high Voltages during the ignition process, which can seriously harm human beings as well damage
either Equipment or Engine periphery.

Important
All safety precautions must be checked prior to start functioning!

WARNING
Keep ready to use the emergency stop of the machine!

Program handling - Usecases EMR3

Important
Further function is only available with access level 2 or higher!

Graphic display EMR3

On the following summary page are information displayed to possible experiments or UseCases. Here the user can select pre-con-

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figured experiments.On the right side is a favorites list shown, which allows to choose experiments directly. Adjacently tree structure
contains all experiments. By selection of a branch and confirm the “ok-button” the respective experiment will be opened.

Fig. 318 - Graphic display

By pushing following button next to the tree structure the favorites list on the right side can be edited.

Following window opens for editing the favorites list:

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Fig. 319 - Editing the favorites list

Important
The favorites list can consist of only 10 favorites!

Favorites can be removed or added to the list by using following arrows:

Fig. 320

The vertical arrows are used to sort within the favorites list.

Fig. 321

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Leaving the settings is possible by pushing button:

Possible interactions for all following experiments

Select readings:
In this dialogue the user can choose a selection of displayed signals. By default,
all signals are activated. Depending on the respective experiment the measured
values of the measurement vary.

Fig. 322

Scaling y-axis: double click onto the values of the axis. Above shown window will
pop up and a new value can be given.

Fig. 323

Change of background color. By default is set black.

Fig. 324

Functions of diagrams
Table 69
Button Function Description
Start of measurement Measurements will be displayed in a diagram. After stopping the
measurement temporary data can be saved.

Fig. 325
Start of measurement record (before start- Before starting recording the data name of the recording must
ing measurement a file name for storing be entered.
data has to be defined).

Fig. 326

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Button Function Description
Interrupt measurement (Pause) The measurement will be interrupted until renewed entering the
button.

Fig. 327
Stop of measurement After stopping the measurement, the displayed data can be
stored, pressing “Save measurement” button.

Fig. 328
Open measurement This button opens a saved measurement.

Fig. 329
Delete measurement With this button the measurement can be discarded.

Fig. 330
Save measurement This buttons stores the measurements data in a measurement
file.If the data name is not entered yet,the dialogue appears to
save the measurement file. The directory can be selected and the
filename has to entered.

Fig. 331
Correlation / Adjust Trigger Hereby a correlation can be created between measured values
and trigger.

Fig. 332
spreadsheet window separating / docking The table of measurement names and the actual measurements
for placing on the screen can be separated or renewed docked.

Fig. 333
Switch to Bosch acronyms instead of nor- By default measurement names will be shown in the selected

_mp
mal parameter labels language. By pushing this button the Bosch acronyms will be dis-
played. By renewed entering the button the selected language
will be displayed renewed.

Fig. 334

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Analogue speed setpoint EMR3
To use this UseCase, the engine has to run in allspeed-governor mode or min-/max-governor mode. Speed set point has to be acti-
vated via analogue signal (foot pedal, hand throttle, e.g.).

Fig. 335 - Screen analog speed setpoint

SerDia is identifying the configuration of the analog speed set point facilities and shows, depending on the setting in the ECU, the
values for foot pedal and / or handgas. Additional the measured values of the signals (in %) are shown on the screen. The resulting
speed setpoint, depending on functional scope (mostly maximum of pedal, handgas wins), is shown, too.
Process of automatic calibration

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Fig. 336 - Chosen “automatic mode”

When pressing button “auto” the automatic mode for calibration is started, Button on the screen is marked yellow. On the left side of
the page the values for minimum, maximum and the actual measured values are shown.

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Fig. 337 - End “automatic mode”

A second click onto the button “auto” stops the automatic mode. The values for pedal, low and high limit are calculated. After starting
the automatic mode SerDia learns the new values for the limits while pushing the pedal several times. The threshold values and the
pedal characteristic is calculated and shown on the screen.
After calculation a validation is done. The values for 0% and 100% pedal have to differ 1V in minimum. The low and high limit have
to have a gap of min. 200mV to the values 0V and 5V. If one of this checks is hurt, the respective value is marked red and the user
is informed about the violation of the limit.
Process of automatic calibration:
By repeatedly up and down moving the pedals SerDia learns the actual pedal limits and calculates the necessary pedal curves and
error limits. The user has to make sure, that the mechanical limits are reached while pushing the pedal or throttle. After finishing
calibration the new values can be stored into the ECU or rejected.
WARNING
The user is responsible for plausibility and check of the new values. The liability for parameter changes is taken by
the user.

Process of hand mode calibration

Important
The manual mode should be used only by experienced users!

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Fig. 338 - Chosen “hand mode”

When pressing button “hand mode” the actual values from dataset are collected and shown at the tables and text fields on the screen.
The user is able to make changes by hand. The “hand mode” button has changed color to yellow.

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Fig. 339 - End “hand mode”

Second click on “hand mode” starts the check and validation procedure in SerDia. The values for 0% and 100% pedal have to dif-
fer 1V in minimum. The low and high limit must have a gap of min. 200mV to the values 0V and 5V. If one of this checks is hurt, the
respective value is red marked and the user is informed about the violation of the limit.
WARNING
It is recommended to use the hand mode function only if experienced.

WARNING
The user is responsible for plausibility and check of the new values. The liability for parameter changes is taken by
the user.

Storing data
Pressing button “read data from ECU” all new values are rejected and deleted.
01101

Pressing button “store in ECU” the new values are transfered to the ECU and stored. Old values are gone.
01101

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Important
It is recommended to use the automatic mode for calibration of the foot pedal. If the hand mode is used by the expe-
rienced user, the values for the throttle have to be prepared by user himself.

Constant speed adjustment EMR3

To use this function, the engine has to be in fixspeed mode or the setting allows to activate the fixspeed mode.

Fig. 340 - Screen change constant speed

The actual setting for the fixspeed values are shown on the left upper part of the screen. The setting of the switch is marked, too. Left
hand placed is the status for the constant speed position switch as marking point. Additionally the actual engine speed and the speed
setpoint is shown as value and tachometer on the right side inclusive hysteresis to have a qualitative feedback.
Pressing button “read from ECU” the original stored values of the ECU were refreshed on the screen.
01101 Changes of the values are deleted

Pressing button “write values to ECU” values shown on the screen for fixspeed 2 (first intermediate speed)
01101 and fixspeed 3 (2. intermediate speed) are flashed to the ECU. If the engine is still running while activation
of this procedure, SerDia will ask to stop engine automatically.

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Important
The values for fixspeed 1 (low idle) and fixspeed 4 (high idle) cannot be changed free because they are linked to low,
respectively high idle.

Text box “Constant Speed 2”,”Constant Speed 3”.

Changes in these text boxes have to be confirmed with ENTER. After confirmation
the new value will get active, if switched on (see marking point at fixspeed). It is not
possible to install a speed below fixspeed one or above fixspeed four.
The fixspeed 1 and 4 are not changeable in this screen (see hints above).

Fig. 341

Limp home adjustment EMR3

In case of failure of the accelerator pedal or the CAN-Bus the emergency speed intervene to be in a constant condition.

Fig. 342 - Screen Set emergency speed

The emergency speed can be pretended in the right text box.
Possible interactions:

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l Store emergency speed in ECU by entering.
01101

l Read emergency speed out of the ECU.

01101

Important
The emergency speed range is limited from low idle up to 1200 rpm!

EEPROM error reset EMR3

Fig. 343 - Screen EEPROM error reset EMR3

The EEPROM errors can be stored by entering following button, the lamp besides the button indicates
01101 whether the system is ready or not.

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Fan control EMR3
The UseCase of the fan control basically consists of the adjustment values:
1. Parameters
2. Characteristics
3. Maps
These consist again of several sub items.

Fig. 344 - Screen fan control

Left side shows an overview about the possible adjustment values. On the right side is a graphical display placed, which shows va-
rious fan parameters, possible to take a look at.
Below the graphic display there is button located for storing data in the ECU.
01101

Below the graphic display there is button located to reset to default values.
01101

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If a parameter is selected, either default and current parameter value is displayed below the graphical
display. Actual measurements and initial values can be confirmed by entering following button.

By default the settings, as described in chapter measurements, are possible to adjust except adjusting the background color.
Scaling y-axis: double click onto the values of the axis. Above shown window will
pop up and a new value can be given.

Fig. 345

Functions of diagrams
Table 70
Button Function Description
Start of measurement Measurements will be displayed in a diagram. After stopping the
measurement temporary data can be saved.

Fig. 346
Start of measurement record (before start- Before starting recording the data name of the recording must
ing measurement a file name for storing be entered.
data has to be defined).

Fig. 347
Interrupt measurement (Pause) The measurement will be interrupted until renewed entering the
button.

Fig. 348
Stop of measurement After stopping the measurement, the displayed data can be
stored, pressing “Save measurement” button.

Fig. 349
Open measurement This button opens a saved measurement.

Fig. 350
Delete measurement With this button the measurement can be discarded.

Fig. 351

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Button Function Description
Save measurement This buttons stores the measurements data in a measurement
file.If the data name is not entered yet,the dialogue appears to
save the measurement file. The directory can be selected and the
filename has to entered.

Fig. 352
Correlation / Adjust Trigger Hereby a correlation can be created between measured values
and trigger.

Fig. 353
spreadsheet window separating / docking The table of measurement names and the actual measurements
for placing on the screen can be separated or renewed docked.

Fig. 354
Switch to Bosch acronyms instead of nor- By default measurement names will be shown in the selected

_mp
mal parameter labels language. By pushing this button the Bosch acronyms will be dis-
played. By renewed entering the button the selected language
will be displayed renewed.

Fig. 355

Parameters
Actual measurements and initial values can be changed directly in following text bar:

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Fig. 356 - Screen actual and default values

Actual measurements and initial values can be confirmed by entering following button and stored into
RAM.

Following parameters can be changed:

l D-component of the amplitude ratio of fan speed
l Extended coolant temperature slope
l Fan speed I-component within range
l I-component fan speed for signals below limit
l I-component fan speed for signals above limit
l P-component fan speed for signals below limit
l Expansion of the coolant temperature P-component
l P-component fan speed for signals above limit
Characteristics
Actual measurements are shown below the graphical display in tabular form with the x-value and the respective FNC.

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Fig. 357 - Screen actual and initial values

Actual measurements and initial values can be confirmed by entering following button and stored into
RAM.

Following characteristics can be changed:

l Group characteristics of the fan speed addicted P-component in range
l P-component group characteristics of the fan speed below the limit
l P-component group characteristics of the fan speed above the limit
l Actual P-component of the PID-controller coolant temperature
l Group characteristics of the fan speed addicted I-component in range
l I-component group characteristics of the fan speed below the limit
l I-component group characteristics of the fan speed above the limit
l Actual I-component of the PID-controller coolant temperature
l Group characteristics of the fan speed addicted D-component in range
l Group characteristics of the fan speed addicted to waiting time
l Group characteristics D-component of the coolant temperature
l Group characteristics D-component of the engine speed
l Actual D-component of the PID-controller coolant temperature
l Group characteristics of the coolant temperature addicted I-component in range
l Group characteristics of the engine speed addicted I-component in range
l I-component of the group characteristics of the coolant temperature below limit
l I-component of the group characteristics of the engine speed below limit
l I-component of the group characteristics of the coolant temperature above limit
l I-component of the group characteristics of the engine speed above limit

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l Group characteristics of the coolant temperature addicted P-component in range
l P-component of the group characteristics of the engine speed above limit
l P-component of the group characteristics of the coolant temperature below limit
l P-component of the group characteristics of the engine speed below limit
l P-component of the group characteristics of the coolant temperature above limit
l ID ‘P-component of the group characteristics of the engine speed above limit not found
l Actual relation of CAN adaptation
l Actual value of output fan speed adaptation
Maps
Current and initial values of the map for fan speed are shown below graphical display and can be changed directly in the map.

Fig. 358 - Screen actual and initial values

The fan speed is divided into 5 steps.
X (horizontal axis) represents engine speed [rpm].
Y (vertical axis) represents the fan speed [rpm].
By double clicking on the FNC-value the respective speed can be changed.
Current and initial values can be confirmed by entering button. These values will be stored in the RAM.

Input test EMR3

With the UseCase “Input test” security systems such as switches, warning lamps can be checked in the left third of the window.
The central part of input test contains current motor values. On the right side of the window are shown the engine speed, injection
volume and rail pressure.

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Fig. 359 - Screen input test

Low idle adjustment EMR3
It is provided for using this function, that the engine is operating in min-/max-governor or allspeed-governor mode (f.e. not fixspeed).

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Fig. 360 - Screen: idling control

SerDia reads out the actual values of idle run and copies them into the labels in the sub array on the left hand side. This values will
be saved further, too. In parallel a tachometer operates on the right hand.
The actual setpoint value and the actual rotating speed are shown, each as a decimal value below the tachometer and also with
indicator and hysteresis region.
Button “read data from ECU” went back to previous value of idling speed, which was acquired at the start
01101 of the UseCase.

Button”store in ECU” writes all variables for idle speed back into the ECU. If the engine is still running,
01101 SerDia will offer to stop the engine automatically, so that the programming of the ECU can take place.

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Text box “new value”, an input into this text box has to be confirmed by ENTER.
After that, SerDia changes all variables for idle speed and switches over to work-
ing page, so all changes will be activated in realtime.

Fig. 361

Important
The input is limited for a speed range of 600 – 1200 1/min.

Fault location
The most frequent reasons for problems in SerDia2010 are:
l Dead file bodies of previous SerDia-installations
l Power management of computer
l long low cost USB-cable (> 2m)
l Intermittent electrical contact in the diagnostic electric line
FAQ
1. Error
l SerDia won’t start, after installing.
Action
l Go to the Folder C:\DEUTZ\SerDia\lic\... and execute workaround2.reg by double-clicking it. Follow the systems-instruction
and restart SerDia2010
2. Error message
l Java Virtual Machine Launcher.

Fig. 362

Action
l To install the workarounds you unpack the ZIP archive (from Z_ into ZIP):C: \DEUTZ\SerDia\Lic and rename the R_data in
.REG. By double clicking on the REG file the workaround will be installed.
3. Error message
l Program for executing could not be found
Action
l Open the .reg file, which can only runs on the target system. This can be seen in: C:\ \Windows\SysWOW64\
4. Error message
l Missing link to DAPS-file

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Action
l Start registry-program for workaround (See error message 1).
5. Error message
l Serdia2010.daps and default .daps find no ECU or no SW-Version. Data speed (baud-rate) error is shown.
Action
l Check termination resistors. CAN-High and CAN-Low exchange. With different baud rates on the Bus take an ECU with 250
KBaud-DS or repair the bus.
6. Error message
l No valid license not found.

Fig. 363

Action
l Will be displayed when a new license file is replaced by an older one. Use newer license file!
7. Error message
l ZIP-installation problem.

Fig. 364

Action
l (Firewall problem)
l Solve the problem:
1. By IT-department which “untreated” takes or
2. new FTP-Link with the same file but “harmless” file ending adjust

8. Error message
l Device manager.

Fig. 365

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Calibrations and electronic
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Action
l See next image.

Fig. 366

9. Error message
l Not a valid password.

Fig. 367

Action
l Install newest SerDia-Version (1.8.750) with newest licence file, because older databases contain old passwords.
SERDIA - Diagnostic socket connection
SERDIA - Diagnostic socket connection
Table 71
Component Image FROM: A:
Dedicated PC for diagnostics - USB cable

Fig. 368
USB cable (p/n ---); A = Connection to Per- Personal Computer SERDIA interface
sonal Computer; B = Connection to SER- (PC) cable
DIA interface cable

Fig. 369

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Component Image FROM: A:
SERDIA interface cable (p/n SERDIA interface SERDIA interface
5.9030.740.2/10); A = Connection to USB cable cable
cable; B = Connection to adapter cable

Fig. 370
Cable for diagnostic socket (p/n SERDIA interface Tractor diagnostic
0.020.0441.4); A =: Connection to 14 Pin A cable socket
diagnostics socket (always connected); B
= Connection to 19 Pin Can-Bus socket B
(only “Maxi Vision Cab”); 1 = Connection to
Serdia interface for EMR1, EMR2, EMR3
electronic regulator type engines; 2 = Con-
nection to Serdia interface for EMR4, elec- 1
tronic regulator type engines;
2
Fig. 371
Tractor diagnostic sockets: - -
(!) Connect to both sockets (!)
A = Deutz-AG engine diagnostic socket;
B = Tractor ECU diagnostic socket (used
as power feed)

B
A

Fig. 372

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20.2 - Diagnostic tool screens
20.2.1 - Position of ECUs and diagnostic instruments
The following ECUs may be installed in these tractors:
Deutz-AG “EDC17CV54” engine control unit
Position:
Outside the cab, on the right side of the tractor, in front of the battery.
Purpose:
Deutz-AG “EDC17CV54” Engine management.

Fig. 373

HLHP2 ECU
Position:
Inside the cab, in the right hand lateral control console. Open the plastic hatch to
access the ECU.
Purpose:
If the tractor is equipped with the mechanical reverse shuttle (LS) and electronic
SAC, this ECU controls the following: Hi-Lo, PTO, hitch (SAC), 60Lt./ECO and
SDD.
If the tractor is equipped with the hydraulic reverse shuttle (GS) and electronic
SAC, this ECU controls the following: hydraulic reverse shuttle, HML/Hi-Lo, PTO,
hitch (SAC), 60Lt./ECO and SDD. Fig. 374

“Smart Lever” hydraulic reverse shuttle lever

Position:
Under the steering wheel, integrated in the steering column.
Purpose:
This lever DOES NOT function as electronic control unit.

Fig. 375

Digital instrument cluster (MTA 2.0)

Fig. 376

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ISO 11786 control unit
Position:
Inside the cab, in the right side control console. (rear part)
Open the plastic hatch to access the ECU.
Purpose:
Managing ISO 11786 socket for using external implements.

Fig. 377

20.2.2 - ECU interrogation

Diagnostics
Diagnostics is the set of analytical and reporting activities which, through the measurement of certain physical parameters characteri-
sing the machine monitored, provide significant information on the status of the machine itself and on how its status varies over time,
to enable the evaluation and prediction of both short and long term reliability.
How diagnostics works
When connected to the diagnostic sockets of tractors with specific cables, the All Round Tester (ART®) and SDF Analyser tools con-
nect to and interrogate the different ECUs in the machine, and display the relative data acquired on screen.
ECUs interrogated by the All Round Tester (ART®) and SDF Analyser
The All Round Tester (ART®) and SDF Analyser tools may acquire and analyse data from the following electronic control units. Rear
hitch (EKR), front suspension, HPSA, HLHP1, HLHP2, PTO, Pre-heat, Hydraulic reverse shuttle (“Smart Lever”), Transmission, ZF
transmissions (TCU/VDC, SGR/FMGR), SLH engines, Instrument CLUSTER: INFOCENTER.
WARNING
The primary diagnostic functions of Deutz-AG ECUs are performed with the Serdia 2000/Serdia 2010 diagnostic tools.

WARNING
However, certain procedures are accessible and certain information viewable also with the All Round Tester (ART®)
and SDF Analyser diagnostic tools.

How to select the ECU interrogated

All Round Tester (ART®)
1. Switch the tractor off and remove the ignition key;
2. Connect the ART® to the diagnostic socket;
3. Turn the ignition switch to “I” (ON);
4. When the ART® tool switches on, the battery charge level test screen is displayed.
WARNING
A voltage of less than 10V is insufficient for the ART® to connect to the ECUs, whereas voltages above 15V may
damage the tool itself.

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5. After a few seconds, the tester attempts to connect to the electronic system of M E N U
the tractor, and displays a screen (which differs in relation to tractor model and the = = = = = = = = = = = = = = = =
diagnostic connector used) in which the technician may select which ECU to con-
nect to, and analyse functions of components. 1 - E N G I N E E C U
3 - S M A R T L E V E R
=> The image aside shows an example of a selection screen visible when using
4 - C L U S T E R
the All Round Tester (ART®), in this case connected to the Agrofarm 115G tractor X - . . . . .
1 - “Engine ECU” / SHL Tier3a engine ECU, Y - . . . . .
2 - “Smart Lever” / Hydraulic reverse shuttle ECU integrated in “Smart Lever”
shuttle lever,
3 - “Cluster” / Digital on-board instrument cluster.

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 378

WARNING
To change from one ECU to another, switch the tractor off, reconnect and select the new ECU.

---
SDF Analyser
1. Switch the tractor off and remove the ignition key;
2. Connect the SDF Analyser to the diagnostic socket;
3. Turn the ignition switch to “I” (ON);
4. Launch the diagnostic programme on your computer;
5. After scanning the channels, the tester attempts to connect to the electronic
system of the tractor, and displays a screen (which differs in relation to tractor
model and the diagnostic connector used) showing the technician a list of the
ECUs recognised. Press “End”.
=> The image aside shows an example of a selection screen visible when using
the SDF Analyser, in this case connected to the Dorado³ 100 tractor:
● “Cluster” / Digital on-board instrument cluster.
● “Smart Lever” / Hydraulic reverse shuttle ECU integrated in “Smart Lever” shut-
tle lever,
● “Engine ECU” / SHL Tier3a engine ECU,
Fig. 379

WARNING
To interrogate a different ECU, simply select the name of the de-
sired ECU
(the image aside shows an example of a selection screen visible when using the
SDF Analyser -
in this case connected to the Dorado³ 100 tractor).

Fig. 380

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Menus available for each ECU
The number of ECUs listed varies in relation to the model of tractor the tool is connected to.
After selecting an ECU, the list of options available usually consists of either
5 choices: M A I N M E N U
1. “Monitors”/Monitor Menu: = = = = = = = = = = = = = = = =
Analyses all sensors in monitor mode. View data received from the different
1 - M o n i t o r s
electronic control units (e.g. sensor, button and potentiometer states etc.) 2 - P a r a m e t e r s
managing the tractor systems. 3 - C a l i b r a t i o n s
2. “Parameters”/Parameter Menu: 4 - T e s t s
For setting certain machine options. 5 - A l a r m s
3. “Calibrations”/Calibration Menu:
For calibrating the different subsystems of the machine, performing the op-
erations necessary for commissioning the tractor, calibrating the hydraulic
reverse shuttle and calibrating sensors.
4. “Tests”/Test Menu:
For testing actuators and testing the functions of the electric components
= = = = = = = = = = = = = = = =
installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.)
[ E ] E x i t
5. “Alarms”/Alarm list:
Displays all active and passive alarms. Alarms may also be cancelled from Fig. 381
this menu.
or
4 choices: M A I N M E N U
1. “Monitors”/Monitor Menu: = = = = = = = = = = = = = = = =
Analyses all sensors in monitor mode. View data received from the different
1 - M o n i t o r s
electronic control units (e.g. sensor, button and potentiometer states etc.)
2 - C a l i b r a t i o n s
managing the tractor systems. 3 - T e s t s
2. “Calibrations”/Calibration Menu: 4 - A l a r m s
For calibrating the different subsystems of the machine, performing the op-
erations necessary for commissioning the tractor, calibrating the hydraulic
reverse shuttle and calibrating sensors.
3. “Tests”/Test Menu:
For testing actuators and testing the functions of the electric components
installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.)
4. “Alarms”/Alarm list:
= = = = = = = = = = = = = = = =
Displays all active and passive alarms. Alarms may also be cancelled from
[ E ] E x i t
this menu.
Fig. 382

---
Hidden menus are also available for certain ECUs, which can only be accessed by M A I N M E N U
entering a specific password. = = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - T e s t s
5 - A l a r m s

C - I n i t i a l i t .

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 383

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20.2.3 - Instrument Cluster Diagnostics - “Monitor”/Monitor screens for ART/PC Tester
(SP286AD)
Structure of the “Monitor”/Monitor screens
The structure of the “Monitor”/Monitor screens is shown in the figure.

1 - Monitor

1 - Freq/Analog
2 - Digital 1
3 - Digital 2
4 - Digital 3
5 - CAN
6 - DCD1
7 - DCD2
8 - PreHeating

Fig. 384

Introductory screen
Digital instrument
C L U S T E R G . B .
l Software version: SP286AD = = = = = = = = = = = = = = = =
l Software release date: 14/04/2014

Press [E] to continue

F i r m w a r e S P 2 8 6 X X
D a t e X X / X X / X X X X

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

Fig. 385

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Main menu
l [1] - “Monitors” / Monitors M A I N M E N U
l [2] - “Calibrations” / Calibrations
= = = = = = = = = = = = = = = =
l [3] - “Tests” / Test
l [4] - “Alarms” / Alarm List
1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s L i s t

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

Fig. 386

Monitor menu
l [1] - Frequency / analogue signals
M O N I T O R M E N U
l [2] - Digital signals 1
= = = = = = = = = = = = = = = =
l [3] - Digital signals 2
l [4] - Digital signals 3
l [5] - CAN 1 - F r e q / A n a l o g i c
l [6] - DCD1 2 - D i g i t a l 1
l [7] - CDC2 3 - D i g i t a l 2
l [8] - Pre-heat 4 - D i g i t a l 3
5 - C A N
6 - D C D 1
7 - D C D 2
8 - P r e H e a t i n g

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

Fig. 387

Monitor -> Freq / Analogue

l Engine speed signal [RPM] M O N I T O R F R E / A N A
l Wheel speed signal [Km/h]
= = = = = = = = = = = = = = = =
l Belt speed signal (not used)
l Rear PTO speed signal [RPM] E n g i n e 0 r p m
l Fuel level [%] B e l t 0 r p m
l Engine coolant temperature [°C ] W h e e l 0 . 0 k m h
R e a r P T O 0 r p m
F u e l L e v e l 2 3 %
E n g i n e T e m p + 1 5 C

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

Fig. 388

20-98
Calibrations and electronic
diagnosis
Monitor -> Digital 1
l Pre-heat indicator lamp state M O N I T O R D I G I T A L 1
l Air filter warning lamp state
= = = = = = = = = =
= = = = = =
l Engine oil pressure warning lamp state P r e H e a t i n g
O F F
l Alternator warning lamp state A i r F i l t e r
O F F
l Belt alarms (not used) E n g . O i l e s P r
O F F
l Engine speed memory indicator state A l t e r n a t o r
O F F
l Park brake indicator lamp state B e l t A l a r m
O F F
l Trailer brake indicator lamp state E n g . M e m o r y
O F F
l Reserve fuel warning lamp state H a n d B r a k e O F F
T r a i l e r B r a
k e O F F
l DT indicator lamp state
L o w T a n k L e v
e l O F F
l DF indicator lamp state 4 W h e e l D e r i v
O F F
l SBA indicator lamp state D i f f . L o c k O F F
S B A O F F
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 389

Monitor -> Digital 2

l Pressurised filter indicator lamp state M O N I T O R D I G I T A L 2
l Intake filter indicator lamp state
l Service pressure indicator lamp state = = = = = = = = = = =
= = = = =
T r a n s . F i l t e
r O F F
l Lubrication pressure indicator lamp state
H y d r . F i l t e
r O F F
l Fast clutch indicator lamp state
T r a n s m . P r e s
s . O F F
l Medium clutch indicator lamp state
T r a n s m . L u b r
. O F F
l Slow clutch indicator lamp state H i g h R a n g e O F F
l Running lights indicator lamp state M e d i u m R a n g e O F F
l High beam lights indicator lamp state L o w R a n g e O F F
l RH/LH turn signal and hazard warning lights indicator lamp state L i g h t O F F
l Trailer 1 and emergency indicator lamp state H i g h B e a m O F F
D i r . L i g h t O F F
l Trailer 2 and emergency indicator lamp state
D i r . L i g h t 1 O F F
Values are given as [On-Off] D i r . L i g h t 2 O F F

[ E ] E x i t

Fig. 390

Monitor -> Digital 3

l Front PTO indicator lamp state M O N I T O R D I G I T A L 3
l Rear PTO indicator lamp state
l Ground speed PTO indicator lamp state = = = = = = = = = = = = = = = =
l 540 PTO indicator lamp state
F r o n t P T O O F F
l 1000 PTO indicator lamp state
R e a r P T O O F F
l PTO ECO indicator lamp state
S y n c r o P T O O F F
l RH alarm indicator lamp state P T O 5 4 0 O F F
l LH alarm indicator lamp state P T O 1 0 0 0 O F F
P T O E C O O F F
Values are given as [On-Off] A l a r m R H O F F
A l a r m L H O F F

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

Fig. 391

20-99
 Calibrations and electronic
diagnosis
Monitor -> CAN
l Messages received M O N I T O R C A N
m Engine alarm reception [M]
= = = = = = = = = = = = = = = =
m Transmission alarm reception [T]
m Hitch alarm reception [L]
R e c e i v e d
m Utilities alarm reception [U]
C A N E n g i n e O F F
l Messages sent C A N T r a n s m O F F
m CAN state C A N L i f t O F F
C A N S y s . C o u n O F F
Values are given as [On-Off]
T r a n s m i t t e d
C A N S t a t u s O F F

[ E ] E x i t

Fig. 392

Monitor -> DCD1

l Instrument operating hours [hours] M O N I T O R D C D 1
l Engine
= = = = = = = = = = = = = = = =
l Engine use < 1200 RPM [%] T o t C o u n t e r 2 h
l Engine use from 1200 to 1600 RPM [%] E n g i n e
l Engine use from 1600 to 2000 RPM [%] S p e e d < 1 2 0 0 0 %
l Engine use > 2000 RPM [%] S p e e d < 1 6 0 0 0 %
l Engine torque use < 40 % [%] S p e e d < 2 0 0 0 0 %
l Engine torque use from 40 to 80 % [%] S p e e d > 2 0 0 0 0 %
l Engine torque use from 80 to 100 % [%] T o r q u e < 4 0 % 0 %
T o r q u e < 8 0 % 0 %
l Engine coolant temp. state < 30°C [%]
T o r q u e > 8 0 % 0 %
l Engine coolant temp. state < 90°C [%] T e m p . < 3 0 C 0 %
l Engine coolant temp. state < 100°C [%] T e m p . < 9 0 C 0 %
l Engine coolant temp. state > 100°C [%] T e m p . < 1 0 0 C 0 %
T e m p . > 1 0 0 C 0 %
[ E ] E x i t

Fig. 393

Monitor -> DCD2

l Instrument operating hours [hours] M O N I T O R D C D 2
l Usage at speed < 5 Km/h [%]
= = = = = = = = = = = = = = = =
l Usage at speed < 10 Km/h [%]
l Usage at speed < 20 Km/h [%] T o t C o u n t e r 2 h
l Usage at speed > 20 Km/h [%] V S p e e d < 5 0 %
l Front PTO use [%] V S p e e d < 1 0 0 %
l Rear PTO use [%] V S p e e d < 2 0 0 %
l 4WD usage [%] V S p e e d > 2 0 0 %
l Pre-heat usage time [minutes] F r o n t P T O 0 %
R e a r P T O 0 %
l No. of starts with pre-heat
4 W D 0 %
P r e H e a t i n g 0 m
E n g i n e S t a r t 0

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

Fig. 394

20-100
Calibrations and electronic
diagnosis
Monitor -> Preheating
On this family of tractors, pre-heat functionality is managed by the engine control
M O N I T O R P R E H E A T
unit.
= = = = = = = = = = = = = = = =
Note
S t a r t P r e H e a t O F F
This screen is used when pre-heat functionality is managed by the K e y 5 0 O F F
instrument. F e e d b a c k R e l e O F F
S t a t u s R e l e O F F
E n g i n e 0 r p m
E n g i n e T e m p + 1 5 C

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

Fig. 395

20.2.4 - Instrument Cluster Diagnostics - “Tests”/Test screens for ART/PC Tester

(SP286AD)
Structure of the “Tests”/Test
The structure of the “Tests”/Test screens is shown in the figure.

1 - Tests

1 - Needles MIN
2 - Needles 1/2
3 - Needles MAX
4 - LCD ON
5 - LCD OFF
6 - LEDs ON
7 - LEDs OFF
8 - Buzzer ON
9 - Buzzer OFF

Fig. 396

20-101
 Calibrations and electronic
diagnosis
Introductory screen
Digital instrument
C L U S T E R G . B .
l Software version: SP286AD = = = = = = = = = = = = = = = =
l Software release date: 14/04/2014

Press [E] to continue

F i r m w a r e S P 2 8 6 X X
D a t e X X / X X / X X X X

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

Fig. 397

Main menu
l [1] – Monitor M A I N M E N U
l [2] – Calibrations
= = = = = = = = = = = = = = = =
l [3] – Test
l [4] – Alarm List
1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s L i s t

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

Fig. 398

Test menu
l [1] - “Needles min” / Needles at MIN position T E S T S M E N U
m All dial needles reach the MIN position.
= = = = = = =
= = = = = = = = =
l [2] - “Needles 1/2” / Needles at 1/2 position 1 - N e e d l
e s M I N
m All dial needles reach the 1/2 position. 2 - N e e d l
e s 1 / 2
3 - N e e d l
e s M A X
l [3] - “Needles max” / Needles at max position 4 - L C D O
N
m All dial needles reach the MAX position.
5 - L C D O
F F
l [4] - “LCD ON” / LCD ON 6 - L E D S O N
m All LCD display screens activate simultaneously.
7 - L E D S O F F
8 - B u z z e r O N
l [5] - “LCD OFF” / LCD OFF 9 - B u z z e r O F F
m All LCD display screens deactivate simultaneously.

l [6] - “Leds ON” / Leds ON

m All LED indicators light simultaneously.
= = = = = = = = = = = = = = = =
l [7] - “Leds OFF” / Leds OFF [ E ] E x i t
m All LED indicators turn off simultaneously.
Fig. 399
l [8] - “Buzzer ON” / Buzzer ON
m The buzzer starts to sound.

l [9] - “Buzzer OFF” / Buzzer OFF

m The buzzer deactivates and stops to sound.

20-102
Calibrations and electronic
diagnosis
20.2.5 - Instrument Cluster Diagnostics - “Alarms”/Alarms screens for ART/PC Tester
(SP286AD)
Structure of the “Alarms”/Alarms screens
The structure of the “Alarms”/Alarms screens is shown in the figure.

4 - Alarms

1 - Cluster Active
2 - Cluster Passive
3 - Erase Alarm

Fig. 400

Introductory screen
Digital instrument
C L U S T E R G . B .
l Software version: SP286AD = = = = = = = = = = = = = = = =
l Software release date: 14/04/2014

Press [E] to continue

F i r m w a r e S P 2 8 6 X X
D a t e X X / X X / X X X X

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

Fig. 401

Main menu
l [1] – Monitor M A I N M E N U
l [2] – Calibrations
= = = = = = = = = = = = = = = =
l [3] – Test
l [4] – Alarm List
1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s L i s t

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

Fig. 402

20-103
 Calibrations and electronic
diagnosis
Alarms menu
l [1] - Active alarms A L A R M M E N U
l [2] – Passive alarms
= = = = = = = = = = = = = = = =
l [3] – Clear alarms
1 - C l u s t e r A c t i v e
2 - C l u s t e r P a s s i v
3 - E r a s e A l a r m s

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

Fig. 403

Alarms ->Active alarms

Where:
- - - - - A L A R M S - - - - -
l Code = Alarm No. displayed on instrument cluster = = = = = = = = = = = = = = = =
l Cnt = Alarm event count # S P N f m i c n t
l Hour = Time at which alarm occurred

= = = = = = = = = = = = = = = =
[ F ] P a g + [ E ] E x i t

Fig. 404

Alarms -> Passive alarms

Where:
- - - - - A L A R M S - - - - -
l Code = Alarm No. displayed on instrument cluster = = = = = = = = = = = = = = = =
l Cnt = Alarm event count # S P N f m i c n t
l Hour = Time at which alarm occurred
T 9 5 5 6 1 1 3 1
T 1 0 5 5 6 0 1 3 2
T 8 1 1 2 7 2 1
T 8 5 5 1 4 0 2 7
T 1 0 3 1 6 1 2 1 8

= = = = = = = = = = = = = = = =
[ F ] P a g + [ E ] E x i t

Fig. 405

20-104
Calibrations and electronic
diagnosis
Alarms -> Clearing alarms
The passive alarms in the control unit memory can be cancelled here.
D e l e t e A l a r m s
= = = = = = = = = = = = = = = =

T h e a l a r m s
h a v e b e e n
d e l e t e d .

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

Fig. 406

20.2.6 - HLHP2 ECU diagnostics (TS171AC) - “Monitors”/Monitor screens for ART/PC

Tester
The “Monitors”/Monitor screens are used to monitor and check the functionality of the solenoid valves, sensors, potentiometers,
switches and other electrical components of the tractor.
“Monitors”/Monitor screens structure
The structure of the “Monitors”/Monitor screens is shown in the figure.

20-105
 Calibrations and electronic
diagnosis

1 - Monitor

1 - Transmission

1 - I/O Monitor

1 - Analog Inputs
2 - Digital Inputs
3 - Digital Inpts2
4 - Frequen Inputs
6 - Outputs

2 - Transmission
3 - Transmission2
4 - CAN
5 - Statistics
6 - Stop&Go
7 - Statistics HML1
8 - Statistics HML2

2 - Hitch
3 - PTO
4 - ASM
5 - Motor
6 - System

1 - Power Supply
2 - SDS
3 - 60 Lt. ECO

7 - SDD

Fig. 407

20-106
Calibrations and electronic
diagnosis
Introductory screen
The moment the tester is connected, the machine introductory screen will appear.
= = = = = = = = = = = = = = = =
l Software versions: TS171AC = = = = = H L H P = = = = =
l Software release date: 13/05/2014 = = = = = = = = = = = = = = = =

S W V e r s i o n
T S 1 7 1 X X

D a t e :
X X - X X - X X X X

C o n f i g u r a t i o n
5 1 X X C P R O F I L I N E

[ E ] E x i t

Fig. 408

Monitor menu
l 1 – Transmission
M O N I T O R M E N U
l 2 – Hitch
= = = = = = = = = = = = = = = =
l 3 – PTO
l 4 – ASM
l 5 - Engine 1 - T r a n s m i s s i o n
l 6 – System 2 - H i t c h
l 7 - SDD 3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m
7 - S D D

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

Fig. 409

Monitor -> Transmission

l 1 – I/O
M O N I T O R S
l 2 – Transmission
= = = = = = = = = = = = = = = =
l 3 – Transmission
1 - I / O
l 4 – CAN 2 - T r a n s m i s s i o n
l 5 – Statistics 3 - T r a n s m i s s i o n 2
l 6 – Stop&Go 4 - C A N
l 7 - Statistic HML1 5 - S t a t i s t i c s
l 8 - Statistic HML2 6 - S t o p & G o
7 - S t a t i s t i c s H M L 1
8 - S t a t i s t i c s H M L 2

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

Fig. 410

20-107
 Calibrations and electronic
diagnosis
Transmission -> I/O Monitor
l 1 – Analogue inputs I / O M O N I T O R
l 2 – Digital inputs
= = = = = = = = = = = = = = = =
l 3 - Digital inputs 2
l 4 - Frequency input 1 - A n a l o g I n p u t s
l 6 – Outputs 2 - D i g i t a l I n p u t s
3 - D i g i t a l I n p u t 1
4 - F r e q u e n I n p u t 2

6 - O u t p u t

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

Fig. 411

Analogue Inputs
l Clutch pedal voltage A n a l o g I n p u t s
l Gearbox oil temperature sensor voltage
= = = = = = = = = = = = = = = =
l Seat voltage
l SmartWheel voltage (wheel on shuttle lever) C l t c h P e d 0 . 0 0 0 V
l RH brake voltage, transducer O i l T e m p 0 . 0 0 0 V
l LH brake voltage, switch S e a t 0 . 0 0 0 V
S m a r t W h e e l 0 . 0 0 0 V
Note
Values indicated in Volts [V] B r a k e R H 0 . 0 0 0 V
B r a k e L H 0 . 0 0 0 V

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

Fig. 412

Digital Inputs
l State of clutch button on gear lever D i g i t a l I n p u t s
l State of clutch switch on pedal
= = = = = = = = = = = = = = = =
l Shuttle lever in neutral state C o n f C l u t c h O F F
l Shuttle lever in forward state S w i t h C l u t c h O F F
l Shuttle lever in reverse state N e u t r L e v e r O F F
l Seat state F r w r d L e v e r O F F
l State of proport. SV pressure switch (4 Bar) R e v e r s e L e v e r O F F
l State of general pressure switch (11 Bar) S e a t O F F
l State of Stop&Go button P r e s 4 b a r p E V O F F
P r e s 1 1 b a r S e r O F F
l State of (+) button on gear lever
l State of (–) button on gear lever S w i t c h S & G O F F
H M L +
Note
H M L -
Values are given as [On-Off] = = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 413

20-108
Calibrations and electronic
diagnosis
Digital Inputs 2
l State of + button on gear lever D i g i t a l I n p u t s 2
l State of – button on gear lever
= = = = = = = = = = = = = = = =
Note H i L o H I O F F
H i L o L O O F F
Values are given as [On-Off]

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

Fig. 414

Frequency inputs
l Shuttle sensor frequency reading F r e q u e n c i e s I n p t
l Wheel speed sensor frequency reading
= = = = = = = = = = = = = = = =
l H-M-L speed sensor frequency reading R e v e r s e r + 0 H z
W h e e l s + 0 H z
Note
H M L + 0 H z
The values are expressed in Hertz (Hz).

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

Fig. 415

Outputs
l Proportional SV O u t p u t s H I L O
m Control [mA]
= = = = = = = = = = = = =
= = =
m Current [mA]
= = = = = = p E V = = = =
= = =
l Reverse and forward drive SV C o n t r o l : 2 0
0 m A
m Reverse request current [On-Off] C u r r e n t : 1 8
9 m A
m Reverse current measured [mA] = = = E V B w d - F w d
= = =
R e q B w d : O F F
m Forward drive request current [On-Off]
M e a s B w d : 0 m A
m Forward drive current measured [mA]
R e q F w d : O F F
l Hi-Lo valve M e a s F w d : 0 m A
m Power [On-Off] = = = H i L o V a l v e
= = =
m Hi-Lo status [Hi-Low] P o w e r e d : O F F
H i / L o w : L o w
m Current [mA]
C u r r e n t : 0 m A
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 416

20-109
 Calibrations and electronic
diagnosis
Transmission info
l Direction | effective direction: [F-N-B] I N F O T R A N S M I S S I O N
l Clutch pedal position [%]
= = = = = = = = = = = = = = = =
l Forward | Reverse SV state [On-Off] D i r . D e s : N R e a l : N
l Proportional SV current [mA] P e d a l P o s : 9 9 9 %
l SV L current [mA] E v F : O F F E v B : O F F
l SV M current [mA] E v P C u r r : 0 0 0 m A
l SV H current [mA] [ L ] C u r r : 0 0 0 m A
l Engine speed sensor signal [RPM] [ M ] C u r r : 0 0 0 m A
l Hydraulic reverse shuttle speed sensor signal [RPM] [ H ] C u r r : 0 0 0 m A
E n g i n e : 0 0 0 r p m
l H-M-L speed sensor signal [RPM]
R e v e r s e : 0 0 0 r p m
l Wheel speed sensor signal [Km/h] H M L : 0 0 0 r p m
W h e e l s : 0 . 0 0 k m/ h

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

Fig. 417

Transmission info 2
l Direction | effective direction: [F-N-B] I N F O T R A N S M I S S I O 2
l Clutch pedal position [%]
= = = = = = = = = = = = = = = =
l Forward | Reverse SV state [On-Off] D i r . D e s : N R e a l : N
l Proportional SV current [mA] P e d a l P o s : 9 9 9 %
l SV L current [mA] E v F : O F F E v B : O F F
l SV M current [mA] E v P C u r r : 0 0 0 m A
l SV H current [mA] [ L ] C u r r : 0 0 0 m A
l Proportional SV pressure switch state [On-Off] [ M ] C u r r : 0 0 0 m A
l Range ratio engaged [ H ] C u r r : 0 0 0 m A
P r x E V p : O F F
l Transmission oil temperature (°C)
R a n g e : 2 V L L
l SmartWheel state O i l T e m p : + 1 7
S m a r t W h e e l : M 0

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

Fig. 418

Transmission -> CAN

l CAN connection state with instrument C A N
l CAN connection state with engine
= = = = = = = = = = = = = = = =
Note I n s t r u m . C A N O F F
C A N E n g i n e O F F
Values are given as [On-Off]

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

Fig. 419

20-110
Calibrations and electronic
diagnosis
Transmission -> Statistics
l Number of direction inversions performed S T A T I S T I C S
l Number of automatic starts performed
= = = = = = = = = = = = = = = =
l Number of gear shifts performed (Clutch button) R e v e r s e r 0 0 0
S t a r t . 0 0 0
G e a r S h i f t 0 0 0

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

Fig. 420

Transmission -> Stop&Go

l State of Stop&Go button [On-Off] S T O P & G O
l Country
= = = = =
= = = = = = = = = = =
l LH brake pressure [Bar] B u t t n
O F F E n b l O F F
l RH brake pressure [Bar] S t a t e
: I D L E
l Pressure [Bar] 0 . 0 0
B a r L H 0
l Brake state [Released-Depressed] 0 . 0 8
B a r R H 0
m STOP torque [%] 0 . 0 0
B a r M n 0
m AND torque [%] B r a k e
s : R E L E A
m GO torque [%] S T O P T h r % : 0 0
A N D T h r %: 0 0
m r torque [%]
G O T o r q u e %: 0 0
l Proportional SV current [mA] r T o r q u e %: + 0
E V p C u r r : 0 0 0 m A

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

Fig. 421

Transmission -> HML 1 Statistics

l Number of upshifts [>]
H M L S T A T P O W E R
m L>M - M>H
= = = = = = = = = = = = = = = =
l Number of downshifts [<] L > M H 4 9 6 7 2 9 5
m L<M - M<H L > M M 4 9 6 7 2 9 5
L > M S 4 9 6 7 2 9 5
l In: L < M H 4 9 6 7 2 9 5
m [H] - Hard, [M] - Medium, [S] - Soft
L < M M 4 9 6 7 2 9 5
L < M S 4 9 6 7 2 9 5
M > H H 4 9 6 7 2 9 5
M > H M 4 9 6 7 2 9 5
M > H S 4 9 6 7 2 9 5
M < H H 4 9 6 7 2 9 5
M < H M 4 9 6 7 2 9 5
M < H S 4 9 6 7 2 9 5
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 422

20-111
 Calibrations and electronic
diagnosis
Transmission -> HML 2 Statistics
l Total number of upshifts [>]
H M L S T A T M O T O R
m L>M - M>H
= = = = = = = = = = = = = = = =
l Total number of downshifts [<] L > M 4 9 6 7 2 9 5
m L<M - M<H L < M 4 9 6 7 2 9 5
M > H 4 9 6 7 2 9 5
M < H 4 9 6 7 2 9 5

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

Fig. 423

Monitor -> Hitch

l Hitch state
L I F T
l MIN | Current | MAX position [%]
0 0 - 0 0 - - - -
A U D 1 -
l Hitch position sensor S t a t u s . . .
L O C K. .
l LH and RH draft sensor M i n P o s i t i on M a x
l [Volt] | [%] total draft | [Volt] 0 0 % 0 . 0 % 9 6 %
l Clutch L H D r a f t R H
l % slippage [%] 0 . 0 0 0 0 . 0 % 0 . 0 0
l Radar signal [Kph] S l i p a g e
l Wheel speed signal [Kph] R e f : O F F 0 . 0 %
l Hitch usage mode R a d a r k m h . 0
l Up SV current W h e e l k m h . 0
M o d e - > P O S
l Down SV current
E V U P 0 0 0 0 O F F
l Ir [mA] E V D W 0 0 0 0 O F F
I r 0 0 0 m A
[ E ] E x i t

Fig. 424

Monitor -> PTO

l Status of front PTO switch [ ON - OFF ] P T O
l Status of rear PTO switch [ ON - OFF ]
= = = = = = = = = =
= = = = = =
l Status of auto PTO switch [ ON - OFF ] F r o n t S w
c h i t
O F F
l State of external button [ON-OFF] R e a r S w i
h t c
O F F
l Rear PTO rpms calculated by board [RPM] A u t . S w i
h t c
O F F
l Ratio (not used) E x t . S w i
h t c
O F F
l Front PTO SV state [ON - OFF] R e a r P T O 0 r p m
l Rear PTO SV state [ON - OFF] G e a r # # # # #
l Valve 750 (not used) F r o n t V a l v e O F F
R e a r V a l v e O F F
l Valve 1000 (not used)
7 5 0 V a l v e # # #
l Hitch position sensor [ % ] 1 0 0 0 V a l v e # # #
l Auto PTO engaging/disengaging height [ % ] R e a r L i f t 0 0 %
l Wheel speed [ km/h ] P T O O f f L i m 0 0 %
S p e e d . 0 k m h
[ E ] E x i t

Fig. 425

20-112
Calibrations and electronic
diagnosis
Monitor -> ASM
l State of DF button [ON - OFF] A S M
l State of SBA/ASM button [ON - OFF]
= = = = = = = = = = = = = = = =
l State of DT button [ON - OFF] D i f f S w i t c h O F F
l LH brake state [ON - OFF] A S M S w i t c h O F F
l RH brake state [ON - OFF] 4 W D S w i t c h O F F
l State of Park Brake pressure switch [ON - OFF] L H B r a k e O F F
l State of DT SV [ON - OFF] R H B r a k e O F F
l State of DF SV [ON - OFF]
l Steering sensor state in degrees [ 0° ] H a n d b r a k e O F F
E V 4 W D O F F
l Wheel speed [ km/h ]
E V D i f f O F F
l Wheel slippage [ON - OFF] A n g l e | 6 0 |
m [On] = Radar enabled
S p e e d . 0 k m h
m [Off] = Radar not enabled
A S M S l i p O F F
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 426

Monitor -> Engine

l Current engine speed (via CAN bus) E N G I N E C O N T R O L
l Requested engine speed
= = = = = = = = = = = = = = = =
l Current torque curve A c t u a l S p e e d 0
l Requested torque curve D s r d S p e e d 0
l Pgrade [1-2] A c t T o r q u e M a p 1
Where: D e s T o r q u e M a p 1
m [1] = Engine response with engine speed not stored 6% P G r a d e 1
m [2] = Engine response with engine speed stored 1%

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

Fig. 427

Monitor -> System

l Power S Y S T E M M O N I T O R
l SDS
= = = = = = = = = = = = = = = =
l 60l. / ECO 1 - P o w e r S u p p l y
2 - S D S
3 - 6 0 L t E C O

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

Fig. 428

20-113
 Calibrations and electronic
diagnosis
Power
l +5V power feed, output 1 P O W E R S U P P L Y
Powers:
= = = = = = = = = = = = = = = =
m RH draft sensor
m LH draft sensor

l +5V power feed, output 2

Powers: + 5 V O u t V 0 . 0 0
+ 5 V O u t V 0 . 0 0
m APS/Eco Power potentiometer
+ 5 V O u t V 0 . 0 0
m Smart Lever
+ 1 2 V B a t t . V 0 0 . 0
m Clutch pedal potentiometer
m Seat sensor
m PTO card to calculate rpm

l +5V power feed, output 3

Powers:
= = = = = = = = = = = = = = = =
m SAC position sensor
[ E ] E x i t
m SBA sensor
m Stop&Go transducer Fig. 429
m SDD proximity sensor

l Central power feed direct from battery +12V

Note
Values indicated in Volts [V]

SDS
l State of SDS button [On-Off] S D S
l State of SDS2 button [On-Off]
= = = = = = = = = = = = = = = =
S D S B u t t o n O F F
S D S B u t t o n 2 O F F

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

Fig. 430

20-114
Calibrations and electronic
diagnosis
60l. / ECO
l Bypass sol.valve current [mA]
6 0 L t E C O
l Proportional SV current [mA]
= = = = = = = = = = = = = = = =
O N / O F F 0 m A
P R O P 0 m A

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

Fig. 431

20.2.7 - HLHP2 ECU diagnostics (TS171AC) - “Tests”/Test screens for ART/PC Tester
This menu may be used to monitor and check the functionality of the solenoid valves, sensors, potentiometers, switches and other
electrical components of the tractor.
WARNING
The use of the test functions can cause the direct activation of the gearbox solenoid valves, without supervision by the
control logic. It is therefore essential to ensure that the vehicle is in a safe condition before proceeding.

Structure of the “Tests”/Test

The structure of the “Tests”/Test screens is shown in the figure.

20-115
 Calibrations and electronic
diagnosis

3 - Tests

1 - Transmission

1 - Solen. Valves
2 - Stop&Go Lamp
3 - Solen. Valv HML

2 - Hitch
3 - PTO
4 - ASM
5 - Motor

1 - Measured Values
2 - Logistic Data
3 - Handgas & Pedal
4 - Various

6 - System

Fig. 432

Introductory screen
The moment the tester is connected, the machine introductory screen will appear.
= = = = = = = = = = = = = = = =
l Software versions: TS171AC = = = = = H L H P = = = = =
l Software release date: 13/05/2014 = = = = = = = = = = = = = = = =

S W V e r s i o n
T S 1 7 1 X X

D a t e :
X X - X X - X X X X

C o n f i g u r a t i o n
5 1 X X C P R O F I L I N E

[ E ] E x i t

Fig. 433

20-116
Calibrations and electronic
diagnosis
Test Menu
l 1 – Transmission
T E S T S M E N U
l 2 – Hitch
= = = = = = = = = = = = = = = =
l 3 – PTO
l 4 – ASM
l 5 - Engine 1 - T r a n s m i s s i o n
l 6 - Distributors 2 - H i t c h
3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m

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

Fig. 434

Test -> Transmission

l [1] – Test shuttle sol.valve block
T E S T S
l [2] – Test Stop&Go indicator lamp on instrument (*)
= = = = = = = = = = = = = = = =
l [3] – Test H-M-L sol.valve
1 - S o l e n . V a l v e s
Note 2 - S t o p & G o L a m p
3 - S o l e n . V a l v . H M L
(*) = Function with Nano button

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

Fig. 435

Shuttle solenoid valve block test

l ECU power [V] T E S T S E V S
l Proportional SV test
= = = = = = = = = = = = = = = =
m [1-2-3]
S u p p 1 2 V 0 0 . 0 0 V
m Absorbed current [mA]
= = P r o p o r t i o n a l = =
l Reverse SV test 1 ] 0 A 2 ] 0 . 5 A 3 ] 1 A
m [4-5] C u r r e n t : 0 0 0 m A
m Absorbed current [mA] = = O n O f f R e v e r s = =
4 ] O FF O N ] 5
l Forward drive SV test C u r r e n t : 0 0 0 m A
m [7-8]
= = O n O f f F o r w r d = =
m Absorbed current [mA] 7 ] O FF O N ] 8
C u r r e n t : 0 0 0 m A
l Controls = = = = = = = = = = = = = = = =
C o n t r o l s : X - X - X
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 436

20-117
 Calibrations and electronic
diagnosis
Stop&Go indicator lamp test
l Stop&Go indicator lamp on instrument [1-2] T E S T S S T O P & G O
= = = = = = = = = = = = = = = =

= = S T O P & G O L A M P = =
1 ] O N 2 ] O F F

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

Fig. 437

H-M-L solenoid valve test

l ECU power [V]
T E S T S E V S H M L
l H SV test
= = = = = = = = = = = = = = = =
m [1-2-3]
S u p p 1 2 V 0 0 . 0 0 V
m H SV current absorption [mA]
= = = = H M L H = = = =
l M SV test 1 ] 0 A 2 ] 0 . 5 A 3 ] 1 A
m [4-5-6] C u r r e n t : 0 0 0 m A
m M SV current absorption [mA]
= = = = H M L M = = = =
l L SV test 4 ] 0 A 5 ] 0 . 5 A 6 ] 1 A
m [7-8-9] C u r r e n t : 0 0 0 m A
m L SV current absorption [mA] = = = = H M L L = = = =
7 ] 0 A 8 ] 0 . 5 A 9 ] 1 A
C u r r e n t : 0 0 0 m A

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

Fig. 438

Test -> Hitch

l [1] – Test SAC potentiometers and buttons T E S T S M E N U
l [2] – Test SAC position and draft sensors
= = = = = = = = = = = = = = = =

1 - C o n s o l e
2 - S e n s o r s

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

Fig. 439

20-118
Calibrations and electronic
diagnosis
Console
l Depth potentiometer signal [V]
C O N S O L L E
l Max height potentiometer signal [V]
= = = = = = = = = = = = = = = =
l Control mode potentiometer signal [V]
l Down speed potentiometer signal [V]
l Slippage potentiometer signal [V] S e t P o i n t g : 0 . 0 0 V
M a x H e i g h t : 0 . 0 0 V
l Buttons: Internal | External C t r l M o d e : 0 . 0 0 V
m State of up button [On-Off] D r o p S p e e d : 0 . 0 0 V
m State of down button [On-Off] S l i p a g e : : 0 . 0 0 V
m State of SAC unlock/lock button [On-Off]
I n t < - B u t t o n - > E x t
O F F U P O F F
O F F D W O F F
O F F S T O P - - -

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

Fig. 440

Sensors
l SAC position sensor
S E N S O R S
m Voltage [V], Position [%]
= = = = = = = = = = = = = = = =
l RH draft sensor P o s i t i o n
m Voltage [V], Draft [%] 0 . 0 0 V 0 0 . 0 %
l LH draft sensor R H D r a f t
m Voltage [V], Draft [%] 0 . 0 0 V 0 0 . 0 %
l Sensitivity of the draft pins [kg] L H D r a f t
0 . 0 0 V 0 0 . 0 %

D r a f t P i n S e t
P l o u g h i n g : k g 0 0 0 0
D u m p e n i n g : k g 0 0 0 0

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

Fig. 441

Tests -> PTO

l Switches: T E S T P T O
m Status of front PTO switch [On-Off]
= = = = = = = = = = = = = = = =
m Status of auto PTO switch [On-Off]
S w i t c h :
m Status of rear PTO switch [On-Off]
F r o n t : O F F
m Not used A u t . : O F F
l Status of external button PTO command [On-Off] R e a r : O F F
R a n g e : # # # # #
l Brake SV current absorption (not installed)
l Rear PTO SV current absorption [mA] E x t . S w i t c h : O F F
l Front PTO SV current absorption [mA] E V B r a k e # # # m A
l 750 SV current absorption (not installed) E V R e a r 0 m A
l 1000 SV current absorption (not installed) E V F r o n t 0 m A
E V 7 5 0 # # # m A
E V 1 0 0 0 # # # m A
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 442

20-119
 Calibrations and electronic
diagnosis
Tests -> ASM
l Differential lock button state [On-Off] A S M
l ASM button state [On-Off]
= = = = = = = = = = = = = = = =
l State of DT button [On-Off] D i f f . L o c k O F F
l Steering sensor signal [V] A S M O F F
l LH brake pedal switch state [On-Off] 4 W D O F F
l State of RH brake pedal transducer [On-Off]
l Differential SV current absorption [mA]
l DT SV current absorption [mA] S t e e r S e n s . 0 . 0 0 V
L H B r a k e O F F
R H B r a k e O F F

E V D i f f 0 m A
E V 4 W D 0 m A

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

Fig. 443

Test -> Engine

l [1] – Engine sensor values E N G I N E
l [2] – Engine ECU data
= = = = = = = = = = = = = = = =
l [3] - Values for pedal accelerator/hand throttle
l [4] – Accelerator positions and memory state S / N 0 0 0 0 0
H D S R A N 0 0
# S T A R T S 0 0 0
S U P P L Y 0 0 . 0 V

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

Fig. 444

Values measured
l Engine speed signal [RPM] E N G I N E
l Engine response to load variation [%]
= = = = = = = = = = = = = = = =
l Torque curve
l Engine coolant temperature [°C ]
l Fuel temperature [°C]
l Turbo pressure [Bar]
l Pre-heat state [On-Off] S P E E D 0 r p m

A C T P - G R A D 0 %
A C T T - M A P 1
C O O L A N T T . + 0 0 0 C
F U E L T . + 0 0 0 C
C H R G P R E S 0 . 0 0 b a r
P R E H E A T O F F
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 445

20-120
Calibrations and electronic
diagnosis
Logistical data
l Deutz-AG code of ECU E N G I N E
l Hours of usage of engine ECU
= = = = = = = = = = = = = = = =
l Number of starts
l ECU power [V] S / N 0 0 0 0 0
H D S R A N 0 0
# S T A R T S 0 0 0
S U P P L Y 0 0 . 0 V

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

Fig. 446

Accelerators
l Accelerator pedal signal [V] E N G I N E
l Accelerator pedal position [%]
= = = = = = = = = = = = = = = =
l Hand throttle signal [V]
l Hand throttle position [%] T H R P E D 0 . 0 0 V
l Power reduction state [On-Off] T H R P E D % 0 %
H A N D G A S 0 . 0 0 V
H A N D G A S % 0 %

P O W E R R E D U C E O F F

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

Fig. 447

Accelerator positions and memory state

l Hand throttle position value [0 to 1,000] E N G I N E C O N T R O L
l Accelerator pedal position value [0 to 1,000]
= = = = = = = = = = = = = = = =
l State of memory button [On-Off]
l Memory 2 button state [On-Off] H a n d G a s 0
T h r o t t l e 0
H o l d B u t t o n O F F
H o l d B u t t o n 2 O F F

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

Fig. 448

20-121
 Calibrations and electronic
diagnosis
20.2.8 - HLHP2 ECU diagnostics (TS171AC) - “Alarms”/Alarms screens for ART/PC Tes-
ter
The passive and active alarms relative to the components listed may be viewed from this menu.
The alarm list may also be deleted for some of these components.
Note
The Serdia 2010 diagnostic tool must be used to delete engine alarms!

Structure of the “Alarms”/Alarms screens

The structure of the “Alarms”/Alarms screens is shown in the figure.

20-122
Calibrations and electronic
diagnosis

4 - Alarms

1 - HLHP+Engine

1 - Active HLHP
2 - Passive HLHP
3 - Deletion

1 - TCU
2 - Engine

4 - Active Engine
5 - Passive Engine

2 - Distributors

1 - Active
2 - Passive
3 - Erase All

3 - Air Conditioned

1 - Active
2 - Passive
3 - Erase All

Fig. 449

20-123
 Calibrations and electronic
diagnosis
Introductory screen
The moment the tester is connected, the machine introductory screen will appear.
A L L D I S T R I B U T O R
l Software versions: TS171AC A L A R M S E R A S E
l Software release date: 13/05/2014

D I S T 1 :
D I S T 2 :
D I S T 3 :
D I S T 4 :
D I S T 5 :
D I S T 6 :

[ C ] E r a s e
[ E ] E x i t

Fig. 450

Alarms menu
l 1 - HLHP alarms + Engine alarms A L A R M S
l 2 - Distributor alarms
= = = = = = = = = = = = = = = =
l 3 - Air conditioner alarms
1 - H L H P + E n g i n e
2 - D i s t r i b u t o r s
3 - A i r C o n d i t i o n e d

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

Fig. 451

Alarms -> HLHP + Engine alarms

l [1] – View active HLHP alarms
A L A R M S M E N U
l [2] – View passive HLHP alarms
= = = = = = = = = = = = = = = =
l [3] – Clear alarms
l [4] – View active engine alarms 1 - A c t i v e H L H P
l [5] – View passive engine alarms 2 - P a s s i v e H L H P
3 - D e l e t i o n
4 - A c t i v e E n g i n e
5 - P a s s i v e E n g i n e

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

Fig. 452

20-124
Calibrations and electronic
diagnosis
HLHP active
l # = Alarm code - - - - - A L A R M S - - - - -
l SPN = Component in alarm state
= = = = = = = = = = = = = = = =
l FMI = Cause of alarm
l Ctn = Alarm count # S P N f m i c n t

= = = = = = = = = = = = = = = =
[ F ] P a g + [ E ] E x i t

Fig. 453

Passive HLHP
l # = Alarm code - - - - - A L A R M S - - - - -
l SPN = Component in alarm state
= = = = = = = = = = = = = = = =
l FMI = Cause of alarm
l Ctn = Alarm count # S P N f m i c n t

T 9 5 5 6 1 1 3 1
T 1 0 5 5 6 0 1 3 2
T 8 1 1 2 7 2 1
T 8 5 5 1 4 0 2 7
T 1 0 3 1 6 1 2 1 8

= = = = = = = = = = = = = = = =
[ F ] P a g + [ E ] E x i t

Fig. 454

Alarm cancellation
l [1] = ECU D e l e t e A l a r m s
l [2] = Engine
= = = = = = = = = = = = = = = =

1 - T C U
2 - E n g i n e

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

Fig. 455

20-125
 Calibrations and electronic
diagnosis
Press [1] or [2] to cancel the ECU or engine alarms
D e l e t e A l a r m s
= = = = = = = = = = = = = = = =

T h e a l a r m s
h a v e b e e n
d e l e t e d .

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

Fig. 456

Alarms -> Distributors

l [1] – View active distributor alarms = D I S T R I B U T O R S =
l [2] – View passive distributor alarms = = = = A L A R M S = = = = =
l [3] – Cancel distributor alarms = = = = = = = = = = = = = = = =

1 - A c t i v e
2 - P a s s i v e
3 - E r a s e A l l

[ E ] E x i t

Fig. 457

Active - Active Distributor alarms

l SPN = Component in alarm state - - - - - A L A R M S - - - - -
l FMI = Cause of alarm
= = = = = = = = = = = = = = = =
l Ctn = Alarm count
# S P N f m i c n t

= = = = = = = = = = = = = = = =
[ F ] P a g + [ E ] E x i t

Fig. 458

20-126
Calibrations and electronic
diagnosis
Clear - Clearing Distributors Control Unit Alarms
l Press [C] to cancel
A L L D I S T R I B U T O R
A L A R M S E R A S E

D I S T 1 :
D I S T 2 :
D I S T 3 :
D I S T 4 :
D I S T 5 :
D I S T 6 :

[ C ] E r a s e
[ E ] E x i t

Fig. 459

20-127
 Calibrations and electronic
diagnosis
20.3 - Commissioning and calibrating the tractor
20.3.1 - Digital Instrument Calibration
Purpose
The purpose of the following assembly standard (p/n 939569*) is to provide the instructions for correctly calibrating the new digital
Check Panel.
Setting parameters with the ART® Diagnostic Tester / SDF Analyser.
The ART® Diagnostic Tester / SDF Analyser may be used to configure the instru- A V A I L A B L E T E S T
ment cluster to function correctly on any tractor model. = = = = = = = = = = = = = = = =
M E N U
l Tractor configuration,
l Wheels constant. 1 - C L U S T E R
Connect the tester to the diagnostics socket and turn the starter key to “power”. 2 - H L H P V I R T U S J
The main tester page will display the names of the electronic control units con-
nected to the serial line:
l Select “X - Cluster” / Cluster (CLUSTER)

C H O I S E
[ E ] E x i t
Fig. 460

The following screen appears, showing the SW version and the date: C L U S T E R
Press E = = = = = = = = = = = = = = = =
= = = = = = = = = = = = = = = =

F i r m w a r e : X X X X X X X
d d / m m / y y y y

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 461

The “Main Menu / Main Menu” screen will appear. M A I N M E N U

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

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 462

20-128
Calibrations and electronic
diagnosis
Press “2 - Calibrations / Calibrations” to enter the calibration menu. C A L I B R A T I O N M E N U
The following screen will appear. = = = = = = = = = = = = = = = =
Press “1 - Parameters” / Parameters to enter the parameter calibration menu.
1 - P a r a m e t e r s

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 463

Change machine configuration

l “Wheel” / Wheels C A L I B R A T I O N
Wheels constant setting = = = = = = = = = = = = = = = =
l “AlarmBelt” / AlarmBelt
Belt alarm setting 1 - W h e e l X X X X
l “ActiveConf” / Configuration 2 - A l a r m B e l t X X
Instrument configuration setting 3 - A c t i v e C o n f . X X
l “Vel” / Speed 4 - V e l . [ 1 = m p h ] X
Speed units of measurement setting: 5 - C l o c k [ 1 = 1 2 h ] X
m 0 = km/h 6 - M a x T e m p X X X
m 1 = mph

l “Clock” / Clock
Time display format setting:
m 0 = 24h
m 1 = 12h
= = = = = = = = = = = = = = = =
l “MaxTemp” / MaxTemp (°C) [ E ] E x i t
Max. engine coolant temperature value above which the red warning light Fig. 464
on the instrument cluster will illuminate.
Press “3 - ActiveConf” / Configuration to configure the instrument on the basis of the machine on which it is installed:
-
-
Virtus J Family (Tier 3b/4i)
WARNING
For tractors WITH HPB (Hydraulic Park Brake) !!!

Table 72
Tractor model Radical Instrument configuration
Virtus J 90-100-110 (LS) Y33-Y37-Y41 55
Virtus J 100-110-120 (GS) Y45-Y49-Y53
Nitro R 90-100-110 (LS) Y34-Y38-Y42
Nitro R 100-110-120 (GS) Y46-Y50-Y54
XM. K 90-100-110 (LS) Y35-Y39-Y43
XM. K 100-110-120 (GS) Y47-Y51-Y55
Deutz-Fahr 5090-5100-5110 C (LS) Y36-Y40-Y44
Deutz-Fahr 5100-5110-5120 C (GS) Y48-Y52-Y56
-

20-129
 Calibrations and electronic
diagnosis
WARNING
For tractors WITHOUT HPB (Hydraulic Park Brake) !!!

Table 73
Tractor model Radical Instrument configuration
Virtus J 90-100-110 (LS) Y33-Y37-Y41 56
Virtus J 100-110-120 (GS) Y45-Y49-Y53
Nitro R 90-100-110 (LS) Y34-Y38-Y42
Nitro R 100-110-120 (GS) Y46-Y50-Y54
XM. K 90-100-110 (LS) Y35-Y39-Y43
XM. K 100-110-120 (GS) Y47-Y51-Y55
Deutz-Fahr 5090-5100-5110 C (LS) Y36-Y40-Y44
Deutz-Fahr 5100-5110-5120 C (GS) Y48-Y52-Y56
-
-
On the next screen, enter the configuration number for the machine on which the 3 - A C T I V E C O N F I G .
instrument panel is installed: = = = = = = = = = = = = = = = =
Press “E” to exit, then press “C” to confirm and save the configuration.

A c t u a l : X X

N e w : Y Y

= = = = = = = = = = = = = = = =
[ D ] E r a s e
[ E ] E x i t
Fig. 465

Edit or Input wheels constant

Return to the “Calibration” menu. C A L I B R A T I O N
Press “1 - Wheels” / Wheels = = = = = = = = = = = = = = = =

1 - W h e e l X X X X
2 - A l a r m B e l t X X
3 - A c t i v e C o n f . X X
4 - V e l . [ 1 = m p h ] X
5 - C l o c k [ 1 = 1 2 h ] X
6 - M a x T e m p X X X

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 466

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Calibrations and electronic
diagnosis
Enter the constant on the basis of the table shown. 1 - W H E E L
Press “E” to exit, then press “C” to confirm and save the configuration. = = = = = = = = = = = = = = = =

A c t u a l : X X X X

N e w : Y Y Y Y

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 467

Wheels constants
The wheels constant parameter to be entered in the instrument must represent the pulses for 25m generated by the speed measu-
rement sensor.
See para. 20.3.2 - Wheels constants - page 20-132
Changing the km/h - mph Parameter
Return to the “Calibration” menu. C A L I B R A T I O N
Press “4 - Vel” to enter the km/h or mph/h selection menu = = = = = = = = = = = = = = = =
To display the speed in mph press (1) or press (0) to display the speed in km/h.
Press “E” to exit, then press “C” to confirm and save the configuration. 1 - W h e e l X X X X
2 - A l a r m B e l t X X
3 - A c t i v e C o n f . X X
4 - V e l . [ 1 = m p h ] X
5 - C l o c k [ 1 = 1 2 h ] X
6 - M a x T e m p X X X

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 468

Setting parameters with the control buttons

The two buttons on the instrument panel are used set certain operating parameters and to select the various display functions.
Table 74
Description Abbreviation
Hour meter display button (high position) PD_H
Multifunction display button (low position) PD_L
Parameter Setting
Press buttons PD_H and PD_L simultaneously and hold them for more than 2 seconds to enter parameter setting mode. The first
parameter that can be set by pressing the buttons is the clock.
Press button PD_L briefly to increase the hours setting one unit at a time (if the hours digit is flashing) or the minutes setting (if the
minutes digit is flashing). The setting procedure always starts with the hours by default.
Press the PD_H button briefly to change the digit being edited, from hours to minutes or from minutes to hours.
A prolonged press of the PD_H button serves to save the new time and change the parameter being edited, from the time to the wheel
constant. If, however, no buttons are pressed for 10 seconds, the system will quit parameter setting mode without saving any of the
changes made to the clock. When the new time has been saved or when the system times out and therefore quits programming, the
display stops flashing.

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 Calibrations and electronic
diagnosis
Likewise, brief presses of PD_L increase the digit being edited, while brief presses of PD_H serve to change the parameter subject
to editing (relative to the size of the tyres).
Press and hold button PD_H to save the new tyre size and change to the next editable parameter: in this case, indicator lamp
brightness. If, however, no buttons are pressed for 10 seconds the system will quit parameter setting mode without saving any of the
changes made to the tyre size (although the changes made to the time setting will be saved).
Likewise, short presses of PD_L increase the digit being edited, which flashes at 1Hz (relative to the indicator lamp brightness).
Check that the message LUM appears on the LCD3 followed by a flashing letter, which can be H, M, or L corresponding to the three
brightness levels: High, Medium, and Low.
A prolonged press of PD_H serves to save the indicator lights brightness parameter and quit parameter setting mode. If, however,
no buttons are pressed for 10 seconds the system will quit parameter setting mode without saving the change made to the indicator
lights brightness setting (although changes made to the time and tyre size settings will be saved).
PD_H button
A brief press of the PD_H button makes it possible to change the information shown on the second line of the central display. When
the on-board panel is switched on, the total hour meter is displayed.
A short press of PD_H shows the metres counter (if available), while a second short press causes the display to return to the total
hours meter, and so forth. During display of the metres counter, a prolonged press of PD_H serves to reset the total. The total hour
meter cannot be reset. At each press (short or prolonged) of the button the buzzer emits a tone.
PD_L button
A prolonged press of PD_L resets the partial hour meter. At each press (short or prolonged) of the button the buzzer emits a tone
(different from the tone associated with PD_H).
20.3.2 - Wheels constants
The wheels constant parameter entered in the cluster is the number of pulses generated by the speed sensor over a distance of 25 m.
Table 75
Tyres Radius index Wheel constant
T -4350 T -5300
420/85R30” 695 6,355 4,976
480/70R30” 695 6,355 4,976
480/70R34” 745 5,928 4,642
420/85R34” 745 5,928 4,642
540/65R34” 745 5,928 4,642
460/85R34” 770 5,736 4,491
460/85R34” 770 5,736 4,491
520/70R34” 770 5,736 4,491
520/70R34” 770 5,736 4,491
600/65R34” 770 5,736 4,491
340/85R38” 740 5,968 4,673
420/85R38” 795 5,556 4,350
480/70R38” 795 5,556 4,350
540/65R38” 795 5,556 4,350
420/85R34” 745 5,928 4,642
340/85R38” 740 5,968 4,673
480/70R34” 740 5,928 4,642
460/85R34” 770 5,736 4,491
420/85R38” 795 5,556 4,350

20.3.3 - Commissioning (939571) - Basic procedure

The steps of the commissioning activation procedure are as follows:
1. Shut off the engine, put the main gearbox and range gearbox in neutral.
2. Connect the SAME ART®/SDF Analyser to the diagnostic socket.
3. Turn the ignition switch to “ON”.

20-132
Calibrations and electronic
diagnosis
4. Select ECU:
A V A I L A B L E T E S T S
“HLHP MAIN” = = = = = = = = = = = = = = = =
M E N U
from the list of connected ECUs.

1 - H L H P M A I N

= = = = = = = = = = = = = = = =
C h o i c e _

Fig. 469

5. In the introductory screen for the shuttle ECU, press [0] twice to display the
= = = = = = = = = = = = = = = =
prompt for password to the re-initialisation menu. = = = = H L H P = = = =
= = = = = = = = = = = = = = = =

S W V E R S I O N
T S 1 7 1 A *

D A T E :
0 0 / 0 0 / 0 0 0 0

C O N F I G U R A T I O N
5 1 * * C P R O F I L I N E

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

Fig. 470

6. A password prompt will appear.

= = = = = = = = = = = = = = = =
To activate: 123456 = = = = = = = = = = = = = = = =

P a s s w o r d : 1 2 3 4 5 6

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

Fig. 471

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 Calibrations and electronic
diagnosis
7. On entering the password, the introductory screen will re-appear. Press [E] to
M A I N M E N U
enter the main menu. If the password is entered correctly, the option “C-Initialit.” /
= = = = = = = = = = = = = = = =
C-Initialize (normally hidden) will be displayed.
1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

C - I n i t i a l i t .

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

Fig. 472

8. Press [C] to activate the machine commissioning procedure. The SAME ART®/
H I D D E N M E N U
SDF Analyser displays the following screen:
= = = = = = = = = = = = = = = =
“1-Initialit.” / Initialisation
1 - I n i t i a l i t .
2 - H i d d e n M e n u
“2-Hidden Menu” / Hidden menu

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

Fig. 473

9. Press [1] to enter the commissioning procedure.

I N I T I A L I S A T I O N
= = = = = = = = = = = = = = = =

C O M M I S S I O N I N G
O F T H E
T R A C T O R

= = = = = = = = = = = = = =
1 - E E P R O M R e I n i t .
2 - E n d L i n e P r g .

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

Fig. 474

10. If necessary, perform the EEPROM reinitialisation procedure described in the following paragraphs:
Table 76
i. 20-135
II. See para. 20.3.5 - Commissioning (939571)... - page 20-135

20-134
Calibrations and electronic
diagnosis
20.3.4 - Commissioning (939571) - Eeprom re-initialisation
1. After selecting [1] in the previous screen, a warning message is displayed.
E E P R O M R E I N I T .
Note = = = = = = = = = = = = = = = =

If you continue with the procedure, the Eeprom will be re- ! ! W A R N I N G ! !

initialised and the parameter values in memory will be over- M E M O R Y W I L L B E
written with the default values. C O M P L E T E L Y
R E P R O G R A M M E D
Press [E] to cancel or [C] to continue with the re-initialisation procedure.
= = = = = = = = = = = = = = = =

P R E S S [ C ]
T O C O N T I N U E

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

Fig. 475
2. Wait. On termination of the re-initialisation procedure the following mes-
E E P R O M R E I N I T .
sage is displayed.
= = = = = = = = = = = = = = = =

M E M O R Y
R E P R O G R A M M E D
S U C C E S S F U L L Y

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

Fig. 476
3. Eeprom re-initialisation in now complete. Switch the machine off and on again to continue.

20.3.5 - Commissioning (939571) - Line end programming of the tractor

1. The end-of-line programming procedure consists of following steps:
m Configuration of the Family
m Configuration of the model
m Shuttle pedal calibration (for GS only)
m Option selection

2. To carry out end-of-line tractor programming, if necessary, repeat steps 1

I N I T I A L I S A T I O N
to 8 of paragraph
= = = = = = = = = = = = = = = =
See para. 20.3.3 - Commissioning (939571)... - page 20-132
C O M M I S S I O N I N G
O F T H E
T R A C T O R

= = = = = = = = = = = = = =
1 - E E P R O M R e I n i t .
2 - E n d L i n e P r g .

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

Fig. 477

20-135
 Calibrations and electronic
diagnosis
3. Press [2] to activate the end-of-line tractor programming procedure. A warning message will be displayed.
DANGER
Once the procedure has been started, the transmission will remain in neutral and it will not be possible to use
the tractor until all the steps in the commissioning procedure have been completed.
In particular, if the machine is switched off before the procedure has terminated, when the tractor is next switched on an alarm
message will appear indicating that the re-initialisation has not been completed and therefore it will be necessary to repeat
the commissioning procedure.
4. Press [C] to activate the line end programming procedure.
W A R N I N G
= = = = = = = = = = = = = = = =

T R A C T O R W O N T B E
U S A B L E U N T I L L
T H E E N D O F T H E
P R O C E D U R E

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

P R E S S [ C ]
T O C O N T I N U E

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

Fig. 478
5. As soon as line end programming is activated, the family configuration page appears on the ART.
6. Press [1] to select the family.
F A M I L Y C O N F I G .
= = = = = = = = = = = = = = = =
1 - F A M I L Y T Y P E : 0

1 - S A M E
2 - D E U T Z - F A H R

= = = = = = = = = = = = = = = =
[ C ] C o n f i r m

Fig. 479
7. Press [1] to select the SAME family (or press [2] to select DEUTZ/LAMBO-
F A M I L Y T Y P E
RGHINI), then press [C] to confirm.
= = = = = = = = = = = = = = = =
F A M I L Y

1 - S A M E
2 - D E U T Z - F A H R /
L A M B O R G H I N I

= = = = = = = = = = = = = = = =
[ C ] C o n f i r m

Fig. 480
8. After the selection is confirmed, the family configuration screen is displayed, with option [1] selected (SAME).

20-136
Calibrations and electronic
diagnosis
9. Press [E] to continue configuration.
F A M I L Y C O N F I G .
= = = = = = = = = = = = = = = =
1 - F A M I L Y T Y P E : 1

1 - S A M E
2 - D E U T Z - F A H R

= = = = = = = = = = = = = = = =
[ C ] C o n f i rm

Fig. 481
10. The tractor model must now be configured
11. Press [1] to select the tractor model.
V E H I C L E M O D E L
= = = = = = = = = = = = = = = =
1 - M o d e l 0

1 - V i r t u s J 9 0
2 - V i r t u s J 1 0 0
3 - V i r t u s J 1 0 0 P
4 - V i r t u s J 1 1 0
5 - V i r t u s J 1 1 0 P
6 - V i r t u s J 1 2 0 P

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

Fig. 482
12. Select the model (in this example VIRTUS J 100 P, by pressing [3]), and
V E H I C L E M O D E L
press [C] to confirm.
= = = = = = = = = = = = = = = =
S A M E

1 - V i r t u s J 9 0
2 - V i r t u s J 1 0 0
3 - V i r t u s J 1 0 0 P
4 - V i r t u s J 1 1 0
5 - V i r t u s J 1 1 0 P
6 - V i r t u s J 1 2 0 P

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

Fig. 483
13. After the selection is confirmed, the model configuration screen is displayed, with option [3] selected (VIRTUS J 100 P).

20-137
 Calibrations and electronic
diagnosis
14. Press [E] to end model configuration.
V E H I C L E M O D E L
= = = = = = = = = = = = = = = =
1 - M o d e l 3

1 - V i r t u s J 9 0
2 - V i r t u s J 1 0 0
3 - V i r t u s J 1 0 0 P
4 - V i r t u s J 1 1 0
5 - V i r t u s J 1 1 0 P
6 - V i r t u s J 1 2 0 P

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

Fig. 484
15. Restart the machine to continue configuration.
W A R N I N G
= = = = = = = = = = = = = = = =

M O D E L S E L E C T I O N
S U C C E S S F U L L Y
C O M P L E T E D
= = = = = = = = = = = = = =

R E - S T A R T U P
T H E T R A C T O R

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

Fig. 485

20-138
Calibrations and electronic
diagnosis
20.3.6 - Commissioning (939571) -Accelerators calibration (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001)
1. The calibration screens for the throttles will appear after repeating the configuration steps indicated in paragraphs:
See para. 20.3.3 - Commissioning (939571)... - page 20-132
See para. 20.3.5 - Commissioning (939571)... - page 20-135
2. Release the accelerator pedal and press [C].
P E D A L C A L I B R .
= = = = = = = = = = = = = = = =

R e l e a s e
a c c e l e r a t o r
p e d a l t o m i n a n d
t h e n p r e s s [ C ]

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

Fig. 486
3. If calibration of the pedal released position is terminated successfully, the
P E D A L C A L I B R .
screen for calibration of the pedal pressed position appears.
= = = = = = = = = = = = = = = =
Here too, follow the on-screen instructions and press [C] after pressing the
pedal.
P r e s s
a c c e l e r a t o r
p e d a l t o m a x a n d
t h e n p r e s s [ C ]

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

Fig. 487
4. If the calibration was not completed successfully, the following error screen
C A L I B R A T I O N
is displayed:
= = P e d a l a c c e l = =

E r r o r i n
c a l i b r a t i o n
p r o c e d u r e

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

Fig. 488
5. Press [E] to confirm.
6. The machine must now be restarted to continue with the configuration procedure.
7. Now repeat the steps described in paragraphs
See para. 20.3.3 - Commissioning (939571)... - page 20-132
See para. 20.3.5 - Commissioning (939571)... - page 20-135

20-139
 Calibrations and electronic
diagnosis
8. The next step is to calibrate the hand throttle.
9. Follow the on-screen instructions and press [C] to confirm, after pulling the
H A N D G A S C A L I B R .
lever back.
= = P e d a l a c c e l = =

P u l l h a n d g a s
t o mi n a n d
t h e n
p r e s s [ C ]

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

Fig. 489
10. Then push the lever forward to the travel limit and press [C] to confirm.
H A N D G A S C A L I B R .
= = P e d a l a c c e l = =

P u s h h a n d g a s
t o ma x a n d
t h e n
p r e s s [ C ]

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

Fig. 490
11. Continue with the tractor commissioning procedure, following the instructions given.
See para. 20.3.9 - Commissioning (939571)... - page 20-144

20-140
Calibrations and electronic
diagnosis
20.3.7 - Commissioning (939571) - Accelerators calibration (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
1. The calibration screens for the throttles will appear after repeating the configuration steps indicated in paragraphs:
Table 77

i. 20-132
II. See para. 20.3.5 - Commissioning (939571)... - page 20-135
2. Release the accelerator pedal and press [C].
P E D A L C A L I B R .
= = = = = = = = = = = = = = = =

R e l e a s e
a c c e l e r a t o r
p e d a l t o m i n a n d
t h e n p r e s s [ C ]

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

Fig. 491
3. If calibration of the pedal released position is terminated successfully, the
P E D A L C A L I B R .
screen for calibration of the pedal pressed position appears.
= = = = = = = = = = = = = = = =
Here too, follow the on-screen instructions and press [C] after pressing the
pedal.
P r e s s
a c c e l e r a t o r
p e d a l t o m a x a n d
t h e n p r e s s [ C ]

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

Fig. 492
4. If the calibration was not completed successfully, the following error screen
C A L I B R A T I O N
is displayed:
= = P e d a l a c c e l = =

E r r o r i n
c a l i b r a t i o n
p r o c e d u r e

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

Fig. 493
5. Press [E] to confirm.
6. The machine must now be restarted to continue with the configuration procedure.

20-141
 Calibrations and electronic
diagnosis
7. Now repeat the steps described in paragraphs:
Table 78

i. 20-132
II. See para. 20.3.5 - Commissioning (939571)... - page 20-135
8. The next step is to calibrate the hand throttle.
9. Follow the on-screen instructions and press [C] to confirm, after pulling the
H A N D G A S C A L I B R .
lever back.
= = P e d a l a c c e l = =

P u l l h a n d g a s
t o mi n a n d
t h e n
p r e s s [ C ]

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

Fig. 494
10. Then push the lever forward to the travel limit and press [C] to confirm.
H A N D G A S C A L I B R .
= = P e d a l a c c e l = =

P u s h h a n d g a s
t o ma x a n d
t h e n
p r e s s [ C ]

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

Fig. 495
11. Continue with the tractor commissioning procedure, following the instructions given.
Table 79

i. See para. 20.3.8 - Commissioning (939571)... - page 20-143

20-142
Calibrations and electronic
diagnosis
20.3.8 - Commissioning (939571) - Clutch pedal calibration (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
1. Important C L U T C H P E D A L
The next step is applicable only for GS transmissions with = = = = = = = = = = = = = = = =
hydraulic reverse shuttle (Virtus J Profiline models), and - P r e s s t h e p e d a l
a l l t h e w a y
consists in calibrating the clutch pedal. - P R E S S [ B ]
- R e l e a s e i t
- P R E S S [ A ]

S w i t c h C l u t c h O F F

M i n . P o s . 1 . 6 5 4
C u r r e n t 1 . 6 4 6
M a x . P o s . 3 . 3 7 0
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 496
2. Fully depress the clutch pedal and press [B]. The “Max.Pos.” value is set to the “Actual” value.
3. If the pedal switch is not pressed when the operator presses [B], the cali-
C L U T C H P E D A L
bration is refused and the following message is displayed:
= = = = = = = = = = = = = = = =
- P r e s s t h e p e d a l
a l l t h e w a y
- P R E S S [ B ]
- R e l e a s e i t
- P R E S S [ A ]

S w i t c h C l u t c h O F F
E r r o r : S w i t c h O F F
[ B ] I g n o r e E r r o r

M i n . P o s . 1 . 5 0 4
C u r r e n t 1 . 5 0 2
M a x . P o s . 4 . 0 6 9
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 497
4. Check that the pedal is fitted correctly.
5. Even if this error message appears, it will still be possible to calibrate the clutch pedal. In this case it will possible to drive the
machine, but the alarm will remain active.
6. Press [B] a second time to proceed with the calibration, even though the switch is not pressed.
7. Fully release the pedal and press [A]. The “Min.Pos.” value is set to the “Actual” value.
8. If the pedal switch is depressed when the operator presses [A], the calibra-
C L U T C H P E D A L
tion is rejected and the following message is displayed:
= = = = = = = = = = = = = = = =
- P r e s s t h e p e d a l
a l l t h e w a y
- P R E S S [ B ]
- R e l e a s e i t
- P R E S S [ A ]

S w i t c h C l u t c h O N
E r r o r : S w i t c h O N
[ A ] I g n o r e E r r o r

M i n . P o s . 1 . 5 0 4
C u r r e n t 1 . 5 0 2
M a x . P o s . 4 . 0 6 9
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 498
9. Check that the pedal is fitted correctly.

20-143
 Calibrations and electronic
diagnosis
10. Even if this error message appears, it will still be possible to calibrate the clutch pedal. In this case it will possible to drive the
machine, but the alarm will remain active.
11. Press [A] a second time to proceed with the calibration, even though the switch is pressed.
12. Press [E] to continue with the tractor commissioning procedure, following the instructions given.
See para. 20.3.9 - Commissioning (939571)... - page 20-144

20.3.9 - Commissioning (939571) - Options selection

1. Important
This step is the commissioning procedure is applicable to all transmissions.

2. The options page will appear. Here too, the software automatically identi-
O P T I O N S
fies the optional equipment installed on the tractor. To make changes, press
= = = = = = = = = = = = = = = =
the button corresponding to the option you wish to edit.
1 - M a x S p e e d 2
2 - F r o n t P T O 0
3 - 4 W D 1
4 - I S O 1 1 7 8 6 0
5 - 6 0 L t . E C O 0
6 - S D D 0
7 - H M L / H i L o 0

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

Fig. 499
3. Description of system options:
Table 80

OPTION DESCRIPTION
Speed Max Sets maximum vehicle speed in Km/h (Default 40Km/h = 2)
Front PTO Enable the front PTO function (Default option disabled=0)
4 WD Enable the 4WD function (Default option enabled=1)
ISO 11786 Enable the ISO11786 function (Default option enabled=0)
60l. / ECO Enable the ECO 60Lt function (Default option enabled=0)
SDD Enable the SDD function (Default option enabled=0)
Hml/HiLo Enables HML or HiLo function (default setting: 1, neither; oth-
erwise set 2 for HML or 3 for Hi-Lo)
4. Press [E] to terminate the commissioning procedure.
W A R N I N G
= = = = = = = = = = = = = = = =

C O M M I S S I O N I N G
O F T H E T R A C T O R
S U C C E S S F U L L Y
C O M P L E T E D

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

Fig. 500
5. Press [E] to return to the main menu. Turn the starter key to OFF and then back to ON. The commissioning procedure is now
complete.

20-144
Calibrations and electronic
diagnosis
20.3.10 - Commissioning (939571) - Hicth calibration
1. To start hitch calibration, select “2-Calibrations” from the main menu:
M A I N M E N U
= = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

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

Fig. 501
2. From the main calibration menu, select “2-Hitch”. The following screen is
C A L I B R A T I O N S
displayed:
= = = = = = = = = = = = = = = =
1 - T r a n s m i s s i o n
2 - H i t c h
3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m
7 - S D D

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

Fig. 502
3. The following screen is displayed on the ART® tool:
P A R A M E T E R S M E N U
= = = = = = = = = = = = = = = =

1 - O p t i o n s
2 - C a l i b r a t i o n s

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

Fig. 503

20-145
 Calibrations and electronic
diagnosis
4. Select “2-Calibrations”. The following screen is displayed:
S E T T I N G S M E N U
= = = = = = = = = = = = = = = =

1 - M i n H e i g h t 0 . 9 8
2 - M a x H e i g h t 4 . 3 4
3 - L o c k S p e e d 2 0

- M a n u a l C o n t r o l -

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

Fig. 504
5. Unlock the hitch, select [1] and calibrate the lowest position, then select [2]
O P T I O N S
and calibrate the highest position.
= = = = = = = = = = = = = = = =
Now set whether the supplementary cylinder is present or absent by press-
ing [6] from the Options menu, and set if the Radar function is present or 1 - A u t o D r o p 1
2 - S e n s i t i v . 2 5 5
absent by pressing [8] in the same menu.
4 - M I X m o d e 1
5 - C o n s o l e 1
6 - O p t . C y l i n d e r 1
7 - D r a f t S e n s . 6 6
8 - R a d a r E n a b l e 0
9 - R a d a r K 1 3 0
A - A . D . S p e e d 3
B - B u z z e r 3
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 505

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Calibrations and electronic
diagnosis
20.3.11 - Commissioning (939571) - Steering sensor calibration (SDD) (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
1. If the tractor is equipped with the following option:
m SDD

the steering angle (wheel angle) sensor must be calibrated.

2. Proceed as follows:
3. From the main menu, select “2-Calibrations”.
M A I N M E N U
= = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

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

Fig. 506
4. Select “4-ASM” (or “7-SDD”)
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - T r a n s m i s s i o n
2 - H i t c h
3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m
7 - S D D

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

Fig. 507
5. Select “7-Cal. Steering” and steer the wheels straight ahead (preferably
A S M
with the engine running)
= = = = = = = = = = = = = = = =

1 - E n a b l e 0
2 - D T / S t e e r 6 0
3 - D i f / S t e e r 1 5
4 - D T / S p e e d 1 5
5 - D i f / S p e e d 1 3

7 - S t e e r C a l . 2 . 7 8
8 - A S M o n H i t c h 0

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

Fig. 508

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 Calibrations and electronic
diagnosis
6. When the wheels are steered exactly in the straight ahead position, press
7 - S t e e r C a l .
[E] then [C] to confirm.
= = = = = = = = = = = = = = = =

C u r r e n t : 2 . 7 8

N e w : 2 . 2 8

= = = = = = = = = = = = = = = =
[ D ] E r a s e
[ E ] E x i t

Fig. 509

20.3.12 - Transmission calibration (939570) - Calibration of the shuttle clutches (5100 C ->
ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
When to calibrate the shuttle clutches
Calibration of the shuttle clutches is one of the final stages of the tractor production process and is therefore performed at least once
before the tractor leaves the factory.
There are three levels of calibration, which are summarised briefly here below and described in more detail in the subsequent para-
graphs:
l Automatic calibration: the simplest, fully automated level, which ensures good all-round shuttle performance.
l Manual calibration: to be carried out by an experienced technician only, allowing fine adjustment of operating parameters to
improve the level of performance obtained by automatic calibration alone.
l Adjustment of comfort parameters: allows the experienced user to adjust the behaviour of the tractor, the comfort settings and
speed at which manoeuvres are performed to suit personal requirements.
The situations during the tractor’s service life in which the shuttle clutch should be calibrated are as follows:
l At the end of the production line, after configuration of the transmission control unit.
See para. 20.3.3 - Commissioning (939571)... - page 20-132
l Each time alarm T10 “Shuttle clutches not calibrated” is generated.
l After replacement of the HLHP Main control unit by the Technical Assistance service. In this case calibration must be preceded
by re-initialisation.
See para. 20.3.3 - Commissioning (939571)... - page 20-132
l If the tractor responds differently depending on whether forward or reverse drive is engaged.
l If tractor behaves irregularly when moving off from stationary, inverting the direction of travel or changing gear without use of
the clutch pedal.
l Following partial or total replacement of the mechanical shuttle clutch assembly.
l In the event of replacement of the Proportional Solenoid Valve of the shuttle hydraulic system.
Before starting shuttle calibration, ensure that the following conditions are met:
l Gear engaged: Second gear, Fast Range, M (if tractor is equipped with HML)
l Engine rotation speed at 1500 RPM (this is set automatically by the tractor)
l Transmission oil temperature above 35°C.
l Tractor parked on level ground, free from obstacles
l Clear space of at least 5m in front and behind the machine.
Depending on the situation, it may not be necessary to perform all three calibration levels. The following table suggests the most
suitable measures for solving possible problems encountered during use:
Table 81
Automatic calibration Manual calibration Editing comfort param-
eters
End of line calibration at Trevi- X
glio
Alarm T10 X
Renewal of control unit X

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Calibrations and electronic
diagnosis
Automatic calibration Manual calibration Editing comfort param-
eters
Renewal of mechanical/hydrau- X
lic shuttle assembly
Replacement of shuttle propor- X
tional valve
Asymmetric behaviour (one X
good clutch, one poor clutch)
Irregular behaviour (both clutch- X
es too sharp or too slow)
Customisation of shuttle behav- X
iour
Instruments and information required for calibration
These operations may only be performed with the ALL_ROUND_TESTER® (henceforth ART®), used by an operator with an under-
standing of its general operating principles.
Initial steps for calibration
1. The steps common to the various calibration procedures are as follows:
A V A I L A B L E T E S T S
m Connect the ART® to the diagnostic socket = = = = = = = = = = = = = = = =
m Start the engine. M E N U
m Select HLHP Virtus J (if working with a SAME tractor) from the list
of connected ECUs.
1 - H L H P M A I N

= = = = = = = = = = = = = = = =
C h o i c e _

Fig. 510
2. From the introductory screen of the ECU, press [E] to access the main
= = = = = = = = = = = = = = = =
menu (in the example given here, a Virtus J 100 PROFILINE is selected) = = = = H L H P = = = =
= = = = = = = = = = = = = = = =

S W V E R S I O N
T S 1 7 1 A *

D A T E :
0 0 / 0 0 / 0 0 0 0

C O N F I G U R A T I O N
5 1 * * C P R O F I L I N E

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

Fig. 511

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 Calibrations and electronic
diagnosis
3. From the main menu press “2-Calibrations”
M A I N M E N U
= = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

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

Fig. 512
4. From the calibrations main menu press “1-Transmission”.
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - T r a n s m i s s i o n
2 - H i t c h
3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m
7 - S D D

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

Fig. 513
5. The ART® displays the main calibration menu.
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - P e d a l
2 - R e v e r s e r
3 - S t o p & G o
4 - H M L

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

Fig. 514

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Calibrations and electronic
diagnosis
Procedure for calibrating the shuttle clutches
1. From the main calibration menu, press “2-Shuttle”. In this submenu you can
C A L I B . R E V E R S E R
choose whether to perform the automatic or the manual clutch calibration
= = = = = = = = = = = = = = = =
procedure. 1 - A u t o m a t i c
2 - M a n u a l
3 - C o m f o r t P a r a m .

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

Fig. 515

Description of the automatic calibration procedure

1. Activate automatic calibration by pressing “1-Automatic”. A summary is dis-
A U T O M . C A L I B R .
played of the conditions in which the calibration must be performed. After
= = = = = = = = = = = = = = = =
having checked that all the above conditions are satisfied, press [E].
C a l i b r a t i o n
C o n d i t i o n s :
= = = = = = = = = = = = = = = =
1 ) O N L E V E L G R N D
2 ) 2 n d F a s t ( M )
3 ) O i l T . 3 5 - 4 5 C
4 ) 1 5 0 0 R P M E n g i n e
= = = = = = = = = = = = = = = =

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

Fig. 516
2. The machine system enters calibration mode and the tester displays the
following screen: = = A= U= T= O= M= . = C= A= L= I = B= R= . = =
= = = = = = = = = = = = = = = =
O i l T e m p . 4 0 C
E n g i n e R P M 1 5 0 0
= = = = F O R W A R D = = = = =
P e a k C u r r n t 0
S t . e n d c r n t 0
C o r r e c t i o n 0

= = = = R E V E R S E = = = = =
P e a k C u r r n t 0
S t . e n d c r n t 0
C o r r e c t i o n 0

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

Fig. 517
3. The machine is now ready to receive the command to start calibration.
4. Move the shuttle lever in the direction corresponding to the clutch to be calibrated to activate the automatic procedure.
5. At this point the system executes a pressure ramp, until the machine moves slightly and then performs a series of clutch fill
operations. The operator will first perceive a slight movement of the machine followed by a series of movements of variable
duration and speed (but never exceeding two seconds in duration and never at speeds over 2km/h).

20-151
 Calibrations and electronic
diagnosis
6. The automatic calibration procedure terminates when the ART displays the
following message in correspondence with clutch being calibrated: “CALI- = = A= U= T= O= M= . = C= A= L= I = B= R= . = =
= = = = = = = = = = = = = = = =
BRATION TERMINATED” O i l T e m p . 4 0 C
E n g i n e R P M 1 5 0 0
= = = = F O R W A R D = = = = =
P e a k C u r r n t 5 2 0
S t . e n d c r n t 4 8 0
C o r r e c t i o n 0
C a l i b r a t . E N D E D
= = = = R E V E R S E = = = = =
P e a k C u r r n t 0
S t . e n d c r n t 0
C o r r e c t i o n 0

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

Fig. 518
7. After calibrating one of the clutches, proceed in one of the following ways:
m to calibrate the second clutch: place the lever in neutral then move the lever in the direction of the clutch still to be

calibrated;
m to repeat calibration of the first clutch: place the lever in neutral again, then move the lever in the direction of the clutch

calibrated previously. In this the values obtained from the previous calibration are lost, unless the calibration was saved;
m To go to the confirmation screen: Press [E].

8. On pressing [E] on completion of the calibration procedure the confirm

C= O= N= F = I = R= M
prompt will appear:
= = = = = = = = = = = = = = = =

C - C o n f i r m
A - A b o r t

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

Fig. 519
9. Press [C] to save the calculated parameter values in the EEPROM memory, otherwise press [A] to cancel the calibration and
restore the values obtained from the last valid calibration performed. After pressing [C] to confirm, the “Shuttle response”
parameter is reset (see following paragraph - “Description of manual calibration procedure”) to its default value. In both of the
above cases you will be returned to the Calibration menu.
10. If not already in neutral, move the lever into neutral to restore normal machine operation.
11. On completion of the automatic calibration procedure it is advisable to test the machine by performing shuttle manoeuvres. If
shift behaviour is still unsatisfactory, proceed with manual calibration.

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Calibrations and electronic
diagnosis
Description of the manual calibration procedure
1. Manual calibration is only necessary when, after automatic calibration, the shuttle behaviour is irregular. More specifically,
manual calibration can correct the following problems:
m The tractor responds differently depending on whether forward or reverse drive is engaged.
m Excessively harsh (or soft) shuttle response to direction inversion command: a jolt is felt at the end of the fill phase (or

the clutch responds too slowly).

m Direction change generally too slow (or too fast):

Note
For reasons of safety, we recommend that all parameter editing operations are carried out with the machine
stationary.

Note
Once manual calibration is complete, both the parameters configured by automatic calibration and the comfort
parameters for direction inversion manoeuvres may be altered (see following paragraph - “Modifying comfort
parameters”)
2. The manual calibration procedure comprises three steps, each of which serves to correct one of three possible faults de-
scribed above. It is not necessary to carry out all these steps, just those relative to the problems encountered.
3. After each step, press [E] to terminate the calibration and then press [C] to confirm the changes or press [A] to cancel them.
4. To carry out the manual calibration proceed as follows:
M A N U A L C A L I B R .
To start manual calibration press “2-Manual” from the shuttle calibration
= = = = = = = = = = = = = = = =
menu. 1 - F / R B a l a n c e
2 - R e v . R e s p o n s e
3 - R e v . A c c e l e r a t .
4 - P e d a l B e h a v .

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

Fig. 520
5. To compensate for differences in behaviour between the forward and re-
F / R B A L A N C E
verse clutches, press “1-Fwd/Rev balance”. The following screen will ap-
= = = = = = = = = = = = = = = =
pear:

I C o n t a c t F 4 9 5
I C o n t a c t R 4 9 1

D : F w d + P r o m p t
C : F w d - P r o m p t
7 : B w d + P r o m p t
A : B w d - P r o m p t
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 521

20-153
 Calibrations and electronic
diagnosis
6. Press [D] or [C] to increase or reduce shuttle response speed when shifting from reverse to forward, or press [7] or [A] to in-
crease or reduce shuttle response speed when shifting from forward to reverse. The system automatically alters the kiss point
current values, which are displayed in the screen pages, to obtain the desired effect.
Note
The purpose of this stage of the calibration procedure is to reduce differences in behaviour between forward
and reverse drive. To perform this step in the calibration procedure, we recommend inverting direction with the
clutch pedal only slightly released, while trying to obtain the same acceleration and speed in both forward and
reverse (keep to a low speed of approx. 1km/h).
7. To adjust the responsiveness of the shuttle, press “2-Shuttle resp.“ in the Manual Calibration menu.
8. The “response” parameter regulates the characteristics of the initial stage of direction change manoeuvres, i.e. the stage im-
mediately following the command. Generally, this parameter is adjusted to eliminate “jolting” or freewheeling sensations when
the shuttle lever is operated.
9. After having made the selection on the tester, the following screen is dis-
R E V E R . R E S P O N S E
played:
= = = = = = = = = = = = = = = =

R e s p o n s e : 4 1 0

7 : M o r e P r o m p t
A : L e s s P r o m p t
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 522
10. Press [7] to increase shuttle response or [A] to reduce response.
11. Use these two keys to increase or reduce the “Response” value.
12. To adjust the speed at which the direction change manoeuvre is completed,
R E V E R . A C C E L E R .
i.e. the average acceleration rate at which the manoeuvre is performed,
= = = = = = = = = = = = = = = =
press “3-Shuttle acc.“ in the Manual Calibration menu. At this point, the
technician should evaluate the overall quality of the drive direction inver-
sion manoeuvre, changing the parameter until the performance is generally A c c e l e r a t . 7 2 0
satisfactory. The following screen appears:

7 : Q u i c k e r
A : S l o w e r
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 523
13. Press [7] for faster shuttle response, or [A] for slower shuttle response.
14. Use these two keys to increase or reduce the value “Accelerat.”.
15. To adjust the clutch pedal release height (i.e. the position in which the shuttle begins to transmit torque), press “4-Pedal re-
lease“ in the Manual Calibration menu.

20-154
Calibrations and electronic
diagnosis
16. At this point, the technician should evaluate the overall quality of the drive
P E D A L C L U T C H
direction inversion manoeuvre, changing the parameter until the perfor-
= = = = = = = = = = = = = = = =
mance is generally satisfactory. The following screen is displayed (note
that the value indicated is merely an example):

I n c h i n g P o s : + 1 5 0

7 : H i g h e r
A : L o w e r
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 524
17. Press [7] to raise the release point or press [A] to lower it.
Adjustment of comfort parameters:
1. To access the comfort parameter menu select “3-Comfort Param.” from the
C A L I B . R E V E R S E R
main calibration menu:
= = = = = = = = = = = = = = = =
1 - A u t o m a t i c
2 - M a n u a l
3 - C o m f o r t P a r a m .

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

Fig. 525
2. On selecting the comfort parameters menu, the following screen is dis-
C O M F O R T P A R A M .
played:
= = = = = = = = = = = = = = = =
= = = = = S t a r t = = = = = =
1 - R e s p o n s e 1 8 9
2 - A c c e l e r a t 3 2 0
= = = I n v e r s i o n = = = =
3 - R e s p o n s e 4 1 0
4 - A c c e l e r a t 7 2 0
= = = G e a r C h a n g e = = =
5 - R e s p o n s e 4 3 0
6 - A c c e l e r a t 6 8 0
= = = = = P e d a l = = = = = =
7 - I n c h i n P o s + 1 5 0
= = = = = = = = = = = = = = = =
[ E ] E x i t

Fig. 526
3. The parameters are divided into three possible manoeuvres and have the following meanings:
m Response: determines the initial response of the clutches in the various manoeuvres, in the stage immediately subse-

quent to the clutch fill time. It is advisable to increase the value for a faster response (to correct a sensation of delay, or
of excessive initial clutch slip), and to lower the value if the response is too sharp (sensation of initial jolt).
m Acceleration: determines the speed at which the machine performs manoeuvres. Increase the value to increase the

speed at which manoeuvres are performed.

20-155
 Calibrations and electronic
diagnosis
4. The “Pedal Release” parameter represents the position of the pedal at which the clutch starts to bites on releasing the pedal.
Note that the higher the value the higher the pedal release position.

20.3.13 - Transmission calibration (939570) - Calibrating HML clutches (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
When to calibrate the HML clutches
Calibration of the HML clutches is one of the final stages of the tractor production process and is therefore performed at least once
before the tractor leaves the factory.
There are two levels of calibration, which are summarised briefly here below and described in more detail in the subsequent para-
graphs:
l Automatic calibration: the simplest, fully automated level, which ensures good all-round HML performance.
l Manual calibration: may be performed by experienced technicians only, and allows fine-adjustment of operating parameters
to correct any functional problems resulting from automatic calibration.
The situations during the tractor’s service life in which the HML clutch should be calibrated are as follows:
l At the end of the production line, after configuration of the transmission control unit.
See para. 20.3.3 - Commissioning (939571)... - page 20-132
l Each time alarm T118 “HML clutches not calibrated” is generated.
l After replacement of the HLHP control unit by the Technical Assistance service. In this case calibration must be preceded by
re-initialisation.
See para. 20.3.3 - Commissioning (939571)... - page 20-132
l In the event of harsh tractor behaviour during HML shift manoeuvres.
l In the event of partial or total replacement of the mechanical HML clutch assembly.
l In the event of replacement of one or more Proportional Solenoid Valves of the HML hydraulic unit.
Before starting shuttle calibration, ensure that the following conditions are met:
l Gear engaged: Fifth gear, NEUTRAL range
l Engine rotation speed at 800 RPM (this is set automatically by the tractor)
l Transmission oil temperature above 35°C.
l Tractor stationary
Depending on the situation, it may not be necessary to perform both of the two calibration levels. The table below gives suggestions
as to which actions should be taken to solve the different problems that may be encountered:
Table 82
Automatic calibration Manual calibration
End of line calibration at Treviglio X
Alarm T118 X
Renewal of control unit X
Renewal of mechanical/hydraulic assem- X
bly
Replacement of one or more HML propor- X
tional valves
Harshness during certain shifts (harsh X
HML behaviour in certain shift types, such
as shifting from M to H: in this case, ad-
just the value relative to clutch H, in other
terms, the clutch towards which the shift
manoeuvre is made)
Instruments and information required for calibration
These operations may only be performed with the ALL_ROUND_TESTER® (henceforth ART®), used by an operator with an under-
standing of its general operating principles.

20-156
Calibrations and electronic
diagnosis
Initial steps for calibration
1. The steps common to the various calibration procedures are as follows:
A V A I L A B L E T E S T S
m Connect the ART® to the diagnostic socket = = = = = = = = = = = = = = = =
m Start the engine. M E N U
m Select HLHP Virtus J (if working with a SAME tractor) from the list
of connected ECUs.
1 - H L H P M A I N

= = = = = = = = = = = = = = = =
C h o i c e _

Fig. 527
2. From the introductory screen of the ECU, press [E] to access the main
= = = = = = = = = = = = = = = =
menu (in the example given here, a Virtus J 100 PROFILINE is selected) = = = = H L H P = = = =
= = = = = = = = = = = = = = = =

S W V E R S I O N
T S 1 7 1 A *

D A T E :
0 0 / 0 0 / 0 0 0 0

C O N F I G U R A T I O N
5 1 * * C P R O F I L I N E

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

Fig. 528
3. From the main menu press “2-Calibrations”
M A I N M E N U
= = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

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

Fig. 529

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 Calibrations and electronic
diagnosis
4. From the calibrations main menu press “1-Transmission”.
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - T r a n s m i s s i o n
2 - H i t c h
3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m
7 - S D D

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

Fig. 530
5. The ART® displays the main calibration menu.
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - P e d a l
2 - R e v e r s e r
3 - S t o p & G o
4 - H M L

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

Fig. 531

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Calibrations and electronic
diagnosis
Procedure for calibrating the HML clutches
1. From the main calibration menu, press “4-Hml”.
H M L C A L I B R A T .
In this submenu you can choose whether to perform the automatic or the
= = = = = = = = = = = = = = = =
manual clutch calibration procedure. 1 - A u t o m a t i c
2 - M a n u a l

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

Fig. 532

Description of the automatic calibration procedure

1. Activate automatic calibration by pressing “1-Automatic”. A summary is dis-
H M L C A L I B R A T .
played of the conditions in which the calibration must be performed. After
= = = = = = = = = = = = = = = =
having checked that all the above conditions are satisfied, press [E]. C o n d i t i o n s f o r
c a l i b r a t i o n s :
= = = = = = = = = = = = = = = =
1 ) T r a c t o r F I R M
2 ) R a n ge i n N E U T R
3 ) G e a r 5 ‘
4 ) O i l T . 3 5 - 4 5 C
= = = = = = = = = = = = = = = =

[ C ] t o s t a r t

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

Fig. 533
2. The machine system enters calibration mode and the tester displays the
H M L C A L I B R A T .
following screen:
= = = = = = = = = = = = = = = =
O i l . T e m p . + 4 0 C
= = = = = = L O W = = = = = = =
S t a t u s : N O T C A L
S t . E n d : 0 m b a r
= = = = = M E D I U M = = = = =
S t a t u s : N O T C A L
S t . E n d : 0 m b a r
= = = = = = H I G H = = = = = =
S t a t u s : N O T C A L
S t . E n d : 0 m b a r

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

Fig. 534
3. The machine is now ready to receive the command to start calibration.
4. Move the shuttle lever into the FORWARD direction to disable the automatic procedure.
5. The calibration process now executes a number of pressure ramps (one per clutch), calibrating one clutch at a time and start-
ing from LOW. The following information is displayed during the calibration of a clutch:

20-159
 Calibrations and electronic
diagnosis
6. m If the clutch has still not been calibrated, the status ‘not calibrated’ is
S t a t u s : N O T C A L
indicated and the approach end pressure remains at 0 Bar. S t . E n d : 0 m b a r

Fig. 535
7. m While the clutch is being calibrated, the status ‘calibration active’ is
S t a t u s : C A L O N
indicated for the clutch and the approach end pressure is refreshed S t . E n d : 4 7 6 5 m b a r
in real time to display the pressure requested from the clutch.
Fig. 536
8. m If an error is encountered during the calibration procedure, the pro-
S t a t u s : C A L E R R
cedure status indicates the condition and the approach end pres- S t . E n d : 8 0 0 0 m b a r
sure is the value attained before the error.
Fig. 537
9. m When the calibration procedure is complete, the procedure com-
S t a t u s : C A L O K
plete confirmation status is indicated and the approach end pres- S t . E n d : 5 8 5 0 m b a r
sure is the value determined by the procedure.
Fig. 538
10. If the calibration procedures for all three clutches are completed without errors (the status “CAL OK” is indicated for all clutch-
es), automatic calibration is ended successfully and the message “CALIB. COMPLETE” is displayed.
11. If the calibration procedure for at least one of the clutches terminated with an error, automatic calibrated is ended unsuccess-
fully and the message “CALIB. ERROR” is displayed. In this case, attempt the procedure again, ensuring that the conditions
necessary for calibration are met.
12. Once the clutch calibration procedure has ended, whether successfully or
C= O= N= F = I = R= M
unsuccessfully, move the lever into neutral or press [E] to access the save
= = = = = = = = = = = = = = = =
menu. The save menu is shown below:

C - C o n f i r m
A - A b o r t

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

Fig. 539
13. Press [C] to save the calculated parameter values in the EEPROM memory, otherwise press [A] to cancel the calibration and
restore the values obtained from the last valid calibration performed. In both of the above cases you will be returned to the
Calibration menu.
14. If not already in neutral, move the lever into neutral to restore normal machine operation.
15. Once the automatic calibration procedure has ended, preferably test the tractor, performing a number of shifts at constant
engine speed. If the shifts are still unsatisfactory, proceed with manual calibration.

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Calibrations and electronic
diagnosis
Description of the manual calibration procedure
1. Manual calibration is only necessary when, after automatic calibration, irregular behaviour is encountered in certain gear
shifts. In particular, manual calibration is used to correct excessively harsh or soft shifts.
Note
For reasons of safety, we recommend that all parameter editing operations are carried out with the machine
stationary.

2. Manual calibration is effected by modifying the approach end pressure (displayed in millibars) of each HML clutch.
3. After performing manual calibration, press [E] to end calibration then, from the confirmation menu displayed, press [C] to con-
firm the changes or press [A] to cancel.
4. To carry out the manual calibration proceed as follows:
5. To start manual calibration press “2-Manual” from the HML calibration menu
C L U T C H E S H M L
(values shown here are as an example only).
= = = = = = = = = = = = = = = =

1 - P C o n t . L 5 2 7 5
2 - P C o n t . M 4 5 7 5
3 - P C o n t . H 4 7 7 5

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

Fig. 540
6. The parameters must be modified as follows:
7. To modify the behaviour of the M > L shift, press 1. to alter the approach end pressure of clutch L.
8. To modify the behaviour of the L > M and H > M shifts, press 2. to alter the approach end pressure of clutch M.
9. To modify the behaviour of the M > H shift, press 3. to alter the approach end pressure of clutch H.
Note
The purpose of this stage of the calibration procedure is to reduce the difference in behaviour between differ-
ent shift types. This stage in the calibration procedure should be conducted with shifts performed at constant
engine speed (1,500 rpm).

20.3.14 - Transmission calibration (939570) - Calibrating the Stop&Go function (5100 C ->
ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
When to calibrate the Stop&Go function
Calibrating the Stop&Go function is NOT necessary for the SAME Virtus tractor range. Only calibrate in the event of incorrect function
behaviour. Calibration of the Stop&Go function is one of the final stages of the tractor production process and is therefore performed
at least once before the tractor leaves the factory. Calibration is only possible on machines with the Stop&Go function enabled.
The situations during the service life of the tractor service life in which the Stop&Go function should be calibrated are indicated as
follows:
l At the end of the production line, after configuration of the transmission control unit.
See para. 20.3.3 - Commissioning (939571)... - page 20-132
l Each time alarm T104 “Stop&Go not calibrated” is generated
l After replacement of the HLHP control unit by the Technical Assistance service. In this case calibration must be preceded by
re-initialisation.
See para. 20.3.3 - Commissioning (939571)... - page 20-132
l If the tractor behaves abnormally during Stop&Go manoeuvres.
l In the event of partial or total replacement of the hydraulic brake system, the brake pressure sensor or the brake depressed
switch.
The calibration procedure does not require any particular conditions, other than to park the tractor on level ground with the engine
running.

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 Calibrations and electronic
diagnosis
Instruments and information required for calibration
These operations may only be performed with the ALL_ROUND_TESTER® (henceforth ART®), used by an operator with an under-
standing of its general operating principles.
Initial steps for calibration
1. The steps common to the various calibration procedures are as follows:
A V A I L A B L E T E S T S
m Connect the ART® to the diagnostic socket = = = = = = = = = = = = = = = =
m Start the engine. M E N U
m Select HLHP Virtus J (if working with a SAME tractor) from the list
of connected ECUs.
1 - H L H P M A I N

= = = = = = = = = = = = = = = =
C h o i c e _

Fig. 541
2. From the introductory screen of the ECU, press [E] to access the main
= = = = = = = = = = = = = = = =
menu (in the example given here, a Virtus J 100 PROFILINE is selected) = = = = H L H P = = = =
= = = = = = = = = = = = = = = =

S W V E R S I O N
T S 1 7 1 A *

D A T E :
0 0 / 0 0 / 0 0 0 0

C O N F I G U R A T I O N
5 1 * * C P R O F I L I N E

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

Fig. 542
3. From the main menu press “2-Calibrations”
M A I N M E N U
= = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t s
4 - A l a r m s

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

Fig. 543

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Calibrations and electronic
diagnosis
4. From the calibrations main menu press “1-Transmission”.
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - T r a n s m i s s i o n
2 - H i t c h
3 - P T O
4 - A S M
5 - M o t o r
6 - S y s t e m
7 - S D D

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

Fig. 544
5. The ART® displays the main calibration menu.
C A L I B R A T I O N S
= = = = = = = = = = = = = = = =
1 - P e d a l
2 - R e v e r s e r
3 - S t o p & G o
4 - H M L

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

Fig. 545

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 Calibrations and electronic
diagnosis
Procedure for calibrating Stop&Go function
1. Calibration of the Stop&Go function IS NOT necessary and must ONLY be performed is abnormal Stop&Go functionality is
encountered.
The procedure is used to reconfigure the operating ranges of the function and some of its operating characteristics (brake
pressure thresholds for function activation, brake modulation when moving off, etc.).
Note
For reasons of safety, we recommend that all parameter editing operations are carried out with the machine
stationary.

Calibration consists of setting a number of parameters, with each parameter modifying the behaviour of the Stop&Go function.
It is not necessary to change all of the parameters (those essential for operating purposes are indicated below).
On completion of the calibration operation, press [E] to exit the procedure and then, at the confirmation prompt, press either
[C] to confirm or [A] to cancel the changes made.
2. To carry out the calibration proceed as follows:
S T O P A N D G O
m To activate calibration of the Stop&Go function press “3-Stop&Go” = = = = = = = = = = = = = = = =
on the calibration main menu.
m Once the Stop&Go function calibration section is accessed, the fol-
P r x D X 0 .
1 6
lowing screen is displayed: [ B ] M i n : 8 0
[ C ] M a x : 2 0 0 0
B r a k e T o r q u e : 0
[ 3 ] w T S t o p : 5 0
- - 1 ] A N D [ 2 + + + 0
- - 4 ] G O [ 5 + + 8 0 0
- - 7 ] R A M P [ 8 + + 6 0

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

Fig. 546
3. This screen shows all the parameters of the Stop&Go function that can be calibrated. Some of these parameters must be
calibrated for the function to operate correctly, whereas others may be modified to adjust the behaviour of the function.
Note
The Brake Torque value is an auxiliary variable indicating a value, from 0 to 1000, representing the pressure of
the right brake in relation to the minimum and maximum parameters set. The success of the different calibration
procedures performed is dependent on the value of this variable.
Parameters necessary for operation
1. these parameters must be recalibrated in the event of abnormal behaviour.
2. Prx Dx: this field shows the current pressure of the right brake. The brake pressure is subject to the following calibrations:
3. m Minimum RH pressure:

n Depress the right hand brake pedal to obtain a value Prx RH of approximately 60.

Press [A].
The saving of the parameter to memory is confirmed by the corresponding field, which assumes the value of the
pressure reading at the moment the key [A] was pressed
m Maximum RH pressure:

n Fully depress the right hand brake pedal to attain a pressure between 18 and 20 Bar (corresponding to a value

of approximately 2000 for the parameter Prx Dx);

Press [0]
The saving of the parameter to memory is confirmed by the corresponding field, which assumes the value of the
pressure reading at the moment the key [0] was pressed.

Parameters used to modify function behaviour (modify ONLY if the function continues to behave abnormally after perform-
ing the previous steps):
1. these parameters may be edited to modify the standard behaviour of the Stop&Go function.

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Calibrations and electronic
diagnosis
2. m wTStop: indicates the threshold above which Stop&Go is activated, on a scale of [0-1000].
n This parameter influences the smoothness with which the machine responds to Stop&Go activation. Higher

thresholds result in the tractor stopping more abruptly, lower thresholds result in the tractor stopping more softly.
To calibrate this parameter, depress both brake pedals, then press [B] once the pressure displayed as the Brake
Torque variable reaches the desired value.
Use a value of approximately 50 for an optimum balance between performance and comfort.
m AND: indicates on a scale of [-100-1000] the torque supplied by the transmission during standing starts/clutch modula-
tion.
n This parameter affects the torque applied when moving off from a standstill. It is a constant parameter that is

INDEPENDENT of brake pressure. If the value is too high, the clutch will not be completely disengaged even
with high braking pressures (not recommended, as this causes excessive clutch wear). If the value is too low,
the machine will be insufficiently responsive at the start of brake pressure modulation.
To change this parameter setting, press [1] to reduce the value or press [2] to increase it.
m GO: indicates on a scale of [0-1000] the torque supplied by the transmission during standing starts/clutch modulation.
n This parameter affects the torque applied when moving off from a standstill. It is a constant parameter that is

DEPENDENT on brake pressure. The parameter influences the modulability of the brake pedal when controlling
inching while moving off from stationary.
To change this parameter setting, press [4] to reduce the value or press [5] to increase it.
m RAMP: indicates on a scale of [0-1000], the gradient of the torque ramp supplied by the transmission when moving off
from a standing start.
n This parameter setting affects the speed at which the tractor moves off from stationary.

To change this parameter setting, press [7] to reduce the value or press [8] to increase it.

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 Calibrations and electronic
diagnosis
20.4 - ECU alarms
20.4.1 - Engine alarms
Engine ECU Alarms: SPN 000016-000175
Table 83
Cod. Instrument panel display error Fault
Spn Fmi
16 0 Engine alarm SPN 16 FMI 0 No detail informationen!
16 0 Engine alarm SPN 16 FMI 0 “BusOff error CAN No detail informationen!”
29 2 Engine alarm SPN 29 FMI 2 Plausibility error between sensor and idle switch, Acceleration Pedal
Detection. In case of Hand Throttle with Low Idle Switch, it is the plau-
sibility.
29 3 Engine alarm SPN 29 FMI 3 Handthrottle idle validation switch; short circuit to battery
29 4 Engine alarm SPN 29 FMI 4 Handthrottle; short circuit to ground
51 3 Engine alarm SPN 51 FMI 3 Intake Throttle Flap, H-Bridge, short circuit to battery. (A02)
51 3 Engine alarm SPN 51 FMI 3 Intake Throttle Flap, H-Bridge, short circuit to battery. (A67)
51 3 Engine alarm SPN 51 FMI 3 Intake Throttle Flap, H-Bridge, short circuit to battery or broken wiring
harness.
51 4 Engine alarm SPN 51 FMI 4 Intake Throttle Flap, H-Bridge, short circuit to ground. (A02)
51 4 Engine alarm SPN 51 FMI 4 Intake Throttle Flap, H-Bridge, short circuit to ground. (A67)
51 4 Engine alarm SPN 51 FMI 4 Intake Throttle Flap, H-Bridge, short circuit to ground.
51 5 Engine alarm SPN 51 FMI 5 Intake Throttle Flap, H-Bridge, wiring harness broken at connected
actuator.
51 6 Engine alarm SPN 51 FMI 6 Intake Throttle Flap, H-Bridge, current above maximum threshold.
51 7 Engine alarm SPN 51 FMI 7 Intake Throttle Flap, H-Bridge, position of actuator not plausible (de-
viation from setpoint more than 7%).
91 3 Engine alarm SPN 91 FMI 3 Sensor error accelerator pedal. Signal range check high.
91 4 Engine alarm SPN 91 FMI 4 Sensor error accelerator pedal. Signal is below the range.
91 11 Engine alarm SPN 91 FMI 11 Plausibility error between APP1 and APP2 or APP1 and idle switch.
94 1 Engine alarm SPN 94 FMI 1 Low fuel pressure; shut off threshold exceeded.
94 1 Engine alarm SPN 94 FMI 1 Low fuel pressure; warning threshold exceeded.
94 3 Engine alarm SPN 94 FMI 3 Sensor error low fuel pressure; signal range check high.
94 4 Engine alarm SPN 94 FMI 4 Sensor error low fuel pressure; signal range check low.
97 3 Engine alarm SPN 97 FMI 3 Sensor error water in fuel; signal range check high.
97 4 Engine alarm SPN 97 FMI 4 Sensor error water in fuel; signal range check low.
98 2 Engine alarm SPN 98 FMI 2 “Plausibility Check No detail informationen!”
97 12 Engine alarm SPN 97 FMI 12 Water in fuel level prefilter; maximum value exceeded.
100 0 Engine alarm SPN 100 FMI 0 High oil pressure; warning threshold exceeded.
100 0 Engine alarm SPN 100 FMI 0 High oil pressure; shut off threshold exceeded.
100 1 Engine alarm SPN 100 FMI 1 Low oil pressure; warning threshold exceeded.
100 1 Engine alarm SPN 100 FMI 1 Low oil pressure; shut off threshold exceeded.
100 3 Engine alarm SPN 100 FMI 3 Sensor error oil pressure; signal range check high.
100 4 Engine alarm SPN 100 FMI 4 Sensor error oil pressure sensor; signal range check low.
102 1 Engine alarm SPN 102 FMI 1 Pressure downstream charge air cooler, pressure below lower physi-
cal threshold.
102 2 Engine alarm SPN 102 FMI 2 Charged air pressure above shut off threshold.
Table 84
Cod. Instrument panel display error Fault
Spn Fmi
102 2 Engine alarm SPN 102 FMI 2 Charged air pressure above warning threshold.
102 2 Engine alarm SPN 102 FMI 2 Pressure downstream charge air cooler, plausibility error.
102 3 Engine alarm SPN 102 FMI 3 Pressure downstream charge air cooler, short circuit to battery or
open load.
102 4 Engine alarm SPN 102 FMI 4 Pressure downstream charge air cooler, short circuit to ground.
105 0 Engine alarm SPN 105 FMI 0 Charged air cooler temperature. System reaction initiated. High
charged air cooler temperature. Warning threshold exceeded.
105 0 Engine alarm SPN 105 FMI 0 Low charged air cooler temperature. Shut off threshold exceeded.
105 1 Engine alarm SPN 105 FMI 1 Charged Air cooler down stream temperature. Temperature below
lower physical threshold.

20-166
Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
105 3 Engine alarm SPN 105 FMI 3 Electrical error charged air temperature. Signal range check high.
(SRC)
105 4 Engine alarm SPN 105 FMI 4 Sensor error charged air temperature; signal range check low.
105 11 Engine alarm SPN 105 FMI 11 Diagnostic fault check for charged air cooler downstream temperature
sensor. No detail information!
107 0 Engine alarm SPN 107 FMI 0 High air filter differential pressure; warning threshold exceeded.
107 0 Engine alarm SPN 107 FMI 0 Sensor error airfilter differential pressure; short circuit to ground.
107 3 Engine alarm SPN 107 FMI 3 Sensor error airfilter differential pressure; short circuit to battery.
108 3 Engine alarm SPN 108 FMI 3 Sensor error ambient air pressure; signal range check high
108 4 Engine alarm SPN 108 FMI 4 Sensor error ambient air pressure; signal range check low
108 11 Engine alarm SPN 108 FMI 11 DFC for CAN message. No detail information!
110 0 Engine alarm SPN 110 FMI 0 High coolant temperature; warning threshold exceeded.
110 0 Engine alarm SPN 110 FMI 0 Coolant temperature; system reaction initiated.
110 0 Engine alarm SPN 110 FMI 0 Physical Range Check high for Coolant temperature.
110 1 Engine alarm SPN 110 FMI 1 Physical Range Check low for Coolant temperature.
110 2 Engine alarm SPN 110 FMI 11 Air flow sensor load correction factor exceeding the maximum drift
limit; plausibility error
110 3 Engine alarm SPN 110 FMI 3 Sensor error coolant temperature; signal range check high.
110 4 Engine alarm SPN 110 FMI 4 Sensor error coolant temperature; signal range check low.
110 11 Engine alarm SPN 110 FMI 2 defect fault check for Absolute plausibility test No detail informationen!
111 1 Engine alarm SPN 111 FMI 1 Coolant level too low
132 1 Engine alarm SPN 132 FMI 1 “The air mass flow AFS_dm is greater than or equal to AFS_PhysRng.
Min_C Physical Range Check low for air mass flow sensor No detail
informationen!”
132 11 Engine alarm SPN 132 FMI 11 Air flow sensor load correction factor exceeding the maximum drift
limit; plausibility error.
157 0 Engine alarm SPN 157 FMI 0 Rail pressure raw value is intermittent No detail informationen!
157 1 Engine alarm SPN 157 FMI 1 rail pressure raw value is above maximum offset No detail informa-
tionen!
157 3 Engine alarm SPN 157 FMI 3 Sensor error rail pressure. Sensor voltage above upper limit.
157 4 Engine alarm SPN 157 FMI 4 Sensor error rail pressure. Sensor voltage below lower limit.
164 2 Engine alarm SPN 164 FMI 2 Rail pressure safety function is not executed correctly.
168 0 Engine alarm SPN 168 FMI 0 Physikal range check high for battery voltage.
168 1 Engine alarm SPN 168 FMI 1 Physikal range check low for battery voltage.
168 2 Engine alarm SPN 168 FMI 2 Low battery voltage; warning threshold exceeded.

20-167
 Calibrations and electronic
diagnosis
Table 85
Cod. Instrument panel display error Fault
Spn Fmi
168 2 Engine alarm SPN 168 FMI 2 High battery voltage; warning threshold exceeded.
168 3 Engine alarm SPN 168 FMI 3 Sensor error battery voltage; signal range check high.
168 4 Engine alarm SPN 168 FMI 4 Sensor error battery voltage; signal range check low.
171 0 Engine alarm SPN 171 FMI 0 Environment temperature sensor, temperature above upper physical
threshold.
171 1 Engine alarm SPN 171 FMI 1 Physical Range Check low for Environment Temperature. No detail
information!
171 3 Engine alarm SPN 171 FMI 3 Sensor error environment temperature; signal range check high
171 4 Engine alarm SPN 171 FMI 4 Sensor error environment temperature; signal range check low
172 0 Engine alarm SPN 172 FMI 0 Air temperature within air filter box above maximum physical value.
172 1 Engine alarm SPN 172 FMI 1 Air inlet filter sensor out of physical range check.
172 1 Engine alarm SPN 172 FMI 1 Environment temperature below minimum level.
172 2 Engine alarm SPN 172 FMI 2 Air inlet filter temperature, plausibility error.
172 3 Engine alarm SPN 172 FMI 3 Air flow temperature sensor; short circuit to battery or open load.
172 4 Engine alarm SPN 172 FMI 4 Air flow temperature sensor; short circuit to ground.
174 11 Engine alarm SPN 174 FMI 11 DFC for fuel temperature plausibility check function No detail infor-
mationen!
175 0 Engine alarm SPN 175 FMI 0 High oil temperature; warning threshold exceeded.
175 0 Engine alarm SPN 175 FMI 0 High oil temperature; shut off threshold exceeded.
175 2 Engine alarm SPN 175 FMI 2 Customer oiltemperature: signal unplausible.
175 3 Engine alarm SPN 175 FMI 3 Sensor error oil temperature; signal range check high.
175 4 Engine alarm SPN 175 FMI 4 Sensor error oil temperature; signal range check low.
-
-
DTC-List-EMR4: Diagnosis and Errorcodes
P: 1/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 000190-001188
Table 86
Cod. Instrument panel display error Fault
Spn Fmi
190 0 Engine alarm SPN 190 FMI 0 Engine speed above warning threshold. Overspeed detection in com-
ponent engine protection.
190 0 Engine alarm SPN 190 FMI 0 Engine speed above warning threshold (FOC-Level 1).
190 2 Engine alarm SPN 190 FMI 2 Offset angle between crank- and camshaft sensor is too large
190 8 Engine alarm SPN 190 FMI 8 Sensor camshaft speed; disturbed signal
190 8 Engine alarm SPN 190 FMI 8 Sensor crankshaft speed; disturbed signal
190 11 Engine alarm SPN 190 FMI 11 Engine speed above warning threshold (FOC-Level 2)
190 12 Engine alarm SPN 190 FMI 12 Sensor camshaft speed; no signal
190 12 Engine alarm SPN 190 FMI 12 Sensor crankshaft speed; no signal
190 14 Engine alarm SPN 190 FMI 14 Engine speed above warning threshold (Overrun Mode)
190 14 Engine alarm SPN 190 FMI 14 Camshaft- and Crankshaft speed sensor signal not available on CAN
411 0 Engine alarm SPN 411 FMI 0 Delta pressure across venturi in EGR line above physical high limit.
411 1 Engine alarm SPN 411 FMI 1 Delta pressure across venturi in EGR line below physical low limit.
411 3 Engine alarm SPN 411 FMI 3 Sensor error differential pressure Venturiunit (EGR), signal range
check low.
411 4 Engine alarm SPN 411 FMI 4 Sensor error differential pressure Venturiunit (EGR), signal range
check high.
411 4 Engine alarm SPN 411 FMI 4 Physical range check low for EGR differential pressure.
411 11 Engine alarm SPN 411 FMI 11 Plausibility Check fault for deviation of desired and actual EGR-mass
flow, where the latter is calculated out of EGR Delta Pressure Sensor.
412 3 Engine alarm SPN 412 FMI 3 Sensor error EGR cooler downstream temperature; signal range
check high.

20-168
Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
412 4 Engine alarm SPN 412 FMI 4 Sensor error EGR cooler downstream temperature; signal range
check low.
520 9 Engine alarm SPN 520 FMI 9 Timeout Error of CAN-Receive-Frame TSC1TR; Setpoint.
598 2 Engine alarm SPN 598 FMI 2 Plausibility check for Clutch No detail informationen!
624 3 Engine alarm SPN 624 FMI 3 SVS lamp; short circuit to battery.
624 4 Engine alarm SPN 624 FMI 4 SVS lamp; short circuit to ground.
624 5 Engine alarm SPN 624 FMI 5 SVS lamp; open load.
624 12 Engine alarm SPN 624 FMI 12 SVS lamp; powerstage over temperature.
630 12 Engine alarm SPN 630 FMI 12 Access error EEPROM memory (write).
630 12 Engine alarm SPN 630 FMI 12 Access error EEPROM memory (delete).
630 12 Engine alarm SPN 630 FMI 12 Access error EEPROM memory (read).
639 14 Engine alarm SPN 639 FMI 14 CAN-Bus 0 “BusOff-Status”.
651 3 Engine alarm SPN 651 FMI 3 High side to low side short circuit in the injector 1 (in firing order).
651 5 Engine alarm SPN 651 FMI 5 Injector 1 (in firing order); interruption of electric connection.

Table 87
Cod. Instrument panel display error Fault
Spn Fmi
652 3 Engine alarm SPN 652 FMI 3 Injector 2 (in firing order); short circuit.
652 5 Engine alarm SPN 652 FMI 5 Injector 2 (in firing order); interruption of electric connection.
653 3 Engine alarm SPN 653 FMI 3 Injector 3 (in firing order); short circuit.
653 5 Engine alarm SPN 653 FMI 5 Injector 3 (in firing order); interruption of electric connection.
654 3 Engine alarm SPN 654 FMI 3 Injector 4 (in firing order); short circuit.
654 5 Engine alarm SPN 654 FMI 5 Injector 4 (in firing order); interruption of electric connection.
655 3 Engine alarm SPN 655 FMI 3 Injector 5 (in firing order); short circuit.
655 4 Engine alarm SPN 655 FMI 4 High side to low side short circuit in the injector 5 (in firing order)
655 5 Engine alarm SPN 655 FMI 5 Injector 5 (in firing order); interruption of electric connection.
656 3 Engine alarm SPN 656 FMI 3 Injector 6 (in firing order); short circuit.
656 4 Engine alarm SPN 656 FMI 4 High side to low side short circuit in the injector 6 (in firing order)
656 5 Engine alarm SPN 656 FMI 5 Injector 6 (in firing order); interruption of electric connection.
676 11 Engine alarm SPN 676 FMI 11 Cold st device relay error
676 11 Engine alarm SPN 676 FMI 11 Cold st aid relay open load.
677 3 Engine alarm SPN 677 FMI 3 Ster relay low side; short circuit to battery.
677 3 Engine alarm SPN 677 FMI 3 Ster relay high side; short circuit to battery
677 4 Engine alarm SPN 677 FMI 4 Ster relay high side; short circuit to ground.
677 4 Engine alarm SPN 677 FMI 4 Ster relay low side; short circuit to ground
677 5 Engine alarm SPN 677 FMI 5 Ster relay; no load error.
677 12 Engine alarm SPN 677 FMI 12 Ster relay; powerstage over temperature.
729 3 Engine alarm SPN 729 FMI 3 Intake Air Heater Device; Short circuit to battery.
729 4 Engine alarm SPN 729 FMI 4 Air intake heater; Short circuit to ground error for powerstage on
CJ945.
729 5 Engine alarm SPN 729 FMI 5 Cold st aid relay open load.
729 12 Engine alarm SPN 729 FMI 12 Cold st aid relay; over temperature error.
898 9 Engine alarm SPN 898 FMI 9 Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint.
975 3 Engine alarm SPN 975 FMI 3 Fan actuator (PWM output); short circuit to battery.
975 4 Engine alarm SPN 975 FMI 4 Fan actuator (PWM output); short circuit to ground.
975 5 Engine alarm SPN 975 FMI 5 Fan actuator (PWM output); open load.
1079 13 Engine alarm SPN 1079 FMI 13 Sensor supply voltage monitor 1 error (ECU).
1080 13 Engine alarm SPN 1080 FMI 13 Sensor supply voltage monitor 2 error (ECU).
1109 2 Engine alarm SPN 1109 FMI 2 Engine shut off demand ignored.
Table 88
Cod. Instrument panel display error Fault
Spn Fmi
1136 0 Engine alarm SPN 1136 FMI 0 Physical range check high for ECU temperature.
1176 0 Engine alarm SPN 1176 FMI 0 Pressure sensor upstream turbine, Physical Range Check high.
1176 1 Engine alarm SPN 1176 FMI 1 Pressure sensor upstream turbine, Physical Range Check low.
1176 2 Engine alarm SPN 1176 FMI 2 Pressure sensor upstream turbine, plausibility error.
1176 3 Engine alarm SPN 1176 FMI 3 Pressure sensor upstream turbine, signal range check (SRC) high.
1176 4 Engine alarm SPN 1176 FMI 4 Pressure sensor upstream turbine, signal range check (SRC) low.

20-169
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
1180 0 Engine alarm SPN 1180 FMI 0 Physical range check high for exhaust gas temperature upstream tur-
bine.
1180 1 Engine alarm SPN 1180 FMI 1 Physical range check low for exhaust gas temperature upstream tur-
bine.
1180 3 Engine alarm SPN 1180 FMI 3 Sensor error exhaust gas temperature upstream turbine; signal range
check high.
1180 4 Engine alarm SPN 1180 FMI 4 Sensor error exhaust gas temperature upstream turbine; signal range
check low.
1188 0 Engine alarm SPN 1188 FMI 0 Turbocharger wastegate, temperature critical high.
1188 2 Engine alarm SPN 1188 FMI 2 Status message from ECU missing.
1188 2 Engine alarm SPN 1188 FMI 2 CAN Fehler Turbocharger wastegate, CAN Error.
1188 3 Engine alarm SPN 1188 FMI 3 Turbocharger wastegate, supply voltage above maximum threshold.
1188 4 Engine alarm SPN 1188 FMI 4 Turbocharger wastegate, supply voltage below minimum threshold.
1188 6 Engine alarm SPN 1188 FMI 6 Turbocharger wastegate, current above maximum threshold.
1188 7 Engine alarm SPN 1188 FMI 7 Wastegate actuator; blocked.
1188 7 Engine alarm SPN 1188 FMI 7 Turbocharger wastegate, mechanical blocking detected.
1188 7 Engine alarm SPN 1188 FMI 7 Turbocharger wastegate, broken spring detected.
1188 11 Engine alarm SPN 1188 FMI 11 Wastegate actuator; internal error.
1188 11 Engine alarm SPN 1188 FMI 11 Wastegate actuator; EOL calibration not performed correctly.
1188 11 Engine alarm SPN 1188 FMI 11 Wastegate actuator; over temperature (> 145°C).
1188 11 Engine alarm SPN 1188 FMI 11 Wastegate actuator; over temperature (> 135°C).
1188 11 Engine alarm SPN 1188 FMI 11 Wastegate actuator; operating voltage error.
1188 12 Engine alarm SPN 1188 FMI 12 Turbocharger wastegate, internal electrical error.
1188 13 Engine alarm SPN 1188 FMI 13 Wastegate actuator calibration deviation too large, recalibration re-
quired.
1188 13 Engine alarm SPN 1188 FMI 13 Turbocharger wastegate, EOL calibration error.
1188 13 Engine alarm SPN 1188 FMI 13 Turbocharger wastegate, learning process aborted.
1188 13 Engine alarm SPN 1188 FMI 13 Turbocharger wastegate, learning process out of range.
-
-
DTC-List-EMR4: Diagnosis and Errorcodes
P: 2/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 001231-003520
Table 89
Cod. Instrument panel display error Fault
Spn Fmi
1231 14 Engine alarm SPN 1231 FMI 14 CAN-Bus 1 “BusOff-Status”.
1235 14 Engine alarm SPN 1235 FMI 14 CAN-Bus 2 = CAN_C reports Bus-error (for engines <8L and CV52
it is the engine-CAN@250kbaud). CAN Bus error passive; warning
CAN C - engine CAN.
1235 14 Engine alarm SPN 1235 FMI 14 CAN-Bus 2 “BusOff-Status”.
1237 2 Engine alarm SPN 1237 FMI 2 Override switch; plausibility error.
1322 12 Engine alarm SPN 1322 FMI 12 Too many recognized misfires in more than one cylinder.
1323 12 Engine alarm SPN 1323 FMI 12 Too many recognized misfires in cylinder 1 (in firing order).
1324 12 Engine alarm SPN 1324 FMI 12 Too many recognized misfires in cylinder 2 (in firing order).
1325 12 Engine alarm SPN 1325 FMI 12 Too many recognized misfires in cylinder 3 (in firing order).
1326 12 Engine alarm SPN 1326 FMI 12 Override switch; plausibility error
1327 12 Engine alarm SPN 1327 FMI 12 Too many recognized misfires in more than one cylinder
1328 12 Engine alarm SPN 1328 FMI 12 Too many recognized misfires in cylinder 1 (in firing order)
1346 0 Engine alarm SPN 1346 FMI 0 Misfire detection monitoring No detail informationen!
1638 2 Engine alarm SPN 1638 FMI 2 Hydraulic oil temperature check for Shut off condition No detail infor-
mationen!
1639 0 Engine alarm SPN 1639 FMI 0 Sensor error fan speed; signal range check high.
1639 1 Engine alarm SPN 1639 FMI 1 Sensor error fan speed; signal range check low.
1639 12 Engine alarm SPN 1639 FMI 12 Fan speed sensor; electrical error or signal disturbed.

20-170
Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
1761 0 Engine alarm SPN 1761 FMI 0 DEF tank, DEF level above upper physical threshold.
1761 1 Engine alarm SPN 1761 FMI 1 DEF tank, DEF level below lower physical threshold.
1761 2 Engine alarm SPN 1761 FMI 2 DEF tank level, plausibility error.
1761 14 Engine alarm SPN 1761 FMI 14 Urea tank level; warning threshold exceeded.
1761 14 Engine alarm SPN 1761 FMI 14 Urea Tank Signal to HMI for indicating the Urea Tank-Level. (Urea
tank volume ratio low threshold 1)
1761 14 Engine alarm SPN 1761 FMI 14 DEF tank, DEF level below first warning threshold.
1761 14 Engine alarm SPN 1761 FMI 14 DEF tank, DEF level below second warning threshold.
1761 14 Engine alarm SPN 1761 FMI 14 DEF tank, DEF level below third warning threshold.
2634 12 Engine alarm SPN 2634 FMI 12 Early opening defect of main relay No detail informationen!
2634 12 Engine alarm SPN 2634 FMI 12 DFC for stuck main relay error No detail informationen!
2659 0 Engine alarm SPN 2659 FMI 0 Exhaust Gas Recirculation AGS Sensor; Sensed exhaust mass value
above maximum physical value.
2659 1 Engine alarm SPN 2659 FMI 0 Exhaust Gas Recirculation AGS Sensor; Sensed exhaust mass value
below miniimum physical value.
2659 2 Engine alarm SPN 2659 FMI 0 Exhaust Gas Recirculation AGS Sensor; signal not plausible.
2659 2 Engine alarm SPN 2659 FMI 0 Exhaust Gas Recirculation AGS Sensor; Temperature of EGR mass
not plausible.
2659 12 Engine alarm SPN 2659 FMI 0 Exhaust Gas Recirculation AGS Sensor; plausibility error, AGS sen-
sor has not passed the burn off process.
2791 0 Engine alarm SPN 2791 FMI 0 EGR actuator, temperature critical high.
2791 2 Engine alarm SPN 2791 FMI 2 EGR actuator, CAN error.
2791 3 Engine alarm SPN 2791 FMI 3 EGR actuator supply voltage is above the maximum threshold.
2791 4 Engine alarm SPN 2791 FMI 4 EGR actuator supply voltage is below minimum threshold.
2791 6 Engine alarm SPN 2791 FMI 6 EGR actuator current is above maximum threshold.
2791 7 Engine alarm SPN 2791 FMI 7 EGR actuator, broken spring detected.
2791 7 Engine alarm SPN 2791 FMI 7 EGR Actuator, internal electrical fault.
2791 7 Engine alarm SPN 2791 FMI 7 EGR actuator, actuator blocked.

Table 90
Cod. Instrument panel display error Fault
Spn Fmi
2791 12 Engine alarm SPN 2791 FMI 12 Actuator EGR Valve; powerstage over temperature.
2791 13 Engine alarm SPN 2791 FMI 13 EGR actuator, EOL calibration error.
2791 13 Engine alarm SPN 2791 FMI 13 EGR actuator, learning process aborted.
2791 13 Engine alarm SPN 2791 FMI 13 EGR actuator, learning process out of range.
2791 16 Engine alarm SPN 2791 FMI 16 EGR actuator, temperature high.
2797 4 Engine alarm SPN 2797 FMI 4 Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 0;_IVDiaShCir-
GndToutBnk_0.
2797 4 Engine alarm SPN 2797 FMI 4 Injector diagnostic; Short circuit to ground cylinder bank 0.
2798 4 Engine alarm SPN 2798 FMI 4 Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 1;_IVDiaShCir-
GndToutBnk_1.
2798 4 Engine alarm SPN 2798 FMI 4 Injector diagnostic; Short circuit to ground cylinder bank 1.
3031 0 Engine alarm SPN 3031 FMI 0 DEF tank, DEF temperature above upper physical threshold.
3031 1 Engine alarm SPN 3031 FMI 1 DEF tank, DEF temperature above upper physical threshold.
3031 2 Engine alarm SPN 3031 FMI 2 Urea tank temperature outside of plausible thresholds
3219 2 Engine alarm SPN 3219 FMI 2 DFC SAE J1939 error No detail informationen!
3224 1 Engine alarm SPN 3224 FMI 1 DFC for plausibility error Max for NOx sensor upstream of SCR Cat.
3224 2 Engine alarm SPN 3224 FMI 2 DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-sys-
tem upstream cat; DPF-system downstream cat); length of frame in-
correct.
3224 2 Engine alarm SPN 3224 FMI 2 DLC Error of CAN-Receive-Frame AT1IG1Vol NOX sensor.
3224 9 Engine alarm SPN 3224 FMI 9 Timeout Error of CAN-Receive-Frame AT1IG1; NOX sensor up-
stream.
3224 9 Engine alarm SPN 3224 FMI 9 Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX sensor.
3226 9 Engine alarm SPN 3226 FMI 2 Nox feed back fault detection No detail informationen!
3227 9 Engine alarm SPN 3227 FMI 2 DFC SAE J1939 error No detail informationen!
3234 2 Engine alarm SPN 3234 FMI 2 DLC Error of CAN-Receive-Frame AT1O1Vol NOX.
3234 2 Engine alarm SPN 3234 FMI 2 DLC Error of CAN-Receive-Frame AT1O1 No detail informationen!
3234 9 Engine alarm SPN 3234 FMI 9 Timeout Error of CAN-Receive-Frame AT1OG1Vol.

20-171
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
3234 9 Engine alarm SPN 3234 FMI 9 Timeout Error of CAN-Receive-Frame AT1OG1; NOX sensor (SCR-
system downstream cat; DPF-system downstream cat).
3234 11 Engine alarm SPN 3234 FMI 11 DFC for plausibility error Min for NOx sensor downstream of SCR Cat.
3241 0 Engine alarm SPN 3241 FMI 0 Sensor SCR catalyst upstream temperature too high; plausibility er-
ror.
3248 4 Engine alarm SPN 3248 FMI 4 Sensor error picle filter downstream temperature; signal range check
low.
3251 0 Engine alarm SPN 3251 FMI 0 Differential pressure DPF maximum value is exceeded.
3251 0 Engine alarm SPN 3251 FMI 0 Differential pressure sensor across DPF exceeds warning high limit.
3251 1 Engine alarm SPN 3251 FMI 1 Differential pressure DPF, pressure below lower shutoff threshold.
3251 1 Engine alarm SPN 3251 FMI 1 Differential pressure DPF, pressure below lower warning threshold.
3253 2 Engine alarm SPN 3253 FMI 2 Differential pressure DPF, plausibility error.
3253 2 Engine alarm SPN 3253 FMI 2 Sensor differential pressure (DPF); plausibility error.
3253 3 Engine alarm SPN 3253 FMI 3 Electrical error differential pressure B58 (DPF). (signal range check
high)
3253 4 Engine alarm SPN 3253 FMI 4 Electrical error differential pressure (DPF). signal range check low.
Table 91
Cod. Instrument panel display error Fault
Spn Fmi
3361 3 Engine alarm SPN 3361 FMI 3 Urea dosing valve; short circuit to battery on low side.
3361 3 Engine alarm SPN 3361 FMI 3 Urea dosing valve; short circuit to battery or open load on high side.
3361 4 Engine alarm SPN 3361 FMI 4 Urea dosing valve; short circuit on high side.
3361 4 Engine alarm SPN 3361 FMI 4 Urea dosing valve; short circuit to ground or open load on low side.
3361 6 Engine alarm SPN 3361 FMI 6 Urea dosing valve; power at the end of injection too high.
3361 7 Engine alarm SPN 3361 FMI 7 AdBlue dosing valve blocked (SCR).
3519 3 Engine alarm SPN 3519 FMI 3 DEF quality sensor, internal temperature sensor short circuit to bat-
tery or open load.
3519 4 Engine alarm SPN 3519 FMI 4 DEF quality sensor, internal temperature sensor short circuit to
ground.
3519 12 Engine alarm SPN 3519 FMI 12 DEF tank temperature, temperature too high.
3519 13 Engine alarm SPN 3519 FMI 13 Temperature at UQS invalid.
3520 2 Engine alarm SPN 3520 FMI 2 DEF quality seonsor, bad DEF quality detected or no DEF measuring
possible.
3520 3 Engine alarm SPN 3520 FMI DEF quality sensor, short circuit to battery or open load.
3520 4 Engine alarm SPN 3520 FMI 4 DEF quality sensor, short circuit to ground.
3520 8 Engine alarm SPN 3520 FMI 8 DEF quality seonsor, measurement conditions not fulfilled.
3520 13 Engine alarm SPN 3520 FMI 13 Urea quality at UQS invalid.
-
-
DTC-List-EMR4: Diagnosis and Errorcodes
P: 3/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 003532-005763
Table 92
Cod. Instrument panel display error Fault
Spn Fmi
3532 3 Engine alarm SPN 3532 FMI 3 Quality at UQS out of MAX physical range.
3532 3 Engine alarm SPN 3532 FMI 3 Sensor error urea tank level; signal range check high.
3532 4 Engine alarm SPN 3532 FMI 4 Quality at UQS out of MIN physical range.
3532 4 Engine alarm SPN 3532 FMI 4 Sensor error urea tank level; signal range check low.
3699 0 Engine alarm SPN 3699 FMI 0 Maximum standstill time reached; oil exchange request ignored.
3699 2 Engine alarm SPN 3699 FMI 2 Temperature sensor us. and ds. DOC simultaneously defect.
3699 2 Engine alarm SPN 3699 FMI 2 DPF differential pressure sensor and a further sensor or actuator CRT
system defective.
3711 12 Engine alarm SPN 3711 FMI 12 Temperature during stand-still main phase too low or too high.

20-172
Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
3936 14 Engine alarm SPN 3936FMI 14 Standstill request ignored too long.
3936 14 Engine alarm SPN 3936FMI 14 Standstill time based escalation requests Inducement step 2.
4171 2 Engine alarm SPN 4171FMI 2 Dynamic temperatur check of temp before SCR
4243 11 Engine alarm SPN 4243 FMI 11 Urea Quality Error Slave.
4334 0 Engine alarm SPN 4334 FMI 0 Supply module DEF, DEF pressure above upper physical threshold.
4334 0 Engine alarm SPN 4334 FMI 0 Urea pump pressure sensor; high signal not plausible.
4334 1 Engine alarm SPN 4334 FMI 1 Urea pump pressure sensor; low signal not plausible.
4334 1 Engine alarm SPN 4334 FMI 1 Urea supply module pressure sensor; physical range check low. (de-
fect pressure sensor)
4334 2 Engine alarm SPN 4334 FMI 2 DEF supply module pressure, plausibility error.
4341 3 Engine alarm SPN 4341 FMI 3 SCR-heater urea supplyline; short circuit to battery.
4341 4 Engine alarm SPN 4341 FMI 4 SCR-heater urea supply line; short circuit to ground.
4341 5 Engine alarm SPN 4341 FMI 5 SCR heater relay urea supply line primary side; open load.
4341 5 Engine alarm SPN 4341 FMI 6 SCR heater relay urea supplyline secondary side; open load.
4343 3 Engine alarm SPN 4343 FMI 3 SCR heater urea pressureline; short circuit to battery.
4343 4 Engine alarm SPN 4343 FMI 4 SCR heater urea pressureline; short circuit to ground.
4343 5 Engine alarm SPN 4343 FMI 5 SCR heater relay urea pressureline secondary side; open load.
4343 5 Engine alarm SPN 4343 FMI 5 SCR heater relay urea pressureline primary side; open load.
4343 11 Engine alarm SPN 4343 FMI 11 SCR Monitoring; Pressure stabilisation error, general pressure check
error (SCR).
4343 12 Engine alarm SPN 4343 FMI 12 Over Temperature error No detail informationen!
4345 3 Engine alarm SPN 4345 FMI 3 SCR heater urea returnline; short circuit to battery.
4345 4 Engine alarm SPN 4345 FMI 4 SCR heater urea returnline; short circuit to ground.
4345 5 Engine alarm SPN 4345 FMI 5 SCR heater relay urea returnline sekondary side; open load.
4345 5 Engine alarm SPN 4345 FMI 5 SCR heater relay urea returnline primary side; open load.
4345 11 Engine alarm SPN 4345 FMI 11 Sensor backflow line pressure (SCR); plausibility error.
4345 12 Engine alarm SPN 4345 FMI 12 Over Temperature error No detail informationen!
Table 93
Cod. Instrument panel display error Fault
Spn Fmi
4360 0 Engine alarm SPN 4360 FMI 0 Exhaust temperature upstream SCR-Cat, temperature above upper
physical threshold.
4360 1 Engine alarm SPN 4360 FMI 1 Sensed exhaust temperature before SCR-Cat is < physical low limit.
4360 2 Engine alarm SPN 4360 FMI 2 Exhaust temperature sensor upstream SCR, plausibility error.
4361 2 Engine alarm SPN 4361 FMI 2 Signal error for CAN message No detail informationen!
4361 3 Engine alarm SPN 4361 FMI 3 Sensor error urea catalyst exhaust gas temperature upstream; signal
range check high.
4361 4 Engine alarm SPN 4361 FMI 4 Sensor error urea catalyst exhaust gas temperature upstream; signal
range check low.
4365 0 Engine alarm SPN 4365 FMI 0 x
4365 2 Engine alarm SPN 4365 FMI 2 Signal error for CAN message.
4365 3 Engine alarm SPN 4365 FMI 3 Sensor error urea tank temperature: short circuit to battery.
4365 3 Engine alarm SPN 4365 FMI 3 DEF qualitysensor, tank temperatur; Short circuit to battery or open
load.
4365 4 Engine alarm SPN 4365 FMI 4 Sensor error urea tank temperature; short circuit to ground.
4365 4 Engine alarm SPN 4365 FMI 4 DEF qualitysensor, tank temperatur; Short circuit to ground.
4366 3 Engine alarm SPN 4366 FMI 3 SCR Tank heating valve; short circuit to battery.
4366 4 Engine alarm SPN 4366 FMI 4 SCR Tank heating valve; short circuit to ground.
4366 5 Engine alarm SPN 4366 FMI 5 SCR tank heating valve primary side; open load.
4366 5 Engine alarm SPN 4366 FMI 5 SCR Tank heating valve secundary side: open load.
4366 5 Engine alarm SPN 4366 FMI 5 SCR main relay (secondary side), heat relay (secondary side), heat-
ing elements or heating valve short to ground.
4366 5 Engine alarm SPN 4366 FMI 5 SCR main relay (secondary side); Shortcut to battery.
4366 5 Engine alarm SPN 4366 FMI 5 SCR main relay (secondary side): open load.
4366 12 Engine alarm SPN 4366 FMI 12 SCR-heater relay urea tank powerstage output; over temperature
4374 13 Engine alarm SPN 4374 FMI 13 Pressure stabilisation error dosing valve (SCR).
4375 3 Engine alarm SPN 4375 FMI 3 Urea pump motor; short circuit to battery.
4375 4 Engine alarm SPN 4375 FMI 4 Urea pump motor; short circuit to ground.
4375 5 Engine alarm SPN 4375 FMI 5 AdBlue Pumpenmotor; Kabelbruch Urea pump motor; open load.
4376 3 Engine alarm SPN 4376 FMI 3 SCR reversal valve; short circuit to battery.

20-173
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
4376 4 Engine alarm SPN 4376 FMI 4 SCR reversing valve; short circuit to ground.
4376 5 Engine alarm SPN 4376 FMI 5 SCR reversal valve; open load.
4376 5 Engine alarm SPN 4376 FMI 5 Supply Modul Umkehrventil SCR; Kabelbruch oder.
4376 12 Engine alarm SPN 4376 FMI 12 SCR reversing valve; over temperature
4765 0 Engine alarm SPN 4765 FMI 0 Temperature upstream DOC, temperature above upper shutoff
threshold.
4765 0 Engine alarm SPN 4765 FMI 0 Temperature upstream DOC, temperature above upper warning
threshold.
Table 94
Cod. Instrument panel display error Fault
Spn Fmi
4766 0 Engine alarm SPN 4766 FMI 0 Temperature downstream DOC, temperature above upper shutoff
threshold.
4766 0 Engine alarm SPN 4766 FMI 0 Temperature downstream DOC, temperature above upper warning
threshold.
4768 2 Engine alarm SPN 4768 FMI 2 Temperature upstream DOC, plausibility error.
4768 2 Engine alarm SPN 4768 FMI 2 Exhaust gas temperature sensors up- and downstream DOC are
physically swapped.
4768 3 Engine alarm SPN 4768 FMI 3 Electrical error exhaust gas temperature upstream (DOC); signal
range check high.
4768 4 Engine alarm SPN 4768 FMI 4 Electrical error exhaust gas temperature upstream (DOC); signal
range check low.
4769 2 Engine alarm SPN 4769 FMI 2 Temperature downstream DOC, plausibility error.
4769 2 Engine alarm SPN 4769 FMI 2 Sensor exhaust gas temperature OxiCat downstream (normal opera-
tion); plausibility error.
4769 2 Engine alarm SPN 4769 FMI 2 Sensor exhaust gas temperature OxiCat downstream (regeneration);
plausibility error.
4769 3 Engine alarm SPN 4769 FMI 3 Sensor error exhaust gas temperature downstream (DOC); signal
range check high.
4769 4 Engine alarm SPN 4769 FMI 4 Sensor error exhaust gas temperature downstream (DOC); signal
range check low.
5763 0 Engine alarm SPN 5763 FMI 0 Warning threshold for an internal actuator error exceeded, < 4L EGR.
actuator und >4L Air Intake Flap.
5763 1 Engine alarm SPN 5763 FMI 1 Shut off threshold for an internal actuator error exceeded, <4L EGR.
actuator und >4L Air Intake Flap.
5763 3 Engine alarm SPN 5763 FMI 3 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to
battery.
5763 3 Engine alarm SPN 5763 FMI 3 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to
battery.
5763 3 Engine alarm SPN 5763 FMI 3 Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-
Valve (4.1;6.1;7.8). Signal range check high.
5763 4 Engine alarm SPN 5763 FMI 4 Position sensor error actuator EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8). Signal range check low.
5763 4 Engine alarm SPN 5763 FMI 4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to
ground.
5763 4 Engine alarm SPN 5763 FMI 4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to
ground.
5763 4 Engine alarm SPN 5763 FMI 4 Voltage below threshold.
5763 5 Engine alarm SPN 5763 FMI 5 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); open
load.
5763 5 Engine alarm SPN 5763 FMI 5 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); sig-
nal range check low.
5763 6 Engine alarm SPN 5763 FMI 6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve. (4.1;6.1;7.8).
Signal range check high.
5763 6 Engine alarm SPN 5763 FMI 6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); sig-
nal range check high.
5763 6 Engine alarm SPN 5763 FMI 6 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over current.

20-174
Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
5763 6 Engine alarm SPN 5763 FMI 6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8);
Overload by short-circuit.
5763 7 Engine alarm SPN 5763 FMI 7 Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8) not plausible.
5763 11 Engine alarm SPN 5763 FMI 11 Power stage overtemperature due to high current.
-
-
DTC-List-EMR4: Diagnosis and Errorcodes
P: 4/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 520521-523632
Table 95
Cod. Instrument panel display error Fault
Spn Fmi
520521 5 Engine alarm SPN 520521 FMI 5 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); sig-
nal range check low.
523008 1 Engine alarm SPN 523008 FMI 1 Manipulation control was triggered.
523008 2 Engine alarm SPN 523008 FMI 2 Timeout error in Manipulation control.
523009 9 Engine alarm SPN 523009 FMI 9 The pressure relief valve (PRV) has reached the number of allowed
activations.
523009 10 Engine alarm SPN 523009 FMI 10 Open time of Pressure Relief Valve (PRV) for wear out monitoring
had exceeded.
523090 2 Engine alarm SPN 523090 FMI 2 Engine Brake Pre-Selection switch; Plausibility Error.
523211 9 Engine alarm SPN 523211 FMI 9 Timeout Error of CAN-Receive-Frame EBC1
523212 9 Engine alarm SPN 523212 FMI 9 Timeout Error of CAN-Receive-Frame ComEngPrt; Engine Protec-
tion.
523213 12 Engine alarm SPN 523213 FMI 12 Timeout Error of CAN-Transmit-Frame ERC1 No detail informationen!
523216 9 Engine alarm SPN 523216 FMI 9 Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat com-
mand, engine command.
523240 9 Engine alarm SPN 523240 FMI 9 Timeout CAN-message FunModCtl; Function Mode Control.
523330 14 Engine alarm SPN 52330 FMI 14 Immobilizer status; fuel blocked.
523330 14 Engine alarm SPN 52330 FMI 14 DFC to block the fuel by Sia No detail informationen!
523330 14 Engine alarm SPN 52330 FMI 14 “DFC to indicate that TEN-code or UC-code received if ECU is
learned. No detail informationen!”
523330 14 Engine alarm SPN 52330 FMI 14 DFC to indicate that no code is received via CAN. No detail informa-
tionen!
523330 14 Engine alarm SPN 52330 FMI 14 DFC to indicate that wrong code is received. No detail informationen!
523350 4 Engine alarm SPN 523350 FMI 4 Injector cylinder-bank 1; short circuit.
523352 4 Engine alarm SPN 523352 FMI 4 Injector cylinder-bank 2; short circuit.
523354 12 Engine alarm SPN 523354 FMI 12 Injector powerstage output defect.
523450 4 Engine alarm SPN 523450 FMI 4 Multiple Stage Switch constant speed; short circuit to battery.
523470 2 Engine alarm SPN 523470 FMI 2 Pressure relief valve is forced to open, perform pressure increase.
523470 2 Engine alarm SPN 523470 FMI 2 Pressure Relief Valve (PRV) forced to open. Performed by pressure
increase.
523470 7 Engine alarm SPN 523470 FMI 7 Maximum rail pressure exceeded (PRV).
523470 11 Engine alarm SPN 523470 FMI 11 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance
range. Pressure Relief Valve (PRV) is open.
523470 11 Engine alarm SPN 523470 FMI 11 Rail pressure out of tolerance range. The PRV can not be opened at
this operating point with a pressure shock.
523470 12 Engine alarm SPN 523470 FMI 12 Pressure Relief Valve (PRV) forced to open. Shutoff conditions.
523470 12 Engine alarm SPN 523470 FMI 12 Pressure Relief Valve (PRV) forced to open. Warning conditions.
523470 14 Engine alarm SPN 523470 FMI 14 Pressure Relief Valve (PRV).
523550 12 Engine alarm SPN 523550 FMI 12 Terminal 50 was operated too long.
523580 2 Engine alarm SPN 523580 FMI 2 “Data set variant with the desired number not found Invalid variant
dataset Identifier error No detail informationen!”

20-175
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
523580 11 Engine alarm SPN 523580 FMI 11 “The code word could not be read correctly from the EEPROM Variant
dataset switching errorNo detail informationen!”
523580 11 Engine alarm SPN 523580 FMI 11 “An error has occurred in the switch over to the desired data set vari-
ant in the code word. Variant dataset switching error No detail infor-
mationen!”
523601 13 Engine alarm SPN 523601 FMI 13 Failure of sensor supply voltage 3.
523602 0 Engine alarm SPN 523602 FMI 0 High fan speed; warning threshold exceeded.
523602 0 Engine alarm SPN 523602 FMI 0 High fan speed; shut off threshold exceeded.
523603 9 Engine alarm SPN 523603 FMI 9 Timeout Error of CAN-Receive-Frame AMB; Ambient Temperature
Sensor.
523605 9 Engine alarm SPN 523605 FMI 9 Timeout Error of CAN-Receive-Frame TSC1AE; Traction Control.
523606 9 Engine alarm SPN 523606 FMI 9 Timeout Error of CAN-Receive-Frame TSC1AR; Retarder.
523612 3 Engine alarm SPN 523612 FMI 3 Reported Over Voltage of Supply.
523612 4 Engine alarm SPN 523612 FMI 4 Reported Under Voltage of Supply.
523612 12 Engine alarm SPN 523612 FMI 12 Internal software error ECU; injection cut off.
Table 96
Cod. Instrument panel display error Fault
Spn Fmi
523612 12 Engine alarm SPN 523612 FMI 12 Diagnosis fault check to report the demand for normal mode due to an
error in the PoI2 quantity.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnosis fault check to report the error to demand for an ICO due to
an error in the PoI2 shut-off.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnosis fault check to report the error to demand for an ICO due to
an error in the PoI3 efficiency factor.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnosis of curr path limitation forced by ECU monitoring level 2.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnosis of lead path limitation forced by ECU monitoring level 2.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnosis of set path limitation forced by ECU monitoring level 2.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report ABE active due to overvoltage detec-
tion.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report ABE active due to undervoltage de-
tection.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report the accelerator pedal position error.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report the engine speed error.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report the error due to non plausibility in
ZFC.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report the error due to torque comparison.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report WDA active due to errors in query-/
response communication.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report the plausibility error in rail pressure
monitoring.
523612 12 Engine alarm SPN 523612 FMI 12 ECU reported internal software error.
523612 12 Engine alarm SPN 523612 FMI 12 Diagnostic fault check to report WDA/ABE active due to unknown rea-
son.
523612 12 Engine alarm SPN 523612 FMI 12 Engine ster, plausibility error of ster release condition.
523612 12 Engine alarm SPN 523612 FMI 12 Error in the plausibility of the injection energizing time.
523612 12 Engine alarm SPN 523612 FMI 12 Injection system,electrical error injectors.
523612 12 Engine alarm SPN 523612 FMI 12 Error in the plausibility of the st of energising angles.
523612 12 Engine alarm SPN 523612 FMI 12 Internal ECU monitoring detection reported error.
523612 12 Engine alarm SPN 523612 FMI 12 Internal software error ECU.
523612 12 Engine alarm SPN 523612 FMI 12 Internal software error ECU; injection cut off.
523612 12 Engine alarm SPN 523612 FMI 12 Internal software error ECU; injection cut off. ECU reported internal
software error.
523612 12 Engine alarm SPN 523612 FMI 12 Monitoring of Fuel Quantity Correction.
523612 14 Engine alarm SPN 523612 FMI 14 CPU SWReset_0 Softwarereset CPU SWReset_0.
523612 14 Engine alarm SPN 523612 FMI 14 CPU SWReset_1 Softwarereset CPU SWReset_1.
523612 14 Engine alarm SPN 523612 FMI 14 CPU SWReset_2 Softwarereset CPU SWReset_2.
523613 0 Engine alarm SPN 523613 FMI 0 Setpoint of metering unit in overrun mode not plausible
523613 0 Engine alarm SPN 523613 FMI 0 Rail pressure metering unit, Positive governor deviation.

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Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
523613 0 Engine alarm SPN 523613 FMI 0 Rail pressure metering unit, Rail pressure disrupted. Maximum posi-
tive deviation of rail pressure exceeded.
Table 97
Cod. Instrument panel display error Fault
Spn Fmi
523613 0 Engine alarm SPN 523613 FMI 0 Rail pressure metering unit, Rail pressure disrupted. Maximum posi-
tive deviation of rail pressure in metering unit exceeded (RailMeUn1).
523613 0 Engine alarm SPN 523613 FMI 0 Rail pressure metering unit, Rail pressure disrupted. Railsystem leak-
age detected.
523613 0 Engine alarm SPN 523613 FMI 0 Rail pressure metering unit, Maximum rail pressure exceeded.
523613 1 Engine alarm SPN 523613 FMI 1 Rail pressure metering unit, Minimum rail pressure exceeded
(RailMeUn3). Negative deviation of rail pressure second stage
(RailMeUn22)
523613 2 Engine alarm SPN 523613 FMI 2 Rail pressure metering unit, Setpoint of metering unit in overrun mode
not plausible.
523615 3 Engine alarm SPN 523615 FMI 3 Metering unit (Fuel-System); short circuit to battery low side.
523615 3 Engine alarm SPN 523615 FMI 3 Metering unit (Fuel-System); short circuit to battery highside.
523615 3 Engine alarm SPN 523615 FMI 3 Metering unit, short circuit to battery.
523615 4 Engine alarm SPN 523615 FMI 4 Metering Unit (Fuel-System); short circuit to ground low side.
523615 4 Engine alarm SPN 523615 FMI 4 Metering unit (Fuel-System); short circuit to ground high side.
523615 4 Engine alarm SPN 523615 FMI 4 Metering unit, short circuit to ground.
523615 5 Engine alarm SPN 523615 FMI 5 Metering unit (Fuel-System); open load.
523615 12 Engine alarm SPN 523615 FMI 12 Metering unit (Fuel-System); powerstage over temperature.
523618 3 Engine alarm SPN 523618 FMI 3 Gearbox oil temperature; Short circuit to battery or broken harness.
523618 4 Engine alarm SPN 523618 FMI 4 Gearbox oil temperature; Short circuit to ground.
523619 2 Engine alarm SPN 523619 FMI 2 Physical range check high for exhaust gas temperature upstream
(SCR-CAT).
523632 0 Engine alarm SPN 523632 FMI 0 Pressure overload of SCR-System.
523632 1 Engine alarm SPN 523632 FMI 1 Pressure build-up error SCR-System.
523632 2 Engine alarm SPN 523632 FMI 2 Signal error for CAN message No detail informationen!
523632 3 Engine alarm SPN 523632 FMI 3 Sensor error urea pump pressure; signal range check high.
523632 4 Engine alarm SPN 523632 FMI 4 Sensor error urea pump pressure; signal range check low.
523632 11 Engine alarm SPN 523632 FMI 11 Pump motor not available for actuation.
523632 16 Engine alarm SPN 523632 FMI 16 Pump pressure SCR metering unit too high.
523632 18 Engine alarm SPN 523632 FMI 18 Pump pressure SCR metering unit too low.
-
-
DTC-List-EMR4: Diagnosis and Errorcodes
P: 5/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 523633-523918
Table 98
Cod. Instrument panel display error Fault
Spn Fmi
523633 11 Engine alarm SPN 523633 FMI 11 Long term adaption factor below threshold.
523633 11 Engine alarm SPN 523633 FMI 11 Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue qual-
ity).
523633 11 Engine alarm SPN 523633 FMI 11 Nox conversion rate insufficient (SCR-Cat defect, bad AdBlue qual-
ity); temperature range 1.
523698 11 Engine alarm SPN 523698 FMI 11 Shut off request from supervisory monitoring function.
523699 3 Engine alarm SPN 523699 FMI 3 Boost pressure control; negative governor deviation below limit
523699 4 Engine alarm SPN 523699 FMI 4 learning valu too high No detail informationen!
523704 12 Engine alarm SPN 523704 FMI 12 Timeout Error of CAN-Transmit-Frame EEC3.
523706 12 Engine alarm SPN 523706 FMI 12 Timeout Error of CAN-Transmit-Frame FlEco No detail informationen!

20-177
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
523717 12 Engine alarm SPN 523717 FMI 12 Timeout Error of CAN-Transmit-Frame AmbCon; Weather environ-
ments.
523718 3 Engine alarm SPN 523718 FMI 3 SCR main relay (primary side); short circuit to battery.
523718 3 Engine alarm SPN 523718 FMI 3 SCR mainrelay; short circuit to battery (only CV56B).
523718 4 Engine alarm SPN 523718 FMI 4 SCR main relay (primary side); short circuit to ground.
523718 4 Engine alarm SPN 523718 FMI 4 SCR mainrelay; short circuit to ground (only CV56B).
523718 5 Engine alarm SPN 523718 FMI 5 SCR mainrelay; open load (only CV56B).
523718 5 Engine alarm SPN 523718 FMI 5 SCR main relay (primary side); open load.
523718 12 Engine alarm SPN 523718 FMI 12 SCR main relay (primary side); powerstage over temperature.
523719 3 Engine alarm SPN 523719 FMI 3 SCR heater urea supplymodule; short circuit to battery.
523719 4 Engine alarm SPN 523719 FMI 4 SCR heater urea supplymodule; short circuit to ground.
523719 5 Engine alarm SPN 523719 FMI 5 SCR heater relay urea supply modul secondary side; open load.
523719 5 Engine alarm SPN 523719 FMI 5 SCR heater relay urea supplymodule primary side; open load.
523719 12 Engine alarm SPN 523719 FMI 12 Over Temperature error No detail informationen!
523720 2 Engine alarm SPN 523720 FMI 2 Urea supply module heater temperature; plausibility error. (normal
condition)
523720 2 Engine alarm SPN 523720 FMI 2 Sensor urea supply module heater temperature; plausibility. error
(cold st condition)
523720 8 Engine alarm SPN 523720 FMI 8 Urea supply module heater temperature; duty cycle in failure range.
523720 8 Engine alarm SPN 523720 FMI 8 Urea supply module heater temperature; duty cycle in invalid range.
523721 2 Engine alarm SPN 523721 FMI 2 Sensor urea supply module temperature; plausibility error. (normal
condition)
523721 2 Engine alarm SPN 523721 FMI 2 Sensor urea supply module temperature; plausibility error. (cold st
condition)
523721 8 Engine alarm SPN 523721 FMI 8 Urea supply module temperature; duty cycle in failure range.
523721 8 Engine alarm SPN 523721 FMI 8 Urea supply module temperature; duty cycle in invalid range.
523721 11 Engine alarm SPN 523721 FMI 11 Urea supply module temperature measurement not available.
523722 8 Engine alarm SPN 523722 FMI 8 Urea supply module PWM signal; period outside valid range.
523722 8 Engine alarm SPN 523722 FMI 8 Detect faulty PWM signal from Supply Modul.
523741 14 Engine alarm SPN 523741 FMI 14 Engine shut off request through CAN No detail informationen!
523752 0 Engine alarm SPN 523752 FMI 0 Plausibiliti error during Rich to Lean switch over No detail informa-
tionen!
523752 0 Engine alarm SPN 523752 FMI 0 Monitoring of Nox signal readyness No detail informationen!
523756 14 Engine alarm SPN 523756 FMI 14 special pattern for special cases No detail informationen!
523757 14 Engine alarm SPN 523757 FMI 14 special pattern for special cases No detail informationen!
523758 14 Engine alarm SPN 523758 FMI 14 special pattern for special cases No detail informationen!
523759 14 Engine alarm SPN 523759 FMI 14 special pattern for special cases No detail informationen!
523760 14 Engine alarm SPN 523760 FMI 14 special pattern for special cases No detail informationen!
523766 9 Engine alarm SPN 523766 FMI 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
523767 9 Engine alarm SPN 523767 FMI 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
523768 9 Engine alarm SPN 523768 FMI 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
523769 9 Engine alarm SPN 523769 FMI 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
523776 9 Engine alarm SPN 523776 FMI 9 Timeout Error of CAN-Receive-Frame TSC1TE - active.
523777 9 Engine alarm SPN 523777 FMI 9 Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint.
523778 9 Engine alarm SPN 523778 FMI 9 Timeout Error of CAN-Receive-Frame TSC1TR.
523779 9 Engine alarm SPN 523779 FMI 9 Passive Timeout Error of CAN-Receive-Frame TSC1TR.

20-178
Calibrations and electronic
diagnosis
Table 99
Cod. Instrument panel display error Fault
Spn Fmi
523788 0 Engine alarm SPN 523788 FMI 0 Wastegate;_ComTrbChActrPlaus.
523788 0 Engine alarm SPN 523788 FMI 0 Timeout Error of CAN-Receive-Frame ComTrbChActr; Wastegate.
523788 12 Engine alarm SPN 523788 FMI 12 Timeout Error of CAN-Transmit-Frame TrbCH; Status Wastegate.
523793 9 Engine alarm SPN 523793 FMI 9 Timeout Error of CAN-Receive-Frame UAA10; AGS sensor service
message.
523794 9 Engine alarm SPN 523794 FMI 9 Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data.
523803 9 Engine alarm SPN 523803 FMI 9 Timeout error of CAN Receive Message RxEngPres; Status Burner
Air Pump.
523858 12 Engine alarm SPN 523858 FMI 12 Timeout Error of CAN-Transmit-Frame UAA11. No detail information!
523867 12 Engine alarm SPN 523867 FMI 12 Timeout Error of CAN-Transmit-Frame UAA1 on CAN A
523889 3 Engine alarm SPN 523889 FMI 3 over teperature of device driver of pressure control valve No detail
informationen!
523891 14 Engine alarm SPN 523891 FMI 14 “When AirHt_ctDefSRCLoOn_mp is less than AirHt_ctMaxDef_C .
DFC to SRC Low error when heater is On No detail informationen!”
523895 13 Engine alarm SPN 523895 FMI 13 Check of missing injector adjustment value programming (IMA) injec-
tor 1 (in firing order).
523896 13 Engine alarm SPN 523896 FMI 13 check of missing injector adjustment value programming (IMA) injec-
tor 2 (in firing order).
523897 13 Engine alarm SPN 523897 FMI 13 Check of missing injector adjustment value programming (IMA) injec-
tor 3 (in firing order).
523898 13 Engine alarm SPN 523898 FMI 13 Check of missing injector adjustment value programming (IMA) injec-
tor 4 (in firing order).
523899 13 Engine alarm SPN 523899 FMI 13 Check of missing injector adjustment value programming (IMA) injec-
tor 5 (in firing order).
523900 13 Engine alarm SPN 523900 FMI 13 Check of missing injector adjustment value programming (IMA) injec-
tor 6 (in firing order).
523906 3 Engine alarm SPN 523906 FMI 5 Electrical fuel pre - supply pump; short circuit to battery
523906 4 Engine alarm SPN 523906 FMI 5 Electrical fuel pre - supply pump. Short circuit to ground.
523906 5 Engine alarm SPN 523906 FMI 5 Electrical fuel pre - supply pump; open load.
523906 12 Engine alarm SPN 523906 FMI 5 Electrical fuel pre - supply pump. ECU powerstage over temperature.
523910 0 Engine alarm SPN 523910 FMI 0 Air Pump; operating voltage error.
523910 6 Engine alarm SPN 523910 FMI 6 Air Pump; over current.
523910 7 Engine alarm SPN 523910 FMI 7 Air pump; CAN communication interrupted no purge function avail-
able.
523910 9 Engine alarm SPN 523910 FMI 9 Burner Control; Air Pump - CAN Lost Air Pump; CAN communication
lost.
523910 12 Engine alarm SPN 523910 FMI 12 Air Pump; internal error.
523910 14 Engine alarm SPN 523910 FMI 14 Air pump doesn´t achieve air mass flow setpoint. Burner Control -
burner air pump.
523911 0 Engine alarm SPN 523911 FMI 0 Burner dosing valve (DV2); overcurrent at the end of the injection
phase.
523911 3 Engine alarm SPN 523911 FMI 3 Burner dosing valve (DV2); short circuit to battery.
523911 4 Engine alarm SPN 523911 FMI 4 Burner dosing valve (DV2); short circuit to ground.
523911 11 Engine alarm SPN 523911 FMI 11 Burner dosing valve (DV2); short circuit high side powerstage.
523911 12 Engine alarm SPN 523911 FMI 12 Burner dosing valve (DV2); powerstage over temperature.
Table 100
Cod. Instrument panel display error Fault
Spn Fmi
523912 0 Engine alarm SPN 523912 FMI 0 Physical range check high for burner dosing valve (DV2) downstream
pressure; shut off regeneration.
523912 1 Engine alarm SPN 523912 FMI 1 Physical range check low for burner dosing valve (DV2) downstream
pressure; shut off regeneration. When burner injector is actuated, the
measured pressure does not rise above ca. 1250mbar abs (expected:
ca. 2400mbar).
523912 2 Engine alarm SPN 523912 FMI 2 Burner dosing valve (DV2) downstream pressure sensor; Plausibility
error.

20-179
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
523912 3 Engine alarm SPN 523912 FMI 3 Sensor error burner dosing valve (DV2) downstream pressure sensor;
signal range check high.
523912 4 Engine alarm SPN 523912 FMI 4 @ engines < 4l: Throttle valve error, Open Load or Short cut to Bat-
tery, blocked valve or wrong control signal for valve. / @ engines
with Burner T4i: Pressure Sensor error after valve (DV2), lower limit
reached.
523913 3 Engine alarm SPN 523913 FMI 3 Sensor error glow plug control diagnostic line voltage; signal range
check high.
523913 4 Engine alarm SPN 523913 FMI 4 Sensor error glow plug control diagnostic line voltage; signal range
check low.
523914 3 Engine alarm SPN 523914 FMI 3 Glow plug control; short circuit to battery water pump control (PWM).
523914 4 Engine alarm SPN 523914 FMI 4 Glow plug control; short circuit to ground water pump control (PWM).
523914 5 Engine alarm SPN 523914 FMI 5 Glow plug control; open load water pump control (PWM).
523914 12 Engine alarm SPN 523914 FMI 12 Glow plug control; powerstage over temperature.
523915 0 Engine alarm SPN 523915 FMI 0 HCI dosing valve (DV1); overcurrent at the end of the injection phase.
523915 3 Engine alarm SPN 523915 FMI 3 HCI dosing valve (DV1); short circuit to battery.
523915 3 Engine alarm SPN 523915 FMI 3 HCI dosing valve (DV1); short circuit to battery high side.
523915 4 Engine alarm SPN 523915 FMI 4 HCI dosing valve (DV1); short circuit to ground.
523915 7 Engine alarm SPN 523915 FMI 7 HCI dosing valve (DV1); blocked open.
523915 11 Engine alarm SPN 523915 FMI 11 HCI dosing valve (DV1); short circuit high side powerstage.
523915 12 Engine alarm SPN 523915 FMI 12 HCI dosing valve (DV1); powerstage over temperature.
523916 0 Engine alarm SPN 523916 FMI 0 Physical range check high for HCI dosing valve (DV1) downstream
pressure; shut off regeneration.
523916 1 Engine alarm SPN 523916 FMI 1 Physical range check low for HCI dosing valve (DV1) downstream
pressure; shut off regeneration.
523916 2 Engine alarm SPN 523916 FMI 2 Sensor HCI dosing valve (DV1) downstream pressure; plausibility er-
ror.
523916 3 Engine alarm SPN 523916 FMI 3 Sensor error HCI dosing valve (DV1) downstream pressure; signal
range check high.
523916 4 Engine alarm SPN 523916 FMI 4 Sensor error HCI dosing valve (DV1) downstream pressure; signal
range check low.
523917 3 Engine alarm SPN 523917 FMI 3 Sensor error DV1 & DV2 upstream pressure; signal range check high.
523917 4 Engine alarm SPN 523917 FMI 4 Sensor error DV1 & DV2 upstream pressure; signal range check low.
523918 3 Engine alarm SPN 523918 FMI 3 Sensor error DV1 & DV2 upstream temperature; signal range check
high.
523918 4 Engine alarm SPN 523918 FMI 4 Sensor error DV1 & DV2 upstream temperature; signal range check
low.

20-180
Calibrations and electronic
diagnosis
-
-
DTC-List-EMR4: Diagnosis and Errorcodes
P: 6/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 523919-524030
Table 101
Cod. Instrument panel display error Fault
Spn Fmi
523919 0 Engine alarm SPN 523919 FMI 0 DPF burner air pump pressure sensor, pressure above upper shutoff
threshold.
523919 1 Engine alarm SPN 523919 FMI 1 DPF burner air pump pressure sensor, pressure below lower shutoff
threshold.
523919 2 Engine alarm SPN 523919 FMI 2 DPF burner air pump pressure sensor, plausibility error.
523919 2 Engine alarm SPN 523919 FMI 2 Sensor air pump airpressure; plausibility error.
523919 3 Engine alarm SPN 523919 FMI 3 DPF burner air pump pressure sensor, short circuit to battery or open
load.
523919 4 Engine alarm SPN 523919 FMI 4 DPF burner air pump pressure sensor, short circuit to ground.
523920 0 Engine alarm SPN 523920 FMI 0 Exhaust Gas Pressure upstream burner, pressure above upper shut-
off threshold.
523920 2 Engine alarm SPN 523920 FMI 2 Sensor exhaust gas back pressure burner; plausibility error.
523920 2 Engine alarm SPN 523920 FMI 2 Exhaust Gas Pressure upstream burner, plausibility error.
523920 3 Engine alarm SPN 523920 FMI 3 Exhaust Gas Pressure upstream burner, short circuit to battery or
open load.
523920 4 Engine alarm SPN 523920 FMI 4 Exhaust Gas Pressure upstream burner, short circuit to ground.
523921 0 Engine alarm SPN 523921 FMI 0 Burner temperature, temperature above upper shutoff threshold.
523921 1 Engine alarm SPN 523921 FMI 1 Burner temperature, temperature below lower shutoff threshold.
523921 2 Engine alarm SPN 523921 FMI 2 Burner temperature sensor; Plausibility Check for burner temperature
sensor. Sensor burner temperature; plausibility error.
523921 3 Engine alarm SPN 523921 FMI 3 Sensor error burner temperature; signal range check high.
523921 4 Engine alarm SPN 523921 FMI 4 Sensor error burner temperature; signal range check low.
523922 3 Engine alarm SPN 523922 FMI 3 Burner shut of valve; short circuit to battery.
523922 4 Engine alarm SPN 523922 FMI 4 Burner Shut Off Valve; short circuit to ground.
523922 5 Engine alarm SPN 523922 FMI 5 Burner Shut Off Valve; open load.
523922 7 Engine alarm SPN 523922 FMI 7 Burner Control; Shut-off Valve - Blocked closed. Burner Shut Off
Valve; blocked closed.
523922 7 Engine alarm SPN 523922 FMI 7 Shut Off Valve; offen blockiert Burner Shut Off Valve; blocked open.
523922 12 Engine alarm SPN 523922 FMI 12 Burner Shut Off Valve; powerstage over.
523923 3 Engine alarm SPN 523923 FMI 3 UB1; Short circuit to battery error of actuator relay 1
523923 4 Engine alarm SPN 523923 FMI 4 Short circuit to ground error No detail informationen!
523924 3 Engine alarm SPN 523924 FMI 3 UB2; Short circuit to battery error of actuator relay 2.
523924 4 Engine alarm SPN 523924 FMI 4 UB2; Short circuit to ground actuator relais 2.
523925 3 Engine alarm SPN 523925 FMI 3 UB3: Short circuit to battery error of actuator relay 3.
523925 4 Engine alarm SPN 523925 FMI 4 UB3; Short circuit to ground actuator relais 3.
523926 4 Engine alarm SPN 523926 FMI 4 UB4; Short circuit to ground aktuator relais 4.
523927 3 Engine alarm SPN 523927 FMI 3 UB5; Short circuit to battery error of actuator relay 5, SCR-Heater/
Rev.Valve
523935 12 Engine alarm SPN 523935 FMI 12 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send
messages.
523936 12 Engine alarm SPN 523936 FMI 12 Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send
messages.
523937 9 Engine alarm SPN 523937 FMI 9 Timeout DFC for NOxSensGlbReqTx. No detail informationen!
Table 102
Cod. Instrument panel display error Fault
Spn Fmi
523938 9 Engine alarm SPN 523938 FMI 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1IGCVol1.

20-181
 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
523939 9 Engine alarm SPN 523939 FMI 9 Broadcast Announce Message of the calibration message of the up-
stream catalytic NOx sensor has failed.
523940 9 Engine alarm SPN 523940 FMI 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1.
523941 9 Engine alarm SPN 523941 FMI 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1OGCVol2.
523942 9 Engine alarm SPN 523942 FMI 9 Calibration message 1 of the after catalyst NOx sensor has failed.
523943 9 Engine alarm SPN 523943 FMI 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2.
523946 0 Engine alarm SPN 523946 FMI 0 Zerofuel calibration injector 1 (in firing order); maximum value ex-
ceeded.
523946 1 Engine alarm SPN 523946 FMI 1 Zerofuel calibration injector 1 (in firing order); minimum value exceed-
ed.
523947 0 Engine alarm SPN 523947 FMI 0 Zerofuel calibration injector 2 (in firing order); maximum value ex-
ceeded.
523947 1 Engine alarm SPN 523947 FMI 1 Zerofuel calibration injector 2 (in firing order); minimum value exceed-
ed.
523948 0 Engine alarm SPN 523948 FMI 0 Zerofuel calibration injector 3 (in firing order); maximum value ex-
ceeded.
523948 1 Engine alarm SPN 523948 FMI 1 Zerofuel calibration injector 3 (in firing order); minimum value exceed-
ed.
523949 0 Engine alarm SPN 523949 FMI 0 Zerofuel calibration injector 4 (in firing order); maximum value ex-
ceeded.
523949 1 Engine alarm SPN 523949 FMI 1 Zerofuel calibration injector 4 (in firing order); minimum value exceed-
ed.
523950 0 Engine alarm SPN 523950 FMI 0 Zerofuel calibration injector 5 (in firing order); maximum value ex-
ceeded.
523950 1 Engine alarm SPN 523950 FMI 1 Zerofuel calibration injector 5 (in firing order); minimum value exceed-
ed.
523951 0 Engine alarm SPN 523951 FMI 0 Zerofuel calibration injector 6 (in firing order); maximum value ex-
ceeded.
523953 2 Engine alarm SPN 523953 FMI 2 “Healing takes place if the condition for error detection is not present.
Air temprature monitoring plausibility check array No detail informa-
tionen!”
523955 2 Engine alarm SPN 523955 FMI 2 “Healing takes place if the condition for error detection is not present.
Air temprature monitoring plausibility check array No detail informa-
tionen!”
523960 0 Engine alarm SPN 523960 FMI 0 _High exhaust gas temperature EGR cooler downstream; warning
threshold exceeded.
523960 0 Engine alarm SPN 523960 FMI 0 Physical range check high for EGR cooler downstream temperature.
523960 1 Engine alarm SPN 523960 FMI 1 Physical range check low for EGR cooler downstream temperature.
523969 11 Engine alarm SPN 523969 FMI 11 Fault entry for override control mode. No detail informationen!
523973 14 Engine alarm SPN 523973 FMI 14 SCR Tamper detection; derating timer below limit 1.
523974 14 Engine alarm SPN 523974 FMI 14 SCR Tamper detection; derating timer below limit 2.
523975 14 Engine alarm SPN 523974 FMI 14 Urea quality; derating timer below limit 1.
523976 14 Engine alarm SPN 523976 FMI 14 Urea quality; derating timer below limit 2.
523977 14 Engine alarm SPN 523977 FMI 14 Urea tank level; derating timer below limit 1.
523978 14 Engine alarm SPN 523978 FMI 14 Urea tank level; derating timer below limit 2.
523981 11 Engine alarm SPN 523981 FMI 11 SCR plausibility, OBD and diagnosis; Stuck in range check of Urea
tank temperature sensor. Urea-tank without heating function (heating
phase).
523982 0 Engine alarm SPN 523982 FMI 0 Powerstage diagnosis disabled; high battery voltage.
523982 1 Engine alarm SPN 523982 FMI 1 Powerstage diagnosis disabled; low battery voltage.
523984 3 Engine alarm SPN 523984 FMI 3 UB7; Short circuit to battery error of actuator relay 6.

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Calibrations and electronic
diagnosis
Table 103
Cod. Instrument panel display error Fault
Spn Fmi
523986 4 Engine alarm SPN 523986 FMI 4 Relais SCR-Heater, Short Circuit to Ground (Highside Contro side)
523987 4 Engine alarm SPN 523987 FMI 4 UB6; Short circuit to ground actuator relay 6
523992 9 Engine alarm SPN 523992 FMI 9 0
523993 9 Engine alarm SPN 523993 FMI 9 0
523995 13 Engine alarm SPN 523995 FMI 13 Check of missing injector adjustment value programming (IMA) injec-
tor 7 (in firing order)
523996 13 Engine alarm SPN 523996 FMI 13 check of missing injector adjustment value programming (IMA) injec-
tor 8 (in firing order)
523997 4 Engine alarm SPN 523997 FMI 4 Injector cylinder bank 1 slave; short circuit
523998 4 Engine alarm SPN 523998 FMI 4 Injector cylinder bank 2 slave; short circuit
523999 12 Engine alarm SPN 523998 FMI 12 Injector powerstage output Slave defect
524000 3 Engine alarm SPN 524000 FMI 3 Injector 7 (in firing order); short circuit.
524000 5 Engine alarm SPN 524000 FMI 5 Injector 7 (in firing order); interruption of electric connection.
524001 3 Engine alarm SPN 524001 FMI 3 Injector 8 (in firing order); short circuit.
524001 5 Engine alarm SPN 524001 FMI 5 Injector 8 (in firing order); interruption of electric connection.
524013 7 Engine alarm SPN 524013 FMI 7 Burner Control; burner Flame; Burner does not st after x trials. (burner
flame lost detection) Burner flame unintentional deleted.
524013 7 Engine alarm SPN 524013 FMI 7 Burner Control; Flame lost max. Burner operation is interrupted too
often.
524014 1 Engine alarm SPN 524014 FMI 1 Air inlet EPV - pressure too low. Air pressure glow plug flush line;
below limit.
524016 2 Engine alarm SPN 524016 FMI 2 Burner Control; HFM - Plausibilitätsfehler 1. Amount of air is not plau-
sible to pump speed.
524016 11 Engine alarm SPN 524016 FMI 11 Burner Control; HFM - Electrical Fault. HFM sensor; electrical fault.
524018 14 Engine alarm SPN 524018 FMI 14 HMI engine derate service state DPF wasn´t regenerated, power re-
duction phase 1. (manual regeneration request).
524019 11 Engine alarm SPN 524019 FMI 11 Burner Control; Air Line-Blocked. Air Pump; air lines blocked
524020 14 Engine alarm SPN 524020 FMI 14 Burner Control: power reduction due to low lambda. Engine power;
Not enough oxygen for regeneration.
524021 11 Engine alarm SPN 524021 FMI 11 Burner Control; Fuel line ShutOff downstream - broken. Burner fuel
line pipe leak behind Shut Off Valve.
524022 14 Engine alarm SPN 524022 FMI 14 HMI engine derate stop state DPF wasn´t regenerated, power reduc-
tion phase 2. (manual regeneration request).
524024 11 Engine alarm SPN 524024FMI 11 Deviation of the exhaust gas temperature setpoint to actual value
downstream (DOC) too high.
524025 5 Engine alarm SPN 524025 FMI 5 _DPF system; operating voltage error.
524025 14 Engine alarm SPN 524025 FMI 14 The standstill-regeneration mode time exceeds the long-limit. Vehicle
was too long or too often in standstill mode. Make oil change and
reset counter.
524025 14 Engine alarm SPN 524025 FMI X The standstill-regeneration mode time exceeds the short-limit. Vehicle
was too long or too often within a short time in standstill mode. Make
oil change and reset counter.
524025 14 Engine alarm SPN 524025 FMI X Piculate filter regeneration. Regeneration after time X is not success-
ful (The error occurs when the regeneration times (3x) over the max.
has been aborted allowed recovery time).
524028 2 Engine alarm SPN 524028 FMI X CAN message PROEGRActr; plausibility error.
524029 2 Engine alarm SPN 524029 FMI X Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas
recirculation positioner.
524030 7 Engine alarm SPN 524030 FMI X _EGR actuator; internal error.
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DTC-List-EMR4: Diagnosis and Errorcodes
P: 7/9
Revision: 1.0
Date: 19/04/2016

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 Calibrations and electronic
diagnosis
Engine ECU Alarms: SPN 524031-524108
Table 104
Cod. Instrument panel display error Fault
Spn Fmi
524031 13 Engine alarm SPN 524031 FMI 13 EGR actuator, calibration error.
524032 2 Engine alarm SPN 524032 FMI 2 EGR actuator; status message “EGRCust” is missing.
524033 7 Engine alarm SPN 524033 FMI 7 _EGR actuator; due to overload in Save Mode.
524034 3 Engine alarm SPN 524034 FMI 3 Disc separator; short circuit to battery.
524034 4 Engine alarm SPN 524034 FMI 4 Disc separator; short circuit to ground.
524034 5 Engine alarm SPN 524034 FMI 5 Disc Separator; open load.
524034 12 Engine alarm SPN 524034 FMI 12 Disc Separator; powerstage over temperature.
524035 12 Engine alarm SPN 524035 FMI 12 Injector diagnostics; time out error in the SPI communication
524036 12 Engine alarm SPN 524036 FMI 12 Injector diagnostics Slave; time out error in the SPI communication.
524038 9 Engine alarm SPN 524038 FMI 9 Timeout error of CAN-Receive-Frame ComMS_Sys1TO (error mem-
ory Slave); Master-Slave internal CAN message.
524039 9 Engine alarm SPN 524039 FMI 9 Timeout error of CAN-Receive-Frame ComMS_Sys2TO (error mem-
ory Slave); Master-Slave internal CAN message.
524040 9 Engine alarm SPN 524040 FMI 9 Timeout error of CAN-Receive-Frame ComMS_Sys3TO (error mem-
ory Slave); Master-Slave internal CAN message.
524041 9 Engine alarm SPN 524041 FMI 9 Timeout error of CAN-Receive-Frame ComMS_Sys4TO (error mem-
ory Slave); Master-Slave internal CAN message.
524042 9 Engine alarm SPN 524042 FMI 9 Timeout error of CAN-Receive-Frame ComMS_Sys5TO (error mem-
ory Slave); Master-Slave internal CAN message.
524043 9 Engine alarm SPN 524043 FMI 9 Timeout error of CAN-Receive-Frame ComMS_Sys6TO (error mem-
ory Slave); Master-Slave internal CAN message.
524044 9 Engine alarm SPN 524044 FMI 9 CAN message ComMS_Sys7 not received from slave.
524045 9 Engine alarm SPN 524045 FMI 9 Master Slave, Error of message counter CAN receive message Com-
MSMoFOvR; ComMSMoFOvR1CNT.
524046 9 Engine alarm SPN 524046 FMI 9 Master-Slave CAN; Error Checksum of CAN-Receive Message.
524047 9 Engine alarm SPN 524047 FMI 9 Master-Slave CAN; Error of message length of CAN receive message
ComMSMoFOvR;_ComMSMoFOvR1DLC.
524048 9 Engine alarm SPN 524048 FMI 9 Timeout error CAN message ComMSMoFOvR1TO error memory
Slave.
524050 11 Engine alarm SPN 524050 FMI 11 CAN; not used.
524051 11 Engine alarm SPN 524051 FMI 11 CAN; not used.
524052 11 Engine alarm SPN 524052 FMI 11 Master ECU and Slave ECU data sets or software are not identical.
524052 11 Engine alarm SPN 524052 FMI 11 Error memory Slave reports FID MSMonFC2. (collective error)
524052 11 Engine alarm SPN 524052 FMI 11 Error memory Slave reports FID MSMonFC3. (collective error)
524057 2 Engine alarm SPN 524057 FMI 11 Fuel low pressure pump; error pressure build up.
524058 2 Engine alarm SPN 524058 FMI 11 Piculate filter; regeneration not succesful
Table 105
Cod. Instrument panel display error Fault
Spn Fmi
524063 3 Engine alarm SPN 524063 FMI 3 SCR heater mainrelay; short circuit to battery.
524063 4 Engine alarm SPN 524063 FMI 4 SCR heater main relay load side (K31) on heating valve (Y31), Short
cut to ground.
524063 5 Engine alarm SPN 524063 FMI 5 SCR heater return line; open load.
524063 5 Engine alarm SPN 524063 FMI 5 SCR main relay not connected.
524063 5 Engine alarm SPN 524063 FMI 5 SCR heater pressureline; open load.
524063 5 Engine alarm SPN 524063 FMI 5 SCR relay for suction line not connected.
524063 5 Engine alarm SPN 524063 FMI 5 SCR heater supply module; open load.
524063 5 Engine alarm SPN 524063 FMI 5 SCR heater tank; open load.
524063 12 Engine alarm SPN 524063 FMI 12 DEF supply modul, time for defrosting too long.
524063 12 Engine alarm SPN 524063 FMI 12 DEF tank, time for defrosting too long.
524065 0 Engine alarm SPN 524065 FMI 0 Pressure sensor upstream SCR-CAT, pressure above upper physical
threshold.
524065 1 Engine alarm SPN 524065 FMI 1 Pressure sensor upstream SCR-CAT, pressure below lower physical
threshold.
524065 2 Engine alarm SPN 524065 FMI 2 Pressure sensor upstream SCR-CAT, plausibility error.

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Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
524065 3 Engine alarm SPN 524065 FMI 3 Pressure sensor upstream SCR-CAT; short circuit battery or open
load.
524065 4 Engine alarm SPN 524065 FMI 4 Pressure sensor upstream SCR-CAT; short circuit ground.
524066 3 Engine alarm SPN 524066 FMI 3 SCR measurement heater output stage; short circuit battery or open
load
524067 0 Engine alarm SPN 524067 FMI 0 DEF supply module, heater temperature above upper physical thresh-
old.
524067 0 Engine alarm SPN 524067 FMI 0 DEF supply module, temperature above upper physical threshold.
524067 1 Engine alarm SPN 524067 FMI 1 DEF supply module, heater temperature below lower physical thresh-
old.
524067 1 Engine alarm SPN 524067 FMI 1 DEF supply module, temperature below lower physical threshold.
524067 2 Engine alarm SPN 524067 FMI 2 Supply module heater temperature, plausibility error.
524067 2 Engine alarm SPN 524067 FMI 2 Supply module temperature, plausibility error.
524068 2 Engine alarm SPN 524068 FMI 2 Master ECU and Slave ECU have been identified as the same types.
524069 9 Engine alarm SPN 524069 FMI 9 Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-
Slave CAN communication faulty.
524070 2 Engine alarm SPN 524070 FMI 2 (Upstream NOx-Sensor) Diagnostic Fault Check for invalid upstream
NOx value (Sensor self diagnostic DFC set by Deutz-SW). NOx-Sen-
sor before SCR-Cat: Invalid upstream NOx value.
524071 2 Engine alarm SPN 524071 FMI 2 (Downstream NOx-Sensor) Diagnostic Fault Check for invalid down-
stream lambda value. (Sensor self diagnostic DFC set by Deutz-SW)
524072 2 Engine alarm SPN 524072 FMI 2 (Upstream NOx-Sensor) Diagnostic Fault Check for invalid upstream
lambda value. (Sensor self diagnostic DFC set by Deutz-SW)
524073 2 Engine alarm SPN 524073 FMI 2 (Downstream NOx-Sensor) Diagnostic Fault Check for invalid down-
stream NOx value. (Sensor self diagnostic DFC set by Deutz-SW)
524074 2 Engine alarm SPN 524074 FMI 2 NOx-Sensor after SCR-Cat: Nox-Sensor dew point problem or plau-
sibility problem.
524074 9 Engine alarm SPN 524074 FMI 9 NOx sensor downstream SCR-CAT, sensor internally open load.
Table 106
Cod. Instrument panel display error Fault
Spn Fmi
524075 11 Engine alarm SPN 524075 FMI 11 NOx sensor downstream SCR-CAT, sensor internally short circuit.
524076 2 Engine alarm SPN 524076 FMI 2 NOx-Sensor before SCR-Cat: Nox-Sensor dew point problem or plau-
sibility problem.
524076 9 Engine alarm SPN 524076 FMI 9 NOx sensor upstream SCR-CAT, sensor internally open line.
524077 11 Engine alarm SPN 524077 FMI 11 NOx sensor upstream SCR-CAT, sensor internally short circuit.
524078 9 Engine alarm SPN 524078 FMI 9 NOx sensor downstream SCR-CAT, lambda value above upper physi-
cal threshold.
524079 9 Engine alarm SPN 524079 FMI 9 NOx sensor downstream SCR-CAT, lambda value below lower physi-
cal threshold.
524080 9 Engine alarm SPN 524080 FMI 9 NOx sensor upstream SCR-CAT, lambda value above upper physical
threshold.
524081 9 Engine alarm SPN 524081 FMI 9 NOx sensor upstream SCR-CAT, lambda value below lower physical
threshold.
524082 9 Engine alarm SPN 524082 FMI 9 (Downstream NOx-Sensor) Diagnostic Fault Check for downstream
NOx value over maximum limit. (DFC set by Deutz-SW)
524083 9 Engine alarm SPN 524083 FMI 9 NOx-Sensor downstream SCR-CAT, NOx value below minimum val-
ue.
524084 9 Engine alarm SPN 524084 FMI 9 NOx-Sensor upstream SCR-CAT, NOx value above maximum value.
524085 9 Engine alarm SPN 524085 FMI 9 NOx sensor upstream SCR-CAT, NOx value below lower physical
threshold.
524087 3 Engine alarm SPN 524087 FMI 3 Urea Error Lamp; short circuit battery.
524087 4 Engine alarm SPN 524087 FMI 4 Urea Error Lamp; short circuit ground.
524087 5 Engine alarm SPN 524087 FMI 5 Urea Error Lamp; open load.
524087 12 Engine alarm SPN 524087 FMI 12 Urea Error Lamp; temperatur over limit.

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 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
524096 14 Engine alarm SPN 524096 FMI 14 “Control of the SCR system; If the st stop counter (EPA-Counter) ex-
ceeds the threshold SCRCtl_ctEngStrtStopThresh_C. This counter
will increment only once in each driving cycle in case of an SCR error.
If the counter reaches the threshold, the DFC will be set to inhibit the
engine st Engine will not be sted, because of EPA-Counter”
524097 9 Engine alarm SPN 524097 FMI 9 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl.
524098 9 Engine alarm SPN 524098 FMI 9 Timeout error of CAN-Transmit-Frame ComDPFBrnPT.
524099 9 Engine alarm SPN 524099 FMI 9 Timeout error of CAN-Transmit-Frame ComDPFC1.
524100 9 Engine alarm SPN 524100 FMI 9 Timeout error of CAN-Transmit-Frame ComDPFHisDat.
524101 9 Engine alarm SPN 524101 FMI 9 Timeout error of CAN-Transmit-Frame ComDPFTstMon.
524102 9 Engine alarm SPN 524102 FMI 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl.
524103 9 Engine alarm SPN 524103 FMI 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp.
524104 9 Engine alarm SPN 524104 FMI 9 Timeout error of CAN-Receive-Frame ComRxDPFCtl.
524105 9 Engine alarm SPN 524105 FMI 9 Timeout error of CAN-Transmit-Frame ComEGRMsFlw.
524106 9 Engine alarm SPN 524106 FMI 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1.
524107 9 Engine alarm SPN 524107 FMI 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2.
524108 9 Engine alarm SPN 524108 FMI 9 Timeout error of CAN-Transmit-Frame ComEGRTVActr.
-
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DTC-List-EMR4: Diagnosis and Errorcodes
P: 8/9
Revision: 1.0
Date: 19/04/2016
Engine ECU Alarms: SPN 524109-524267
Table 107
Cod. Instrument panel display error Fault
Spn Fmi
524109 9 Engine alarm SPN 524109 FMI 9 Timeout error of CAN-Receive-Frame ComR11EGRTVActr.
524110 9 Engine alarm SPN 524110 FMI 9 Not Available.
524111 9 Engine alarm SPN 524111 FMI 9 Timeout error of CAN-Receive-Frame ComR11ETVActr.
524112 9 Engine alarm SPN 524112 FMI 9 Timeout ComIntake Throttle Valve Actr.
524113 9 Engine alarm SPN 524113 FMI 9 Timeout error of CAN-Receive-Frame ComR11ITVActr.
524114 9 Engine alarm SPN 524114 FMI 9 Timeout error of CAN-Transmit-Frame A1DOC.
524115 9 Engine alarm SPN 524115 FMI 9 Timeout error of CAN-Transmit-Frame AT1S.
524116 9 Engine alarm SPN 524116 FMI 9 Timeout error of CAN-Transmit-Frame SCR2.
524117 9 Engine alarm SPN 524117 FMI 9 Timeout error of CAN-Transmit-Frame SCR3.
524118 9 Engine alarm SPN 524118 FMI 9 Timeout error of CAN-Receive-Frame ComRxCM1.
524119 9 Engine alarm SPN 524119 FMI 9 Timeout error of CAN-Receive-Frame ComRxCustSCR3.
524120 9 Engine alarm SPN 524120 FMI 9 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag.
524121 9 Engine alarm SPN 524121 FMI 9 Timeout error of CAN-Receive-Frame ComRxTrbChActr.
524122 9 Engine alarm SPN 524122 FMI 9 Timeout error of CAN-Receive-Frame ComRxUQSens.
524123 9 Engine alarm SPN 524123 FMI 9 Timeout error of CAN-Receive-Frame ComSCRHtCtl.
524124 9 Engine alarm SPN 524124 FMI 9 Timeout error of CAN-Receive-Frame ComTxAT1IMG.
524125 9 Engine alarm SPN 524125 FMI 9 Timeout error of CAN-Receive-Frame ComTxTrbChActr.
524132 0 Engine alarm SPN 524132 FMI 0 Fuel low pressure upstream fuel low pressure pump, pressure above
maximum warning threshold.
524132 0 Engine alarm SPN 524132 FMI 0 Fuel low pressure upstream fuel low pressure pump, pressure above
maximum shut off threshold.
524132 1 Engine alarm SPN 524132 FMI 1 Fuel low pressure upstream fuel low pressure pump, pressure below
minimum shut off threshold.
524132 1 Engine alarm SPN 524132 FMI 1 Fuel low pressure upstream fuel low pressure pump, pressure below
minimum warning threshold.
524132 2 Engine alarm SPN 524132 FMI 2 Fuel low pressure upstream fuel low pressure pump not plausible.
524133 2 Engine alarm SPN 524133 FMI 2 HMI system; set if restore button blocked.
524134 0 Engine alarm SPN 524134 FMI 0 DPF, ash load exceeds the shutoff threshold.
524134 0 Engine alarm SPN 524134 FMI 0 DPF, ash load exceeds the warning threshold.
524135 0 Engine alarm SPN 524135 FMI 0 DPF, soot load exceeds the shutoff threshold.

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Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
524135 0 Engine alarm SPN 524135 FMI 0 DPF, soot load exceeds the warning threshold.
524135 14 Engine alarm SPN 524135 FMI 14 DPF, soot load exceeds the service request threshold.
524141 7 Engine alarm SPN 524141 FMI 7 DEF dosing valve, dosing valve blocked.
524147 7 Engine alarm SPN 524147 FMI 7 SCR-System, reverting valve blocked.
Table 108
Cod. Instrument panel display error Fault
Spn Fmi
524147 13 Engine alarm SPN 524147 FMI 13 SCR System,pressure build up not possible.
524147 13 Engine alarm SPN 524147 FMI 13 “Set together with DFC_SCRCoBldUpLoPres. DFC_SCRCoBldU-
pLoPresRst is only used for inducement purposes. It ensures that
legal inducement is working correctly.”
524149 2 Engine alarm SPN 524149 FMI 2 Plausibility error between pressure downstream turbine (PTrbnDs)
and ambient air pressure (EnvP).
524149 2 Engine alarm SPN 524149 FMI 2 Pressure downstream turbine, plausibility error.
524152 2 Engine alarm SPN 524152 FMI 2 Urea Quality Sensor; Timeout CAN message.
524153 2 Engine alarm SPN 524153 FMI 2 Timeout CAN-Botschaft Urea tank level & urea tank temperature via
CAN bus, timeout of CAN message.
524156 9 Engine alarm SPN 524156 FMI 9 Timeout error of CAN-Receive-Frame ComRxEBC2.
524175 0 Engine alarm SPN 524175 FMI 0 SCR-CAT, Nox emissions above maximum threshold.
524177 7 Engine alarm SPN 524177 FMI 7 SCR System, DEF suction line blocked.
524178 7 Engine alarm SPN 524178 FMI 7 SCR System, DEF pressure out of range.
524189 9 Engine alarm SPN 524189 FMI 9 Master / Slave Can disturbed.
524190 14 Engine alarm SPN 524190 FMI 14 Inducement level 1 active.
524191 14 Engine alarm SPN 524191 FMI 14 Inducement level 2 active.
524193 8 Engine alarm SPN 524193 FMI 8 The standstill-regeneration mode time exceeds the long limit thresh-
old. Vehicle was too long or too often in standstill mode.
524194 8 Engine alarm SPN 524194 FMI 8 The standstill-regeneration mode time exceeds the short-limit. Vehicle
was too long or too often within a short time in standstill mode.
524195 14 Engine alarm SPN 524195 FMI 14 Standstill request due to crystalisation ignored too long.
524196 2 Engine alarm SPN 524196 FMI 2 Variant handling, Synchronisation error.
524196 13 Engine alarm SPN 524196 FMI 13 Variant handling, address error.
524197 7 Engine alarm SPN 524197 FMI 7 Urea backflow line is blocked.
524198 11 Engine alarm SPN 524198 FMI 11 Inducement HW Failure Master.
524199 11 Engine alarm SPN 524199 FMI 11 Inducement SCR Tamp Master.
524200 11 Engine alarm SPN 524200 FMI 11 Inducement Urea QTY Master.
524201 11 Engine alarm SPN 524201 FMI 11 Urea Level Error Master.
524202 11 Engine alarm SPN 524202 FMI 11 Urea Temp. Error Master.
524203 11 Engine alarm SPN 524203 FMI 11 M/S Monitoring Fault Coupling: FID06 in the slave not present. Urea
Level Replace Master.
524204 11 Engine alarm SPN 524204 FMI 11 M/S Monitoring Fault Coupling: FID07 in the slave not present. SCR
System Afterrun Master.
524205 11 Engine alarm SPN 524205 FMI 11 M/S Monitoring Fault Coupling: FID08 in the slave not present. Switch
Off SCR System Master.
524206 11 Engine alarm SPN 524206 FMI 11 M/S Monitoring Fault Coupling: FID09 in the slave not present. Dis-
able SCR Dosing Master.
524207 11 Engine alarm SPN 524207 FMI 11 M/S Monitoring Fault Coupling: FID10 in the slave not present. INH
EAT Regeneration Master
524208 11 Engine alarm SPN 524208 FMI 11 M/S Monitoring Fault Coupling: FID11 in the slave not present. Power
Reduction 1 Master.
524209 11 Engine alarm SPN 524209 FMI 11 M/S Monitoring Fault Coupling: FID12 in the slave not present. Power
Reduction 2 Master.
Table 109
Cod. Instrument panel display error Fault
Spn Fmi
524210 11 Engine alarm SPN 524210 FMI 11 Urea CONC Replace Master.
524211 11 Engine alarm SPN 524211 FMI 11 Urea Quality Error Master.
524212 11 Engine alarm SPN 524212 FMI 11 DEF Sensor Diag. Off Master.
524213 11 Engine alarm SPN 524213 FMI 11 DEF Sens Temp. Replace Master.

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 Calibrations and electronic
diagnosis
Cod. Instrument panel display error Fault
Spn Fmi
524230 11 Engine alarm SPN 524230 FMI 11 Inducement HW Failure Slave.
524231 11 Engine alarm SPN 524231 FMI 11 Inducement SCR Tamp. Slave.
524232 11 Engine alarm SPN 524232 FMI 11 Inducement Urea QTY Slave.
524233 11 Engine alarm SPN 524233 FMI 11 Urea Level Error Slave.
524234 11 Engine alarm SPN 524234 FMI 11 Urea Temp. Error Slave.
524235 11 Engine alarm SPN 524235 FMI 11 M/S Monitoring Fault Coupling: FID06 in the master not present. Urea
Level Replace Slave.
524236 11 Engine alarm SPN 524236 FMI 11 M/S Monitoring Fault Coupling: FID07 in the master not present. SCR
System Afterrun Slave.
524237 11 Engine alarm SPN 524237 FMI 11 M/S Monitoring Fault Coupling: FID08 in the master not present.
Switch Off SCR System Slave.
524238 11 Engine alarm SPN 524238 FMI 11 M/S Monitoring Fault Coupling: FID09 in the master not present. Dis-
able SCR Dosing Slave.
524239 11 Engine alarm SPN 524239 FMI 11 M/S Monitoring Fault Coupling: FID10 in the master not present. INH
EAT Regeneration Slave.
524240 11 Engine alarm SPN 524240 FMI 11 Power Reduction 1 Slave.
524241 11 Engine alarm SPN 524241 FMI 11 M/S Monitoring Fault Coupling: FID12 in the master not present. Pow-
er Reduction 2 Slave.
524242 11 Engine alarm SPN 524242 FMI 11 M/S Monitoring Fault Coupling: FID13 in the master not present. Urea
CONC Replace Slave.
524243 11 Engine alarm SPN 524243 FMI 11 M/S Monitoring Fault Coupling: FID14 in the master not present. Urea
Quality Error Slave.
524244 11 Engine alarm SPN 524244 FMI 11 M/S Monitoring Fault Coupling: FID15 in the master not present. DEF
Sensor Diag. Off Slave.
524245 11 Engine alarm SPN 524245 FMI 11 M/S Monitoring Fault Coupling: FID16 in the master not present. DEF
Sens Temp. Replace Slave.
524248 11 Engine alarm SPN 524248 FMI 11 NOX sensor downstream error in slave ECU
524249 11 Engine alarm SPN 524249 FMI 11 DEF dosing valve error in slave ECU
524251 11 Engine alarm SPN 524251 FMI 11 DEF pressure problems in slave ECU
524252 11 Engine alarm SPN 524252 FMI 11 Reverting valve error in slave ECU
524253 11 Engine alarm SPN 524253 FMI 11 DEF back flow line heater error on slave ECU
524254 11 Engine alarm SPN 524254 FMI 11 Error NOx-Tailpipe emissions exceeded on Slave ECU
524255 11 Engine alarm SPN 524255 FMI 11 DEF suction line heater error on slave ECU
524256 11 Engine alarm SPN 524256 FMI 11 DEF supply module heater error on slave ECU
524257 11 Engine alarm SPN 524257 FMI 11 Error Exhaust pressure upstream SCR on Slave ECU
524258 11 Engine alarm SPN 524258 FMI 11 Error Exhaust temperature upstream SCR on Slave ECU
524259 11 Engine alarm SPN 524259 FMI 11 DEF pressure line heater error on slave ECU
524260 11 Engine alarm SPN 524260 FMI 11 Error Urea pump temperature on Slave ECU
524261 11 Engine alarm SPN 524261 FMI 11 Error DEF heater relais on Slave ECU
524266 14 Engine alarm SPN 524266 FMI 14 Announcement triggers the Inducement Level 2
524267 14 Engine alarm SPN 524267 FMI 14 Max. launch time for stand still exceeded (60min).

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diagnosis
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DTC-List-EMR4: Diagnosis and Errorcodes
P: 9/9
Revision: 1.0
Date: 19/04/2016
20.4.2 - Instrument panel alarms
Alarms - Instrument alarms list (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110
C -> ZKDY440200TD10001)
Table 110
Instru- Severity Component Fault Controls Link to system
ment
panel
display
error
I 18 Low - Temperature sensor short cir- -
cuit to earth
I 19 Low - Temperature sensor power -
supply short circuit
I 20 Low K010 Fuel level sensor short circuit - 40-338
to battery
I 21 Low - Frequency sensor 1 not con- -
nected
I 22 Low - Frequency sensor 2 not con- -
nected
I 23 Low - Power output 0 disconnected -
I 24 Low - Power output 0 short circuit -
to earth
I 25 Low - Power output 0 short circuit -
to battery
I 26 Low - Power output 0 short circuit -
to battery or open circuit
I 32 Low - Power output 1 disconnected -
I 33 Low - Power output 1 short circuit -
to earth
I 34 Low - Power output 1 short circuit -
to battery
I 35 Low - Power output 1 short circuit -
to battery or open circuit
I 36 Medium - Relay shorting or feedback -
wire connected to power in-
put instead of output (Pre-
heating function)
I 37 Low - Relay faulty (preheating func- -
tion)
I 38 Medium - Seat sensor S.C. to earth -
I 39 Medium - Seat sensor S.C. to Vdc -
I 40 Medium - Seat sensor out of range -
M 41 Low - Timeout of CAN message -
“Measured Data1” sent by
engine ECU
T 42 Low - Timeout of CAN message -
“FPS transmission controller”
sent by transmission ECU
L 43 Low - Timeout of CAN message -
“System controller MSG#2”
sent by hitch ECU

20-189
 Calibrations and electronic
diagnosis
Instru- Severity Component Fault Controls Link to system
ment
panel
display
error
U 44 Low - Timeout of CAN message -
“HLHP Control” sent by User
Controller ECU
Alarms - Instrument alarms list (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001)
Table 111
Instru- Severity Component Fault Controls Link to system
ment
panel
display
error
I 18 Low - Temperature sensor short cir- -
cuit to earth
I 19 Low - Temperature sensor power -
supply short circuit
I 20 Low K010 Fuel level sensor short circuit - 40-354
to battery
I 21 Low - Frequency sensor 1 not con- -
nected
I 22 Low - Frequency sensor 2 not con- -
nected
I 23 Low - Power output 0 disconnected -
I 24 Low - Power output 0 short circuit -
to earth
I 25 Low - Power output 0 short circuit -
to battery
I 26 Low - Power output 0 short circuit -
to battery or open circuit
I 32 Low - Power output 1 disconnected -
I 33 Low - Power output 1 short circuit -
to earth
I 34 Low - Power output 1 short circuit -
to battery
I 35 Low - Power output 1 short circuit -
to battery or open circuit
I 36 Medium - Relay shorting or feedback -
wire connected to power in-
put instead of output (Pre-
heating function)
I 37 Low - Relay faulty (preheating func- -
tion)
I 38 Medium - Seat sensor S.C. to earth -
I 39 Medium - Seat sensor S.C. to Vdc -
I 40 Medium - Seat sensor out of range -
M 41 Low - Timeout of CAN message -
“Measured Data1” sent by
engine ECU
T 42 Low - Timeout of CAN message -
“FPS transmission controller”
sent by transmission ECU
L 43 Low - Timeout of CAN message -
“System controller MSG#2”
sent by lift ECU

20-190
Calibrations and electronic
diagnosis
Instru- Severity Component Fault Controls Link to system
ment
panel
display
error
U 44 Low - Timeout of CAN message -
“HLHP Control” sent by User
Controller ECU

20.4.3 - HLHP alarms

HLHP2 Service ECU alarms “User Control”
Alarms in “Uxx” code order
U0x alarms
Table 112
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U1 664-12 ECU detects a PTO speed sensor fault. -
U2 662-3 ECU detects that the rear PTO control buttons on the mudguards are still -
pressed.
U3 697-3 ECU detects that the rear PTO control button is shorting to ground. -
U4 698-3 ECU detects that the front PTO control button is shorting to ground. -
U5 - - -
U6 550-7 ECU detects that the rear PTO solenoid valve solenoid is not connected. -
U7 550-4 ECU detects that the rear PTO solenoid valve solenoid is shorting to earth. -
U8 550-3 The ECU detects that the rear PTO solenoid valve solenoid is shorting to -
positive.
U9 551-7 ECU detects that the front PTO solenoid valve solenoid is not connected. -
-
U1x alarms
Table 113
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U10 551-4 ECU detects that the front PTO solenoid valve solenoid is shorting to earth. -
U11 551-3 The ECU detects that the front PTO solenoid valve solenoid is shorting to -
positive.
U12 653-7 The control unit detects that the differential lock solenoid valve is not con- -
nected.
U13 653-4 The control unit detects that the differential lock solenoid valve is shorting -
to earth.
U14 653-3 The control unit detects that the differential lock solenoid valve is shorting -
to positive.
U15 552-7 ECU detects that the dual traction solenoid valve is not connected. -
U16 552-4 ECU detects that the dual traction solenoid valve is shorting to earth. -
U17 552-3 ECU detects that the dual traction solenoid valve is shorting to battery posi- -
tive.
U18 654-5 ECU detects that the Energy Saving solenoid valve is not connected. -
U19 1507-9 Distributor “1” disconnected from CAN network. -
-
U2x alarms
Table 114
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U20 1508-9 Distributor “2” disconnected from CAN network. -
U21 1509-9 Distributor “3” disconnected from CAN network. -

20-191
 Calibrations and electronic
diagnosis
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U22 1510-9 Distributor “4” disconnected from CAN network. -
U23 1511-9 Distributor “5” disconnected from CAN network. -
U24 1520-12 Distributor “1” indicates detection of a WARNING problem. (Alarm reset) -
U25 1521-12 Distributor “2” indicates detection of a WARNING problem. (Alarm reset) -
U26 1522-12 Distributor “3” indicates detection of a WARNING problem. (Alarm reset) -
U27 1523-12 Distributor “4” indicates detection of a WARNING problem. (Alarm reset) -
U28 1524-12 Distributor “5” indicates detection of a WARNING problem. (Alarm reset) -
U29 1525-12 Distributor “1” indicates detection of a SEVERE alarm. (Distributor locked) -
-
U3x alarms
Table 115
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U30 1526-12 Distributor “2” indicates detection of a SEVERE alarm. (Distributor locked) -
U31 1527-12 Distributor “3” indicates detection of a SEVERE alarm. (Distributor locked) -
U32 1528-12 Distributor “4” indicates detection of a SEVERE alarm. (Distributor locked) -
U33 1529-12 Distributor “5” indicates detection of a SEVERE alarm. (Distributor locked) -
U34 1530-12 Distributor “1” joystick faulty. -
U35 1531-12 Distributor “2” joystick faulty. -
U36 1532-12 Distributor “3” joystick faulty. -
U37 1533-12 Distributor “4” joystick faulty. -
U38 1534-12 Distributor “3” timer potentiometer faulty. -
U39 1535-12 Distributor “4” timer potentiometer faulty. -
-
U4x alarms
Table 116
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U40 689-3 Steering angle sensor – Short circuit to power. -
U41 689-4 Steering angle sensor – Short circuit to ground or sensor disconnected. -
U42 1536-12 PTO ratio electronic circuit board - Fault. -
U43 1542-4 AUTO PTO button - Fault. -
U44 1453-4 ASM button - Fault. -
U45 1544-4 Differential Lock Button - Fault. -
U46 1541-4 Dual Traction Button – Fault. -
U47 - - -
U48 - - -
U49 - - -
-
U5x alarms
Table 117
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U50 620-4 Front Suspension Position Sensor – Short circuit to ground or disconnected. -
U51 620-3 Front Suspension Position Sensor – Short circuit to power. -
U52 621-7 Front Suspension Up Solenoid Valve – Low current. -
U53 621-4 Front Suspension Up Solenoid Valve – Short circuit to ground or discon- -
nected.
U54 621-3 Front Suspension Up Solenoid Valve – Short circuit to power. -
U55 622-7 Front Suspension Down Solenoid Valve – Low current. -
U56 622-4 Front Suspension Down Solenoid Valve – Short circuit to ground or discon- -
nected.

20-192
Calibrations and electronic
diagnosis
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U57 622-3 Front Suspension Down Solenoid Valve – Short circuit to power. -
U58 623-7 Front Suspension Lock Solenoid Valve – Low current. -
U59 623-4 Front Suspension Lock Solenoid Valve – Short circuit to ground or discon- -
nected.
-
U6x alarms
Table 118
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U60 623-3 Front Suspension Lock Solenoid Valve – Short circuit to power. -
U61 1537-12 60 lt ECO ON/OFF solenoid valve - Fault. -
U62 1538-12 60 Lt ECO proportional solenoid valve – Fault. -
U63 1539-12 Distributor “5” joystick faulty. -
U64 1540-12 Distributor “5” timer potentiometer faulty. -
U65 1545-4 SDD button - Fault. -
U66 1546-9 HLHP2 Main - HLHP2 Aux communication time out. -
U67 1547-4 5V_1 Aux voltage - Fault. -
U68 1548-4 5V_2 Aux voltage - Fault. -
U69 1549-4 5V_3 Aux voltage - Fault. -
-
U7x alarms
Table 119
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U70 1550-12 HLHP2 Main - HLHP2 Aux. incompatibility. -
U71 1551-4 Suspension Button – Fault. -
U72 550-12 Rear PTO SV - Fault. -
U73 551-12 Front PTO SV - Fault. -
U74 653-12 Differential lock SV - Fault. -
U75 552-12 Dual traction SV - Fault. -
U76 1537-7 60 lt ECO ON/OFF solenoid valve - Fault. -
U77 1537-4 60 Lt ECO ON/OFF solenoid valve – Short circuit to earth or valve discon- -
nected.
U78 1537-3 60 Lt ECO ON/OFF solenoid valve – Short circuit to power. -
U79 1538-7 60 Lt ECO proportional solenoid valve – Fault. -
-
U8x alarms
Table 120
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U80 1538-4 60 lt ECO proportional solenoid valve – Short circuit to earth or valve discon- -
nected.
U81 1538-3 60 lt ECO proportional solenoid valve – Short circuit to power. -
U82 654-12 Energy Saving solenoid valve - Fault. -
U83 654-7 Energy Saving solenoid valve - Fault. -
U84 654-4 Energy Saving solenoid valve – Short circuit to ground or valve disconnect- -
ed.
U85 654-3 Energy Saving solenoid valve – Short circuit to power. -
U86 1552-12 SDD solenoid valve - Fault. • Check the wiring loom,
• Check the valve,
=> System status indicated by state of the indicator lamp! • Check valve-ECU connection.

20-193
 Calibrations and electronic
diagnosis
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U87 1552-7 SDD solenoid valve - Fault. • Check the wiring loom,
• Check the valve,
=> System status indicated by state of the indicator lamp! • Check valve-ECU connection.
U88 1552-4 SDD solenoid valve – Short circuit to ground or valve disconnected. • Check the wiring loom,
• Check the valve,
=> System status indicated by state of the indicator lamp! • Check valve-ECU connection.
U89 1552-3 SDD solenoid valve – Short circuit to power. • Check the wiring loom,
• Check the valve,
=> System status indicated by state of the indicator lamp! • Check valve-ECU connection.
-
U9x alarms
Table 121
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U90 676-12 AUTO air conditioning - Fault. -
=> Identify specific alarm with diagnostic tool at following location: Alarms »
Auto AC » Active Alarms.
U91 677-4 SDD sensor. Short circuited to ground or disconnected. • Check the wiring loom,
1=> If system is active: System is disabled when conditions permit. • Check sensor,
2=> If system is inactive: System is NOT activated. • Check sensor power feed,
U92 677-3 SDD sensor – Short circuit to power. • Check the wiring loom,
1=> If system is active: System is disabled when conditions permit. • Check sensor,
2=> If system is inactive: System is NOT activated. • Check sensor power feed,
U93 677-7 SDD sensor – Invalid state. • Check the wiring loom,
1=> If system is active: System is disabled when conditions permit. • Check sensor,
2=> If system is inactive: System is NOT activated. • Check sensor power feed,
U94 678-7 SDD system - Plausibility error. -
=> System remains locked in standard displacement mode.
U95 678-12 SDD system - Plausibility error. -
=> System remains locked in dual displacement mode.
U96 1553-4 SDS button – Fault. -
U97 1554-4 SDS consent button – Fault. -
U98 1555-4 Distributor Lock Button – Fault. -
U99 1556-4 Distributor Flow Programming Button – Fault. -
-
U10x alarms
Table 122
On dis- ART Fault Checks/Corrective action
play code
SPN-FMI => Notes:
U100 621-12 Suspension Up Solenoid Valve - Fault. -
U101 622-12 Suspension Down Solenoid Valve - Fault. -
U102 623-12 Suspension Lock Solenoid Valve - Fault. -
U103 689-13 Steering sensor - not calibrated -
-
-
Version: 1.0
Date: 23/06/2014

20-194
Calibrations and electronic
diagnosis
20.4.4 - AC system alarms
Manual Air Conditioner Alarms
Position of the water valve
When the control unit switches off the position of the water valve is memorised in the EEPROM.
When the control unit switches on the previously memorised position of the water valve is read from the EEPROM.
Diagnostics
The ECU will manage the following faults:
l Short Circuit (S.C.) of one of the valve stepper motor outputs,
l Open Circuit (O.C.) of one of the valve stepper motor outputs,
l Closed Circuit (C.C.) of one of the recirculation actuator DC motor outputs,
Only for the air conditioned version
l Evaporator temperature sensor in Open Circuit (O.C.),
l Evaporator temperature sensor in Short Circuit (S.C.),
l A/C compressor relay output in Open Circuit (O.C.) or to Battery +,
l A/C compressor relay output in Short Circuit (S.C.) or to Earth,
The faults will be signalled by a function LED flashing (A/C or recirculation) timed as described below:

Fig. 547
Flashes
The first part (flash every 100 msec) indicates that a fault has been detected, whereas the second part indicates the type of fault as
indicated in the table below:
Table 123
Priority Description Function LED No. of flashes
1 Valve stepper motor Open Circuit (O.C.) or Short Circuit (S.C.) RECIRCULATION 1
to Earth
2 Valve stepper motor Short Circuit (S.C.) to Battery + RECIRCULATION 2
3 Recirculation DC motor Short Circuit (S.C.) RECIRCULATION 3
Table 124
Only for the air conditioned version
Priority Description Function LED No. of flashes
1 Evaporator temperature sensor in Open Circuit (O.C.) A/C 1
2 Evaporator temperature sensor in Short Circuit (S.C.) A/C 2
3 A/C compressor relay output in Open Circuit (O.C.) or to Battery + A/C 3

20-195
 Calibrations and electronic
diagnosis
Only for the air conditioned version
Priority Description Function LED No. of flashes
4 A/C compressor relay output in Short Circuit (S.C.) or to Earth A/C 4
WARNING
In the event of several simultaneous faults they will be managed through the priority table and therefore the one with
the highest priority will be displayed.

WARNING
Therefore one fault will be managed at a time. When the managed fault is removed the next one in order or priority
will be displayed.

The following are the fault validation times:

Table 125
Description Check period Validation and Notes
(msec) de-validation
period (msec)
Valve stepper motor Open Circuit (O.C.) 100 500 Detected only during valve move-
ment.
Valve stepper motor Short Circuit (S.C.) 100 500 Detected only during valve move-
ment.
Recirculation DC motor Short Circuit (S.C.) 100 1000 Detected only during actuator move-
ment.
Table 126
Only for the air conditioned version
Description Check period Validation and Notes
(msec) de-validation
period (msec)
A/C compressor relay output in Open Circuit (O.C.) 100 1000 Detected only if the output is acti-
vated.
A/C compressor relay output in Short Circuit (S.C.) 100 1000 Detected only if the output is acti-
vated.
Evaporator temperature sensor in Open Circuit (O.C.) 100 1000 -
Evaporator temperature sensor in Short Circuit (S.C.) 100 1000 -
WARNING
Any faults are memorised in the EEPROM.

Calibration of the water valve

Calibration of the valve consists in rotating the stepper motor for about 30 seconds clockwise (toward the valve closing) in order to
have a certain point of reference (zero).
The stepper motor stroke applied to the valve is 300° which corresponds to 6,000 steps.
Therefore the completely closed valve (0%) corresponds to 0 steps, whereas the completely open valve (100%) corresponds to 6,000
steps.
The duration of the valve calibration must be greater than 6,000 steps in order to guarantee certain mechanical stop (consider 6,000
+ 100 = 6,100 steps).
Considering that the configuration of the stepper motor outputs will be updated every 5 msec (200Hz), the duration of the calibration
phase will be:
6,100 x 5 msec = 30.5 seconds.

20-196
Calibrations and electronic
diagnosis
20.4.5 - Lift alarms
Lift E.C.U. Alarms (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZK-
DY560200TD10001)
Table 127
A.R.T. code Display on Component Priority Fault Possible Substitute Connec-
SPN FMI instrument remedies function tion to sys-
panel tem
540 3 L4 K041 - Left LOW The control Check wiring 40-235
hand lift draft unit detects loom, check
tie-rod sen- that the LH sensor,
sor draft sensor check sensor
is shorting to power, check
positive. sensor instal-
lation.
540 4 L5 K041 - Left LOW The control Check wiring 40-235
hand lift draft unit detects loom, check
tie-rod sen- that the LH sensor,
sor draft sensor check sensor
is shorting to power, check
earth. sensor instal-
lation.
541 3 L6 K040 - Right LOW The control Check wiring 40-235
hand lift draft unit detects loom, check
tie-rod sen- that the RH sensor,
sor draft sensor check sensor
is shorting to power, check
positive. sensor instal-
lation.
541 4 L7 K040 - Right LOW The control Check wiring 40-235
hand lift draft unit detects loom, check
tie-rod sen- that the RH sensor,
sor draft sensor check sensor
is shorting to power, check
earth. sensor instal-
lation.
600 4 L16 H009 - Lift LOW The control 40-448
control con- unit detects
sole that the lift
control po-
tentiometer
is shorting to
ground
600 3 L17 H009 - Lift LOW The control 40-448
control con- unit detects
sole that the lift
control com-
mand is
shorting to
battery posi-
tive.

20-197
 Calibrations and electronic
diagnosis
A.R.T. code Display on Component Priority Fault Possible Substitute Connec-
SPN FMI instrument remedies function tion to sys-
panel tem
601 3 L27 K005 - Rear LOW The ECU Check wiring 40-448
lift position detects that loom, check
sensor the lift posi- sensor,
tion sensor check sensor
is shorting to power, check
positive. sensor instal-
lation.
601 4 L28 K005 - Rear LOW The control Check wiring 40-448
lift position unit detects loom, check
sensor that the lift sensor,
position sen- check sensor
sor is short- power, check
ing to ground. sensor instal-
lation.
601 12 L29 K005 - Rear LOW The ECU Check wiring 40-448
lift position detects an loom, check
sensor internal fault sensor,
in the ECU check sensor
on the input power, check
signal of the sensor instal-
lift position lation.
sensor
602 3 L30 L005 - Rear LOW The control Check wiring 40-448
lift ‘UP’ con- unit detects loom, check
trol solenoid that the lift valve, check
valve ‘UP’ sole- valve power.
noid valve is
shorting to
positive.
602 4 L31 L005 - Rear LOW The control Check wiring 40-448
lift ‘UP’ con- unit detects loom, check
trol solenoid that the lift valve, check
valve ‘UP’ sole- valve power.
noid valve is
shorting to
ground.
602 5 L32 L005 - Rear LOW The ECU Check wiring 40-448
lift ‘UP’ con- detects that loom, check
trol solenoid the current valve, check
valve draw of the valve power.
lift UP sole-
noid valve is
excessive
602 6 L33 L005 - Rear LOW The ECU de- Check wiring 40-448
lift ‘UP’ con- tects a short loom, check
trol solenoid circuit in the valve, check
valve control wire valve power.
of the lift
‘up’ solenoid
valve
602 11 L51 L005 - Rear LOW Lift Up SV 40-448
lift ‘UP’ con- - Unknown
trol solenoid fault
valve

20-198
Calibrations and electronic
diagnosis
A.R.T. code Display on Component Priority Fault Possible Substitute Connec-
SPN FMI instrument remedies function tion to sys-
panel tem
602 7 L52 L005 - Rear LOW Lift Up SV – 40-448
lift ‘UP’ con- Open circuit
trol solenoid
valve
602 12 L005 - Rear LOW Lift Up SV – 40-448
lift ‘UP’ con- Internal ECU
trol solenoid error
valve
603 3 L34 L004 - Rear LOW The control Check wiring 40-448
lift ‘DOWN’ unit detects loom, check
control sole- that the lift valve, check
noid valve ‘DOWN’ so- valve power.
lenoid valve
is shorting to
positive.
603 4 L35 L004 - Rear LOW The ECU de- Check wiring 40-448
lift ‘DOWN’ tects that the loom, check
control sole- lift DOWN so- valve, check
noid valve lenoid valve valve power.
is shorting to
earth
603 5 L36 L004 - Rear LOW The control Check wiring 40-448
lift ‘DOWN’ unit detects loom, check
control sole- that the cur- valve, check
noid valve rent draw valve power.
of the lift
‘DOWN’ so-
lenoid valve
is excessive.
603 6 L37 L004 - Rear LOW The ECU Check wiring 40-448
lift ‘DOWN’ detects a loom, check
control sole- short-circuit valve, check
noid valve in the control valve power.
wire of the lift
‘down’ sole-
noid valve
603 11 L56 L004 - Rear LOW Lift Down so- 40-448
lift ‘DOWN’ lenoid valve
control sole- - Unknown
noid valve fault
603 7 L57 L004 - Rear LOW Lift Down so- 40-448
lift ‘DOWN’ lenoid valve
control sole- – Open cir-
noid valve cuit
603 12 L58 L004 - Rear LOW Lift down 40-448
lift ‘DOWN’ SV – Internal
control sole- ECU error
noid valve

20-199
 Calibrations and electronic
diagnosis
A.R.T. code Display on Component Priority Fault Possible Substitute Connec-
SPN FMI instrument remedies function tion to sys-
panel tem
604 12 L38 LOW The ECU has
detected that
the depth
ploughing
control po-
tentiometer is
faulty
605 12 L40 LOW The ECU has
detected that
the maximum
height poten-
tiometer is
faulty
606 12 L42 LOW The ECU has
detected that
the descent
speed poten-
tiometer is
faulty
607 12 L44 LOW The ECU
has detected
that the work
mode control
potentiom-
eter is faulty
656 12 L79 LOW Radar – Fault Check wiring
loom, con-
nector and
installation of
component.
690 4 L87 I066/I015 - LOW Lift STOP 40-448
Rear lift stop push-button
push-button - short circuit
to GND
690 7 L94 I066/I015 - LOW Lift STOP 40-448
Rear lift stop button - Me-
push-button chanical fault
691 4 L88 LOW Lift TRANS-
PORT push-
button - short
circuit to
GND
691 7 L96 LOW Lift TRANS-
PORT button
– Mechanical
fault
692 4 L89 LOW Lift CTRL
push-button
- short circuit
to GND
692 7 L95 LOW Lift CTRL
button - Me-
chanical fault

20-200
Calibrations and electronic
diagnosis
A.R.T. code Display on Component Priority Fault Possible Substitute Connec-
SPN FMI instrument remedies function tion to sys-
panel tem
693 12 L90 LOW Slippage po-
tentiometer
– short circuit
to power
694 3 L92 I027/I030 - LOW The ECU 40-448
RH rear lift detects that
up button the lift ‘UP’
control but-
tons on the
rear mud-
guards are
continuously
pressed
695 3 L93 I025/I028 - LOW The ECU de- 40-448
LH rear lift tects that the
down button lift ‘DOWN’
control but-
tons on the
rear mud-
guards are
continuously
pressed

20-201
 Calibrations and electronic
diagnosis

PAGE LEFT INTENTIONALLY BLANK

20-202
30 - Method of intervention

30-1
 Method of intervention
30.1 - Tools for engine disassembly and reassembly
30.1.1 - Commercially available tools
Deutz TCD 3.6 engine
Table 128
No. Figure Code, description & function Q.ty
1 Code 01899034 (8005) 1
Compression value test for diesel engines. (10 - 40 bar) Check of the
compression value.

© 35410-2

Fig. 548
2 01899035 / 5.9035.102.0 (8008) 1
Tool for testing injectors with nebulised spray collection container. Check
the injectors.

© 35411-2

Fig. 549
3 Code 01899037 (8011) 1
Pliers for hose clips. For loosening and tightening cable clamps (e.g. fuel
return line)

© 39426-1

Fig. 550
4 Code 01899041 (8015) 1
Box spanner insert. Wrench width 14, reinforced For loosening and tight-
ening big end bearing screw.

© 37503-1

Fig. 551
5 Code 01899042 (8016) 1
Box spanner insert. Wrench width 17, reinforced For loosening and tight-
ening flywheel nuts.

© 37504-1

Fig. 552

30-2
Method of intervention
No. Figure Code, description & function Q.ty
6 Code 01899044 7 5.9035.104.0 (8018) 1
Socket wrench. Wrench width 17, reinforced For loosening and tighten-
ing injection line sleeve nut.

© 37506-1

Fig. 553
7 Code 01899050 (8024) 1
Assembly pliers: Removal of the valve stem gaskets.

© 37509-4

Fig. 554
8 Code 01899062 (8115) 1
V-belt tension tester from 150 to 600 N. Checking the V-belt tension.

© 35416-3

Fig. 555
9 Code 01899093 (8190) 1
Rotation angle gauge with magnet. Adjustment of valve clearance.

© 42528-1

Fig. 556
10 Code 01899094 (8191) 1
Slotted head screwdriver bit (8x16). Valve clearance adjustment.

© 43060-0

Fig. 557
11 Code 01899099 (8196) 1
Open-ended wrench: SW 13, for the torque wrench. Tighten the check
nuts of the valve clearance adjustment screw.

© 43197-0

Fig. 558

30-3
 Method of intervention
No. Figure Code, description & function Q.ty
12 Code ... (8198) 1
Bradawl: Disassembly of the shaft seal ring.

© 43206-1

Fig. 559
13 Code 01899110 (9017) 1
Assembly lever. (e.g. valve assembly and disassembly)

© 37511-1

Fig. 560

30-4
Method of intervention
30.2 - Workshop tools for engine disassembly and reassembly
(Lv.2)
30.2.1 - Workshop tools for engine disassembly and reassembly (Lv.2)
Deutz TCD 3.6 engine
Table 129
No. Figure Code, description & function Q.ty
1 Code 01899031 / 5.9035.100.0 (8002) 1
Pressure pump. Check the seal of the cooling system.

© 35409-2

Fig. 561
2 Code 01899037 (8011) 1
Pliers for hose clips. Loosening and fastening hose clips.

© 39426-1

Fig. 562
3 Code 01899050 / 5.9035.105.0 (8024) 1
Assembly pliers. Removal of the valve stem gaskets.

© 49353-0

Fig. 563
4 Code 01899062 / 5.9035.108.0 (8115) 1
V-belt tension tester from 150 to 600 N. Checking the V-belt tension.

© 35416-3

Fig. 564
5 Code 01899092 / 5.9035.110.0 (8189) 1
Torx tool set. Case content: • Double ring wrench E6/E8, • Double ring
wrench E10/E12, • Box spanner inserts E8 and E10 (1/4 inch), • Box
spanner inserts E10 and E12 (3/8 inch), • Box spanner inserts E18 (1/2
inch).

© 39432-1

Fig. 565

30-5
 Method of intervention
No. Figure Code, description & function Q.ty
6 Code 01899093 (8190) 1
Rotation angle gauge with magnet. Adjustment of valve clearance.

© 49342-0

Fig. 566
7 Code 01899103 (8202) 1
Punch. Removing shaft seal ring.

© 49345-0

Fig. 567
8 Code 01899110 / 5.9035.111.0 (9017) 1
Assembly lever (e.g. Fitting and removing valves)

© 37511-2

Fig. 568
9 Code 01899112 / 5.9035.112.0 (9090) 1
Circlip pliers (320 mm) For opening circlips.

© 35420-3

Fig. 569
10 Code 01899132 / 5.9035.075.0 (110700) 1
Long box spanner insert. Fitting and removing pressure sensors (Rail
pressure, oil pressure, fuel pressure)

© 49357-0

Fig. 570
11 Code 01899144 / 5.9035.095.0 (170160) 1
Plugs and caps: 1 set of different sized plugs and caps. For closing the
holes in the fuel distribution system.

© 43663-0

Fig. 571

30-6
Method of intervention
No. Figure Code, description & function Q.ty
12 Code 01899184 (...) 1
Handle with preset 0.6-1.5 Nm torque.

Fig. 572
13 Code 01899185 (...) 1
Socket holder: 1/4” square socket / 1/4” hexagonal socket.

© 51489-0

Fig. 573
14 Code 02992112 / 5.9035.072.0 (110500) 1
Special wrench. Wrench opening 17. Removing and fitting high pressure
lines.

© 35436-1

Fig. 574
15 Code 02992117 / 5.9035.073.0 (110620) 1
Lever tool. Removal of the injector.

© 49375-0

Fig. 575
16 Code 02992127 / 5.9035.245.0 (110901) 1
Disassembly tool. Remove the O-ring.

© 49360-0

Fig. 576
17 Code 02992138 (120690) 1
Extraction device. For use with slide hammer extractor, code 02992294 /
5.9035.094.0 (150800). Removing fixed injector seal ring.

© 35437-1

Fig. 577

30-7
 Method of intervention
No. Figure Code, description & function Q.ty
18 Code 02992214 (142680) 1
Assembly tool. Fitting crankshaft O-ring (flywheel side).

© 49366-0

Fig. 578
19 Code 02992294 / 5.9035.094.0 (150800) 1
Slide hammer extractor. For use with extractor tool code 02992137 /
5.9035.077.0 (120680). Removing injector seal ring

© 49372-0

Fig. 579
20 Code 02992301 (151500) 1
Tool for truncation. Removing pressed steel lubricant oil sump pan from
crankcase

© 49373-0

Fig. 580

30-8
Method of intervention
30.3 - Workshop tools for engine disassembly and reassembly
(Lv.3)
30.3.1 - Workshop tools for engine disassembly and reassembly (Lv.3)
Deutz TCD 3.6 engine
Table 130
No. Figure Code, description & function Q.ty
1 Code 01899000 (6066) 1
Taking up weight of engine on both sides Max. load at centre of gravity
approx. 1,200 Kg

© 35451-2

Fig. 581
2 Code 01899002 (6066/151) 1
Support for taking up weight of engine on both sides. Connected to as-
sembly stand code 01899099 (6066).

© 37601-1

Fig. 582
3 Code 02992013 (100130) 1
Connection. In combination with compression tester, code 01899034 /
5.9035.101.0 (8005)

© 37602-1

Fig. 583
4 Code 02992022 (100300) 1
Rotation device. With mechanical TDC indicator and graduated scale for
checking start of delivery. Rotating and immobilising crankshaft.

© 37603-1

Fig. 584
5 Code 02992025 (100350) 1
Rotation device. Rotating crankshaft from V-belt pulley.

© 37604-1

Fig. 585

30-9
 Method of intervention
No. Figure Code, description & function Q.ty
6 Code 01899126 / 5.9035.068.0 (100400) 1
Dial gauge with stop wheel. Measurement range 0 -10 mm / 0.01 mm

© 37605-1

Fig. 586
7 Code 01899127 (100410) 1
Digital dial gauge. Measurement range 0 -30 mm / 0.01 mm

© 43205-0

Fig. 587
8 Code ... (100850) 1
Measurement tool with measurement plate Piston protrusion check.

© 37606-1

Fig. 588
9 Code 02992066 (101830) 1
Dial gauge-adapter: Measuring insertion of speed sensor in respective
seat

© 45906-0

Fig. 589
10 Code 02992073 (102560) 1
Tester. Base tool with two measurement rods Measuring spray angle of
piston cooling nozzle (previous version)

© 37608-1

Fig. 590
11 Code 02992074 (102565) 1
Measurement rod. With tester, code 02992073 (102560). Measuring
spray angle of piston cooling nozzle (new version)

© 37628-1

Fig. 591

30-10
Method of intervention
No. Figure Code, description & function Q.ty
12 Code 02992081 (103240) 1
Dial gauge mount. With probe extension (diameter 5/100 mm) Checking
maximum aperture stroke of injection pumps

© 43927-3

Fig. 592
13 Code 02992084 / 5.9035.126.0 (110030) 1
Extractor. In combination with slide hammer extractor, code 02992294 /
5.9035.094.0 (150800). Removing injection valve.

© 35433-2

Fig. 593
14 Code 02992089 / 5.9035.127.0 (110110) 1
Support. Wrench aperture 11. Tighten injection valve in screw clamp.

© 35434-2

Fig. 594
15 Code 02992091 (110130) 1
Ring gear nut wrench. Tightening and loosening injection valve sleeve
nut.

© 37610-1

Fig. 595
16 Code 02992112 / 5.9035.072.0 (110500) 1
Special wrench. Wrench opening 17. Fitting and removing injection pipes

© 35436-1

Fig. 596
17 Code ... (110510) 1
Special wrench. Removing and fitting air intake pipe

© 43928-3

Fig. 597

30-11
 Method of intervention
No. Figure Code, description & function Q.ty
18 Code 01899132 / 5.9035.075.0 (110700) 1
Box spanner insert. Wrench width 27. Long. Fitting and removing oil
pressure transducer

© 42341-2

Fig. 598
19 Code 02992127 / 5.9035.245.0 (110901) 1
Disassembly tool. For removing O-rings.

© 45950-1

Fig. 599
20 Code 02992136 / 5.9035.246.0 (120660) 1
Extraction device. In combination with slide hammer extractor, code
02992294 / 5.9035.094.0 (150800). Removing fixed seal ring on injec-
tion valve

© 45421-0

Fig. 600
21 Code 02992139 / 5.9035.078.0 (120900) 1
Adjustable support stand. For tightening cylinder head fasteners

© 35438-2

Fig. 601
22 Code 02992140 / 5.9035.079.0 (120910) 1
Base plate. In combination with support stand, code 02992139 /
5.9035.078.0 (120900), if support stand is not fixed with screws.

© 35439-2

Fig. 602
23 Code 02992145 / 5.9035.081.0 (121410) 1
Assembly tool. Assembly of the valve stem gasket.

© 37614-1

Fig. 603

30-12
Method of intervention
No. Figure Code, description & function Q.ty
24 Code ... (121420) 1
Assembly bushes. Set of assembly bushes for the valve stem gasket.

© 43210-0

Fig. 604
25 Code 02992155 / 5.9035.083.0 (130300) 1
Universal pliers for piston rings. Disassembly and assembly of piston
rings.

© 35441-2

Fig. 605
26 Code 02992161 (130400) 1
Trapezoidal groove wear gauge. Check piston ring groove.

© 36461-1

Fig. 606
27 Code 02992179 (130650) 1
Piston ring compression collar. Disassembly and assembly of piston
rings.

© 35443-2

Fig. 607
28 Code 02992187 (131200) 1
Base plate. In combination with assembly tool set, code 02992188
(131210) For press-fitting and removing small end bushing

© 37616-1

Fig. 608
29 Code 02992188 (131210) 1
Set of assembly tools. In combination with base plate, code 02992187
(131200) For press-fitting and removing small end bushing

© 37617-1

Fig. 609

30-13
 Method of intervention
No. Figure Code, description & function Q.ty
30 Code 02992210 (142640) 1
Assembly tool. Fitting crankshaft O-ring (on side opposite flywheel)

© 37618-1

Fig. 610
31 Code 02992211 (142650) 1
Assembly tool. Fitting crankshaft O-ring (flywheel side).

© 37619-1

Fig. 611
32 Code 02992250 (143830) 1
Assembly tool. Fitting and removing camshaft bearings

© 37621-1

Fig. 612
33 Code 02992259 (144150) 1
Counterhead. Fastening camshaft gear wheel

© 37622-1

Fig. 613
34 Code 02992277 (150030) 1
Tool set. Correcting contact points of cylinder sleeve

© 40221-0

Fig. 614
35 Code ... (150120) 1
Assembly tool. Installing cylinder liner

© 37624-1

Fig. 615

30-14
Method of intervention
No. Figure Code, description & function Q.ty
36 Code ... (150130) 1
Extraction device. Removing cylinder liner

© 37625-1

Fig. 616
37 Code 02992294 / 5.9035.094.0 (150800) 1
Slide hammer extractor. Disassembly of the injection valve.

© 35449-2

Fig. 617
38 Code 0189 9142 / 5.9035.176.0 (170050) 1
Special wrench. Removal of the filter cartridges.

© 37629-1

Fig. 618
39 Code 02992329 (170100) 1
Special wrench. Removing and fitting turbocharger lubricant oil line.

© 37626-1

Fig. 619
40 Code 02992331 (170120) 1
Assembly and disassembly tool. Press-fitting and removing the rocker
shaft ball pin.

© 37627-1

Fig. 620
41 Code 01899144 / 5.9035.095.0 (170160) 1
Plugs and caps: 1 set of different sized plugs and caps. For closing the
holes in the fuel distribution system.

© 43663-0

Fig. 621

30-15
 Method of intervention
30.4 - Workshop tools for disassembly and reassembly (5090 C ->
ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)
Table 131
No. Figure Code, description & Q.ty Link to the proce-
function dure
1 5.9030.603.0 1
Socket wrench for HI 30-242
range clutch ring nut

2 5.9030.676.0 1
Tool for disassembling HI 30-242
range clutch housing

3 5.9035.521.0 1
Disassembling PTO 30-351
clutch

4 5.9035.532.0 1
Tool for installing circlips 30-322
on gearbox secondary
shaft

5 5.9035.538.0 1
Tool for installing oil seal 30-575
on front PTO flange shaft

6 5.9035.539.0 1
Tool for installing oil seal 30-575
on front PTO input shaft

7 5.9035.540.0 1
Tool for installing oil seal 30-229
on HI-LO

8 5.9035.542.0 1
Support for servicing 30-575
front PTO

30-16
Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
9 5.9035.545.0 1
Tool for rotating ground 30-376
speed PTO output flange
shaft (for tightening pin-
ion ring nut on versions
with ground speed PTO)
Disassembling PTO final 30-363
flange shaft
10 5.9035.546.0 1
Dial gauge base for 30-514
shims between housing-
front carrier

11 5.9035.547.0 1
Tool for installing dual 30-436
traction shaft bearing

12 5.9035.548.0 1
Tool for installing pinion 30-376
bearing (thrust plate +
conical bush, or hydrau-
lic pusher tool + conical
bush)
13 5.9035.549.0 1
Tool for installing differ- 30-490
ential lock selector de-
vice spring

14 5.9035.551.0 1
Tool for removing fan 30-154

15 5.9035.552.0 1
Tool for loosening/tight- 30-376
ening pinion ring nut

16 5.9035.553.0 1
Tool for installing Easys- 30-461
hift oil seal

17 5.9035.555.0 1
Tool for installing rear 30-332
PTO cover oil seal

30-17
 Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
18 5.9035.556.0 1
Tool for installing ground 30-433
speed PTO cover oil seal

19 5.9035.558.0 1
Dummy housing for 30-242
aligning HI range clutch
plates

20 5.9035.559.0 1
Tool disassembling 30-477
wheel carriers

21 5.9035.562.0 1
Tool for installing SAC oil 30-587
seal

22 5.9035.563.0 1
Service bush for adjust- 30-415
ing pinion

30-18
Method of intervention
30.5 - Workshop tools for disassembly and reassembly (5110 C ->
ZKDY440200TD10001)
Table 132
No. Figure Code, description & Q.ty Link to the proce-
function dure
1 5.9030.603.0 1
Socket wrench for LO 30-254
range clutch ring nut

2 5.9030.676.0 1
Tool for disassembling 30-254
LO range clutch housing

3 5.9035.521.0 1
Disassembling PTO 30-355
clutch

4 5.9035.532.0 1
Tool for installing circlips 30-322
on gearbox secondary
shaft

5 5.9035.535.0 1
Tool for removing bear- 30-305
ings on gearbox second-
ary shaft

6 5.9035.538.0 1
Tool for installing oil seal 30-575
on front PTO flange shaft

7 5.9035.539.0 1
Tool for installing oil seal 30-575
on front PTO input shaft

8 5.9035.540.0 1
Tool for installing oil seal 30-236
on HI-LO

30-19
 Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
9 5.9035.542.0 1
Support for servicing 30-575
front PTO

10 5.9035.545.0 1
Tool for rotating ground 30-381
speed PTO output flange
shaft (for tightening pin-
ion ring nut on versions
with ground speed PTO)
Disassembling PTO final 30-363
flange shaft
11 5.9035.546.0 1
Dial gauge base for 30-514
shims between housing-
front carrier

12 5.9035.547.0 1
Tool for installing dual 30-438
traction shaft bearing

13 5.9035.548.0 1
Tool for installing pinion 30-381
bearing (thrust plate +
conical bush, or hydrau-
lic pusher tool + conical
bush)
14 5.9035.549.0 1
Tool for installing differ- 30-493
ential lock selector de-
vice spring

15 5.9035.551.0 1
Tool for removing fan 30-154

16 5.9035.552.0 1
Tool for loosening/tight- 30-381
ening pinion ring nut

17 5.9035.553.0 1
Tool for installing Easys- 30-461
hift oil seal

30-20
Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
18 5.9035.555.0 1
Tool for installing rear 30-332
PTO cover oil seal

19 5.9035.556.0 1
Tool for installing ground 30-433
speed PTO cover oil seal

20 5.9035.558.0 1
Dummy housing for 30-254
aligning LO range clutch
plates

21 5.9035.559.0 1
Tool disassembling 30-477
wheel carriers

22 5.9035.562.0 1
Tool for installing SAC oil 30-587
seal

23 5.9035.563.0 1
Service bush for adjust- 30-424
ing pinion

30-21
 Method of intervention
30.6 - Workshop tools for disassembly and reassembly (5100 C ->
ZKDY480200TD10001)
Table 133
No. Figure Code, description & Q.ty Link to the proce-
function dure
1 5.9030.603.0 1
Socket wrench for LO 30-254
range clutch ring nut

2 5.9030.676.0 1
Tool for disassembling 30-254
LO range clutch housing

3 5.9035.521.0 1
Tool for installing HML 30-275
clutch springs 30-280
Disassembling PTO 30-355
clutch

4 5.9035.532.0 1
Tool for installing circlips 30-322
on gearbox secondary
shaft

5 5.9035.535.0 1
Tool for removing bear- 30-305
ings on gearbox second-
ary shaft

6 5.9035.538.0 1
Tool for installing oil seal 30-575
on front PTO flange shaft

7 5.9035.539.0 1
Tool for installing oil seal 30-575
on front PTO input shaft

8 5.9035.540.0 1
Tool for installing oil seal 30-236
on HML/HI-LO 30-272

30-22
Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
9 5.9035.542.0 1
Support for servicing 30-575
front PTO

10 5.9035.545.0 1
Tool for rotating ground 30-386
speed PTO output flange
shaft (for tightening pin-
ion ring nut on versions
with ground speed PTO)
Disassembling PTO final 30-363
flange shaft
11 5.9035.546.0 1
Dial gauge base for 30-514
shims between housing-
front carrier

12 5.9035.547.0 1
Tool for installing dual 30-441
traction shaft bearing

13 5.9035.548.0 1
Tool for installing pinion 30-386
bearing (thrust plate +
conical bush, or hydrau-
lic pusher tool + conical
bush)
14 5.9035.549.0 1
Tool for installing differ- 30-496
ential lock selector de-
vice spring

15 5.9035.550.0 1
Tool for installing H range 30-280
clutch springs

16 5.9035.551.0 1
Tool for removing fan 30-154

17 5.9035.552.0 1
Tool for loosening/tight- 30-386
ening pinion ring nut

30-23
 Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
18 5.9035.553.0 1
Tool for installing Easys- 30-461
hift oil seal

19 5.9035.554.0 1
Tool for detaching hy- 30-187
draulic reverse shuttle

20 5.9035.555.0 1
Tool for installing rear 30-332
PTO cover oil seal

21 5.9035.556.0 1
Tool for installing ground 30-433
speed PTO cover oil seal

22 5.9035.557.0 1
Bush for installing HML 30-275
pistons

23 5.9035.558.0 1
Dummy housing for 30-254
aligning LO range clutch
plates

24 5.9035.559.0 1
Tool disassembling 30-477
wheel carriers

25 5.9035.560.0 1
Park Brake pressurisa- 30-484
tion valves 30-487

26 5.9035.561.0 1
Park Brake belleville 30-487
washer retainer brackets

30-24
Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
27 5.9035.562.0 1
Tool for installing SAC oil 30-587
seal

28 5.9035.563.0 1
Service bush for adjust- 30-424
ing pinion

30-25
 Method of intervention
30.7 - Workshop tools for disassembly and reassembly (5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Table 134
No. Figure Code, description & Q.ty Link to the proce-
function dure
1 5.9030.603.0 1
Socket wrench for LO 30-254
range clutch ring nut

2 5.9030.676.0 1
Tool for disassembling 30-254
LO range clutch housing

3 5.9035.521.0 1
Tool for installing HML 30-275
clutch springs 30-280
Disassembling PTO 30-355
clutch

4 5.9035.532.0 1
Tool for installing circlips 30-322
on gearbox secondary
shaft

5 5.9035.535.0 1
Tool for removing bear- 30-305
ings on gearbox second-
ary shaft

6 5.9035.538.0 1
Tool for installing oil seal 30-575
on front PTO flange shaft

7 5.9035.539.0 1
Tool for installing oil seal 30-575
on front PTO input shaft

8 5.9035.540.0 1
Tool for installing oil seal 30-236
on HML/HI-LO 30-272

30-26
Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
9 5.9035.542.0 1
Support for servicing 30-575
front PTO

10 5.9035.545.0 1
Tool for rotating ground 30-386
speed PTO output flange
shaft (for tightening pin-
ion ring nut on versions
with ground speed PTO)
Disassembling PTO final 30-363
flange shaft
11 5.9035.546.0 1
Dial gauge base for 30-514
shims between housing-
front carrier

12 5.9035.547.0 1
Tool for installing dual 30-441
traction shaft bearing

13 5.9035.548.0 1
Tool for installing pinion 30-386
bearing (thrust plate +
conical bush, or hydrau-
lic pusher tool + conical
bush)
14 5.9035.549.0 1
Tool for installing differ- 30-496
ential lock selector de-
vice spring

15 5.9035.550.0 1
Tool for installing H range 30-280
clutch springs

16 5.9035.551.0 1
Tool for removing fan 30-154

17 5.9035.552.0 1
Tool for loosening/tight- 30-386
ening pinion ring nut

30-27
 Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
18 5.9035.553.0 1
Tool for installing Easys- 30-461
hift oil seal

19 5.9035.554.0 1
Tool for detaching hy- 30-189
draulic reverse shuttle

20 5.9035.555.0 1
Tool for installing rear 30-332
PTO cover oil seal

21 5.9035.556.0 1
Tool for installing ground 30-433
speed PTO cover oil seal

22 5.9035.557.0 1
Bush for installing HML 30-275
pistons

23 5.9035.558.0 1
Dummy housing for 30-254
aligning LO range clutch
plates

24 5.9035.559.0 1
Tool disassembling 30-477
wheel carriers

25 5.9035.560.0 1
Park Brake pressurisa- 30-484
tion valves 30-487

26 5.9035.561.0 1
Park Brake belleville 30-487
washer retainer brackets

30-28
Method of intervention
No. Figure Code, description & Q.ty Link to the proce-
function dure
27 5.9035.562.0 1
Tool for installing SAC oil 30-587
seal

28 5.9035.563.0 1
Service bush for adjust- 30-424
ing pinion

30-29
 Method of intervention
30.8 - B0 - Engine
30.8.1 - Separating engine from transmission
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
Separation
1. Disconnect the connector (1) of the SBA (steering angle sensor) wiring har-
ness.

Fig. 622
2. Undo the unions (2) and disconnect the steering lines (3).

Fig. 623
3. Undo the unions (4) and disconnect the brake lines (5).
4. Undo the union (6) and disconnect the front differential lock oil line (7).
4 5

6
7

Fig. 624
5. Remove the retainer fork (8) and disconnect the engine wiring loom con-
8
nector (9) from the mounting bracket (10).

10

Fig. 625

30-30
Method of intervention
6. Disconnect the brake fluid level sensor connector (11).
7. Undo the screw (12) on the mounting bracket and detach the brake fluid
reservoir (13), securing it to the cab.

11

13
12

Fig. 626
8. Open the clamps (14) and disconnect the cab heating lines (15), noting
14
their respective positions for subsequent reconnection.

15

Fig. 627
9. Undo the screws (16) fastening the right and left hand lower cab guards (17).
10. Undo the unions (18) and disconnect the A/C system refrigerant lines (19).
17
16

19
18

Fig. 628
11. Disconnect the engine ECU connectors (20), undo the nuts fastening the two clamps (21) and free the wiring loom (22).
12. Remove the cap (23), undo the nut and disconnect the starter motor cables
20
(24).
24

23

22

21

Fig. 629

30-31
 Method of intervention
13. Disconnect the coolant sensor connector (25), open the clamp (26) and
move the wiring looms aside (27).
25

27

26

Fig. 630
14. Disconnect the water in fuel filter sensor (28), open the clamp (29) and dis-
connect the fuel delivery line (30), noting its correct position for subsequent
reconnection.
29

30

28

Fig. 631
15. Disconnect the fuel pump connector (31).
16. Undo the unions (32) and disconnect the transmission oil delivery and return lines (33) from the radiator.
17. Open the clamp (34) and disconnect the fuel return line (35), marking its
correct position for subsequent reconnection. Secure the lines together 31

with a cable tie and move them aside. 32

34

35 33

Fig. 632
18. Disconnect the engine wiring loom connectors (36).

36

Fig. 633

30-32
Method of intervention
19. Undo the nut (37), disconnect the ground cables (38), undo the second
nut (39), retrieving the spacer, and disconnect the third ground cable (40).
39

37

38 40

Fig. 634
20. Place two wooden wedges (41) between the front axle (42) and the front
carrier (43) to prevent the engine from wobbling.
43
41

42

Fig. 635
21. Place a stand (44) under the transmission, with a block of wood in between.
22. Place a trolley stand (45) under the engine oil sump (46), with a block of
wood in between.

46
44

45

Fig. 636
23. Undo the two lower nuts (47) fastening the engine to the transmission.
47

Fig. 637

30-33
 Method of intervention
24. Undo the two upper nuts (48) fastening the engine to the transmission.

48

Fig. 638
25. Undo the lateral screws (49) (3 on right and 3 on left) fastening the engine
to the transmission.

49
49

Fig. 639
26. Move the engine/front axle assembly (50) forward to separate it from the
transmission (51).

50

51

Fig. 640

30-34
Method of intervention
Connection
1. Follow the procedure for separation in reverse order, noting the following additional instructions for the steps indicated.
2. Fit and hand-tighten all the screws fastening the engine to the transmission.
3. Tighten the (shorter) upper and central lateral screws (49) to a torque of 96.3 to 117.7 Nm.
4. Tighten the (longer) lower lateral screws (49) to a torque of 148.5 to 181.5 Nm.
5. Tighten the upper (48) and lower (47) nuts to a torque of 158.4 to 193.6 Nm.
Completion
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.8.2 - Replace the crankshaft O-ring (flywheel end)

Special tools:
l Bradawl: 01899103
l Assembly lever: 01899110
l Assembly tool: 02992214
l Self-tapping screw
l Washer
Removal of the crankshaft oil seal
1. m 1 - Gasket housing
m 2 - Shaft O-ring
m 3 - Hex screw
m 188 - Sealant

Fig. 641
2. m Remove the flywheel.
Construction unit
05

m Using a bradawl, make a hole about 3 mm in diameter in the old

crankshaft oil seal.
WARNING
Take care not to damage the seal seat or the crankshaft!

Fig. 642

30-35
 Method of intervention
3. m Insert a self-tapping screw (1) with washer.

Fig. 643
4. m Extract the crankshaft O-ring using the assembly lever.
NOTE
Be careful not to damage the crankshaft.

m Carefully examine the crankshaft O-ring sliding surfaces.

Fig. 644

Assembly of the crankshaft O-ring

1. m Fit guide bush (1).
m Tighten screws (2).
Note
The holes in the guide bush must be aligned with the
threaded holes in the crankshaft flange.

Fig. 645

30-36
Method of intervention
2. m Carefully place the crankshaft O-ring on the sliding surface.
Note
Do not oil the waxed crankshaft O-rings. The seal lip
should be facing the engine crankcase.

Fig. 646
3. m Fit installation bush (1).
m Push the crankshaft O-ring to the support.
m Insert bearing (2).
m Screw in nut (3);

Fig. 647
4. m Screw in the nut until it seats against installation bush (1).
NOTE
Installation depth is determined by the installation
tool.

m Remove the installation tool.

m Fit the flywheel.
Construction unit
05

Fig. 648

30-37
 Method of intervention
30.8.3 - Fitting and removing seal seat
Readily available commercial tools:
l Pin punch
l Sealant: DEUTZ DW 67
Removing the seal seat
1. m 1 - Gasket housing
m 2 - Shaft O-ring
m 3 - Hex screw
m 188 - Sealant

© 50518-0

Fig. 649
2. m Remove the flywheel.
n See para. 30.8.9 - Removal and refitting ... - page 30-47

m Disassemble the connector box.

n See para. 30.8.49 - Disassembly and assemb... - page 30-

108
n See para. 30.8.50 - Disassembly and assemb... - page 30-

109
n See para. 30.8.51 - Disassembly and assemb... - page 30-

111
n See para. 30.8.52 - Disassembly and assemb... - page 30-

113
n See para. 30.8.53 - Disassembly and assemb... - page 30-

115
m Remove the oil sump pan. © 50519-0

n See para. 30.8.6 - Removal and refitting ... - page 30-42 Fig. 650
m Remove all the screws (1).
m Remove the seal seat (2).

30-38
Method of intervention
Fitting the seal seat
1. m Clean the mating surfaces.
m Apply sealant (1) evenly to the mating surface.
NOTE
Sealing edge thickness, approx. 0.5 - 0.6 mm.

© 50521-0

Fig. 652
2. m Fit the seal seat.
m Tighten screws (1).

© 50522-0

Fig. 653
3. Note
Trim any protruding gasket (arrows) flush with the mating
surface of the oil sump pan.

© 50523-0

Fig. 654

30-39
 Method of intervention

Technical data
Tightening torque
Table 135
ID no. Designation Indications/ob- Value
servations
A01 095 Seal seat on crankcase Observe the indi- 20 Nm
cated tightening se-
quence.
NOTE
Tighten to +/- 10% of the specified torque using a torque wrench.

30.8.4 - Fitting and removing transition pipe

l Sealant: DEUTZ DW 67
Removing the transition pipe
1. m 1 - Transition pipe
m 2 - Torx screw
m 3 - Hole blanking screw: 35 Nm
m 291 - Sealant

© 50424-0

Fig. 656

30-40
Method of intervention
2. m Remove the oil sump pan.
Construction unit
02

m Remove screws (1).

m Remove the transition pipe (2)
m Carry out a visual inspection of the component.

© 50425-0

Fig. 657

Fitting the transition pipe

1. m Clean the mating surfaces.
WARNING
Keep the sealant out of the oil channel (1)!

© 50723-1

Fig. 658
2. m Apply sealant (1) evenly to the mating surface.

© 51276-0

Fig. 659

30-41
 Method of intervention
3. m Clean the mating surfaces.
m Fit the transition pipe (1)
m Tighten the screws (2): 20 Nm.
m Fit the oil sump pan.
Construction unit
02

© 50427-0

Fig. 660

Technical data
Tightening torque
Table 136
ID no. Designation Screws type Indications/observa- Value
tions
A01 016 Transition pipe on crank- 20 Nm
case
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.5 - Line
1. m 1 - Pipe retaining clip
m 2 - Pipe
m 3 - Spring clip
m 4 - Rubber sleeve
m 5 - Intake manifold
m 6 - Spring clip
m 7 - Hex screw: 8 Nm

© 50658-0

Fig. 661

30.8.6 - Removal and refitting of the oil sump pan.

Special tools:
l Tool for truncation: 02992301
l Sealant: DEUTZ DW 73
WARNING
Make sure that no sealant residue enters the engine crankcase! Close all holes.

30-42
Method of intervention
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
Removal of the oil sump pan.
1. m 1 - Lubricant oil sump
m 2 - Nut
m 3 - Torx screw
m 244 - Sealant

© 51286-0

Fig. 662
2. m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.
m Remove all the screws (arrowed).
m Remove the lubricant oil sump (1).

© 51287-0

Fig. 663
3. m Insert lever (1) up to shoulder (2).
WARNING
The lever may only be used on the engine crankcase. Do
not use it to apply leverage on aluminium castings. Do not
damage the mating surfaces.

© 51288-0

Fig. 664

30-43
 Method of intervention
4. m Insert the second lever (1) up to shoulder (2).
WARNING
The lever may only be used on the engine crankcase. Do
not use it to apply leverage on aluminium castings. Do not
damage the mating surfaces.

© 51289-0

Fig. 665
5. m Prise the sump pan off the crankcase.
m Remove the sump pan.

© 51290-0

Fig. 666

Refitting the oil sump pan.

1. m Remove the old sealant using the lever.
WARNING
Wear eye protection.

m Clean the mating surfaces with a wire brush.

Note
The mating surfaces must be clean, dry and free of
grease or other contaminants.

© 51291-0

Fig. 667

30-44
Method of intervention
2. WARNING
Wear eye protection.

m Clean the mating surfaces of the oil sump pan with a wire brush.
NOTE
The mating surfaces must be clean, dry and free of
grease or other contaminants.

© 51292-0

Fig. 668
3. m To align the oil sump pan with crankcase, screw four stud bolts (1)
into the crankcase as shown.

© 45678-1

Fig. 669
4. m Clean the mating surfaces.
NOTE
The mating surfaces must be clean, dry and free of
grease or other contaminants.

m Apply sealant on the separation points (arrows).

© 51293-0

Fig. 670

30-45
 Method of intervention
5. m Apply sealant evenly to the sealing surface.

© 51294-0

Fig. 671
6. m Line the oil sump pan up using the stud bolts as guides.
m Fit the oil sump pan.
WARNING
Once positioned on the crankcase, be careful not to disturb
the oil sump pan. Allow the sealant to cure.

m Unscrew the stud bolts.

m Screw in all the screws (1).

© 51295-0

Fig. 672
7. m Tighten the screws in the sequence indicated: 20 Nm.
m Top up the engine oil following the instructions provided.

© 51296-0

Fig. 673

30-46
Method of intervention
Technical data
Tightening torque
Table 137
ID no. Designation Screws type Indications/observa- Value
tions
A02 030 Lubricant oil sump in Observe the indicated 20 Nm
correspondence of the tightening sequence!
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.7 - Closing components

1. NOTE
Collect used lubricating oil and dispose of it in accordance
with the applicable regulations.

m 1 - Hole blanking screw: 55 Nm

m 2 – O-ring
NOTE
Use a new O-ring.

© 50331-0

Fig. 674

30.8.8 - Topping up with oil

1. m 1 - Oil filler pipe
m 2 - Hex screw: 30 Nm
m 3 - Closing plug
m 4 - Gasket
m 5 - Hole blanking screw: 95 Nm
NOTE
Use a new gasket.

© 50668-0

Fig. 675

30.8.9 - Removal and refitting of the flywheel (fixing elements)

Special tools:
l Guide pin (shop-made tool)
l M10x120 auxiliary screws
l Rotation angle gauge 01899093

30-47
 Method of intervention
Removal of the flywheel
1. m 1 – Flywheel
m 2 – Ring gear
m 3 – Screw
m 4 - Bearing bush

© 51460-0

Fig. 676
2. m Hold the crankshaft from the central screw.
m Fit service screws (1).
m Remove screws (2).
m Remove the flywheel using the service screws.
m Carry out a visual inspection of the components.

© 51462-0

Fig. 677

Refitting the flywheel

1. m Insert the shop-made guide pin
NOTE
The holes in the flywheel must coincide with the
threaded hole in the V-belt pulley.

m Fit the flywheel using the service screws.

© 51463-0

Fig. 678

30-48
Method of intervention
2. WARNING
The screws must be renewed after being removed.

m Tighten the screws in alternate sequence.

n Stage 1: 30 Nm.

m Tighten the screws using the rotation angle gauge.

n Stage 2: 60°

n Stage 3: 30°
m Withdraw locating dowel “A”.
m Unscrew the service screws.

© 51464-0

Fig. 679

Technical data
Tightening torque
Table 138
ID no. Designation Screws type Indications/observa- Value
tions
A05 001 Flywheel to engine block Stage 1: Use new screws 30 Nm
A05 001 Flywheel to engine block Stage 2: 60°
A05 001 Flywheel to engine block Stage 3: 30°
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.10 - Removal and refitting of the cylinder head cover

Removal of the cylinder head cover
1. m 1 - Cylinder head cover
m 2 - Gasket
m 3 – Screw
m 4 - Closing plug
m 5 - Connector

© 50507-0

Fig. 680

30-49
 Method of intervention
2. m Remove the crankcase breather.
Construction unit
01

m Remove screws (1).

m Remove cylinder head cover (2).

© 50508-0

Fig. 681
3. m Remove seal (1).

© 50509-0

Fig. 682

Refitting the cylinder head cover

1. m Fit the new gasket (1).

© 50509-0

Fig. 683

30-50
Method of intervention
2. m Fit cylinder head cover (1).

© 50510-0

Fig. 684
3. m Tighten the screws in the sequence indicated: 8.5 Nm
m Fit the crankcase breather.
Construction unit
01

© 50511-0

Fig. 685

Technical data
Tightening torque
Table 139
ID no. Designation Screws type Indications/observa- Value
tions
A08 004 Cylinder head cover to 8.5 Nm
cylinder head
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-51
 Method of intervention
30.8.11 - Support
1. WARNING
Ensure maximum cleanliness during all work. Before pro-
ceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. All fuel lines
and unions should be closed immediately after opening us-
ing new, clean plugs or caps. Remove plugs and caps only
immediately prior to assembly.
m 1 – Mount
m 2 - Speed sensor
m 3 - Hex screw: 8.5 Nm
m 4 - Hex screw: 5 Nm
© 51285-0
n Position 2:
Fig. 686
NOTE
Use a new O-ring.

30.8.12 - Intermediate gear

1. m 1 - Intermediate gear
m 2 - Shaft
m 3 - Hex screw: 30 Nm

© 51284-0

Fig. 687

30.8.13 - Removal and refitting of the oil cooler

NOTE
Collect auxiliary materials in suitable containers and dispose of them in compliance with the applicable regulations.
The engine oil should be drained and replenished following the instructions given in the operation manual.

30-52
Method of intervention
Removal of the oil cooler
1. m 1 - Lubricant oil radiator
m 2 - Gasket
m 3 - Hex screw

© 50278-0

Fig. 688
2. m Remove all the screws (1).
m Remove oil cooler (2).
m Remove seal (3).
NOTE
Collect used lubricating oil and dispose of it in accor-
dance with the applicable regulations.

m Carry out a visual inspection of the components.

© 50279-0

Fig. 689

Refitting the oil cooler

1. m Carry out a visual inspection of the components.
m Clean the mating surfaces.
m Tighten the screws (arrowed).
n M8x20-10.9

m Fasten the new gasket (1) to the oil cooler with the screws.

© 50280-0

Fig. 690

30-53
 Method of intervention
2. m Fit the lubricant oil cooler (1).
m Tighten screws (2).
m Tighten all screws (2) alternately: 30 Nm

© 50281-0

Fig. 691

Technical data
Tightening torque
Table 140
ID no. Designation Screws type Indications/observa- Value
tions
A15 051 Oil cooler housing in 30 Nm
correspondence of the
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.14 - Lubricating oil filter console

1. NOTE
Collect operating materials in suitable containers and dis-
pose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, fol-
low the instructions provided.
m 1 - Replacement filter: 12 Nm
m 2 - Threaded bush
m 3 - Cover
m 4 - O-ring
m 5 - Hex screw: 30 Nm
NOTE
Use a new O-ring. © 50390-0

Fig. 692

30.8.15 - Removal and refitting of the oil pickup pipe

l DEUTZ DW 73 sealant

30-54
Method of intervention
Removal of the oil pickup pipe
1. m 1 - Oil intake pipe
m 2 - Torx screw
m 291 - Sealant

© 50409-0

Fig. 693
2. m Remove the oil sump pan.
Construction unit
02

m Remove screws (1).

m Remove oil pickup pipe (2).
m Carry out a visual inspection of the component.

© 50725-0

Fig. 694

Refitting the oil pickup pipe

1. m Clean the sealing surface.
m Apply sealant (1) evenly to the mating surface.

© 50726-0

Fig. 695

30-55
 Method of intervention
2. m Clean the sealing surface.
m Fit the oil pickup pipe (1).
m Tighten the screws (2): 22 Nm
m Fit the oil sump pan.
Construction unit
02

© 50727-0

Fig. 696

Technical data
Tightening torque
Table 141
ID no. Designation Screws type Indications/observa- Value
tions
A16 015 Oil cooler housing in M8x25-10.9 22 Nm
correspondence of the
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.16 - Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger)
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, follow the instructions provided.

Removal of the lube oil pipe

1. m 1 - Oil intake pipe
m 2 - Hollow screw
m 3 – O-ring

© 50444-0

Fig. 697

30-56
Method of intervention
2. m Unscrew banjo bolt (1)
m Remove oil seals (2).

© 50445-0

Fig. 698
3. m Unscrew banjo bolt (1)
m Remove oil seals (2).
m Remove lubricating oil pipe (3).

© 50446-0

Fig. 699

Refitting the lubricating oil pipe

1. m Clean the sealing surface.
m Fit lube oil pipe (1).
m Fit new seals (2).
m Screw in banjo bolt (3).

© 50447-0

Fig. 700

30-57
 Method of intervention
2. m Clean the sealing surface.
m Fit lube oil pipe (1).
m Fit new seals (2).
m Screw the hollow screw (3): 18 Nm.
WARNING
When fitting the pipe, ensure that it is not under tension.

© 50448-0

Fig. 701
3. m Tighten the hollow screw (1): 18 Nm.
WARNING
When fitting the pipe, ensure that it is not under tension.

© 50449-0

Fig. 702

Technical data
Tightening torque
Table 142
ID no. Designation Screws type Indications/observa- Value
tions
A43 047 Lubricant oil pipe in cor- Hollow screw Fit new seals 18 Nm
respondence with the ex-
haust gas turbocharger
A43 048 Lubricant oil pipe in cor- Hollow screw Fit new seals 18 Nm
respondence of the
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.17 - Removal and refitting of the lubricating oil pipe (exhaust gas turbocharger)
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, follow the instructions provided.

30-58
Method of intervention
Removal of the lube oil pipe
1. m 1 - Lubricant oil pipe
m 2 - Hollow screw
m 3 – O-ring

© 50656-0

Fig. 703
2. m Unscrew banjo bolt (1)
m Remove oil seals (2).

© 50675-0

Fig. 704
3. m Unscrew banjo bolt (1)
m Remove oil seals (2).
m Remove lubricating oil pipe (3).

© 50676-0

Fig. 705

30-59
 Method of intervention
Refitting the lubricating oil pipe
1. m Clean the sealing surface.
m Fit lube oil pipe (1).
m Fit new seals (2).
m Screw in banjo bolt (3).

© 50676-0

Fig. 706
2. m Clean the sealing surface.
m Fit lube oil pipe (1).
m Fit new seals (2).
m Screw the hollow screw (3): 18 Nm.
WARNING
When fitting the pipe, ensure that it is not under tension.

© 50678-0

Fig. 707
3. m Tighten the hollow screw (1): 18 Nm.
WARNING
When fitting the pipe, ensure that it is not under tension.

© 50679-0

Fig. 708

30-60
Method of intervention
Technical data
Tightening torque
Table 143
ID no. Designation Screws type Indications/observa- Value
tions
A43 047 Lubricant oil pipe in cor- Hollow screw Fit new seals 18 Nm
respondence with the ex-
haust gas turbocharger
A43 048 Lubricant oil pipe in cor- Hollow screw Fit new seals 18 Nm
respondence of the
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.18 - Removal and refitting of the lubricating oil return pipe (exhaust gas turbo-
charger)
Special tools:
l Disassembly tool 02992127
l Assembly product: DEUTZ AP1908
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, follow the instructions provided.

Disassembly of the oil return pipe

1. m 1 - Fastening flange
m 2 - O-ring
m 3 - Oil return pipe
m 4 - O-ring
m 5 - Hex screw
m 6 - Hex screw
m 7 - Gasket

© 50435-0

Fig. 709

30-61
 Method of intervention
2. m Remove screws (1).
m Remove seal (2)

© 50436-0

Fig. 710
3. m Remove screw (1).
m Withdraw oil return pipe (2) in the direction of the arrow.

© 50437-0

Fig. 711
4. m Withdraw the flange (1) in the direction of the arrow.
m Remove the O-ring (2) with the disassembly tool.
m Carry out a visual inspection of the component.

© 50438-0

Fig. 712

30-62
Method of intervention
5. m Remove seal (1) using the removal tool.
m Carry out a visual inspection of the component.

© 50683-0

Fig. 713

Refitting the oil return pipe

1. m Clean the mating surfaces.
m Apply a thin coating of assembly product DEUTZ AP1908 on the
new O-ring.
m Fit new O-ring (1).

© 50684-0

Fig. 714
2. m Clean the mating surfaces.
m Apply a thin coating of assembly product DEUTZ AP1908 on the
new O-ring.
m Fit new O-ring (1).
m Insert the flange (2) in the direction of the arrow.

© 50440-0

Fig. 715

30-63
 Method of intervention
3. m Clean the mating surfaces.
m Fit oil return pipe (1)
m Insert oil return pipe (1) in the direction of the arrow.
m Tighten screws (2).

© 50441-0

Fig. 716
4. m Clean the mating surfaces.
m Fit a new O-ring (1).
m Fit oil return pipe (2).
m Tighten the screw (3): 8.5 Nm.

© 50442-0

Fig. 717
5. m Tighten (1) the screw: 8.5 Nm.
WARNING
When fitting the pipe, ensure that it is not under tension.

© 50443-0

Fig. 718

30-64
Method of intervention
Technical data
Tightening torque
Table 144
ID no. Designation Screws type Indications/observa- Value
tions
A43 044 Oil return pipe on the ex- 8.5 Nm
haust gas turbocharger
A43 046 Oil return pipe on the 8.5 Nm
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.19 - Removal and refitting of the lubricating oil return pipe (exhaust gas turbo-
charger)
Special tools:
l Disassembly tool 02992127
l Assembly product: DEUTZ AP1908
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, follow the instructions provided.

Disassembly of the oil return pipe

1. m 1 - Fastening flange
m 2 - O-ring
m 3 - Oil return pipe
m 4 - O-ring
m 5 - Hex screw
m 6 - Hex screw
m 7 - Gasket

© 50657-0

Fig. 719
2. m Remove screws (1).
m Remove seal (2)

© 50680-0

Fig. 720

30-65
 Method of intervention
3. m Remove screw (1).
m Withdraw oil return pipe (2) in the direction of the arrow.

© 50681-0

Fig. 721
4. m Withdraw the flange (1) in the direction of the arrow.
m Remove the O-ring (2) with the disassembly tool.
m Carry out a visual inspection of the component.

© 50682-0

Fig. 722
5. m Remove seal (1) using the removal tool.
m Carry out a visual inspection of the component.

© 50683-0

Fig. 723

30-66
Method of intervention
Refitting the oil return pipe
1. m Clean the mating surfaces.
m Apply a thin coating of assembly product DEUTZ AP1908 on the
new O-ring.
m Fit new O-ring (1).

© 50684-0

Fig. 724
2. m Clean the mating surfaces.
m Apply a thin coating of assembly product DEUTZ AP1908 on the
new O-ring.
m Fit new O-ring (1).
m Insert the flange (2) in the direction of the arrow.

© 50685-0

Fig. 725
3. m Clean the mating surfaces.
m Fit oil return pipe (1)
m Insert oil return pipe (1) in the direction of the arrow.
m Tighten screws (2).

© 50686-0

Fig. 726

30-67
 Method of intervention
4. m Clean the mating surfaces.
m Fit a new O-ring (1).
m Fit oil return pipe (2).
m Tighten the screw (3): 8.5 Nm.

© 50687-0

Fig. 727
5. m Tighten (1) the screw: 8.5 Nm.
WARNING
When fitting the pipe, ensure that it is not under tension.

© 50688-0

Fig. 728

Technical data
Tightening torque
Table 145
ID no. Designation Screws type Indications/observa- Value
tions
A43 044 Oil return pipe on the ex- 8.5 Nm
haust gas turbocharger
A43 046 Oil return pipe on the 8.5 Nm
crankcase
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.20 - Fitting and removing the high pressure pump

Readily available commercial tools:
l Extractor-separator
Special tools:
l Special wrench: 02992112
l Disassembly tool: 02992127
l Plugs and caps: 01899144
l Mirror
l Water resistant, indelible marker pen

30-68
Method of intervention
DANGER
Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off.
In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape.
WARNING
Ensure maximum cleanliness during all work. Before proceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be worked on. Dry any wet areas with an air jet. When handling
fuel observe the safety directives and specific local regulations. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly. Collect
operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
Removing the high pressure pump
1. m 1 - High pressure pump
m 2 - Spacer
m 3 - Hexagonal nut
m 4 - Washer
m 5 - O-ring
m 6 - Hexagonal nut
m 7 - O-ring

© 51433-0

Fig. 729
2. m Unlock and disconnect the connectors.
m Remove the high-pressure line.
m Remove the fuel lines.
Construction unit
21

m Do not fully unscrew drain plug (1).

m Remove the seal.
Construction unit
09

© 50702-0

Fig. 730

30-69
 Method of intervention
3. m Turn the crankshaft in the direction of rotation of the engine until the
marking is visible.
n (1) Marking on gear wheel of high pressure pump.

© 50703-0

Fig. 731
4. m Apply the reference marking (1).
n High pressure pump gear wheel and intermediate wheel

WARNING
Stop turning the crankshaft!

© 50704-0

Fig. 732
5. m Unscrew nuts (1).
WARNING
Do not bend the high pressure pump.

m Remove high-pressure pump (2).

WARNING
Stop turning the crankshaft!

© 50705-0

Fig. 733

30-70
Method of intervention
6. WARNING
Do not damage the high pressure pump gear wheel.

NOTE
Use a suitable tool.

m Hold the high pressure pump gear wheel (1).

m Unscrew nuts (2).
m Remove the washer (3).
m Remove the high pressure pump gear wheel (1) with the extractor-
© 51434-0
separator.
Fig. 734
m Remove the spacer (4).
m Carry out a visual inspection of the components.
7. m Remove O-rings (1) with the removal tool.
WARNING
When replacing a component, restore the reference mark-
ings correctly. Stop turning the crankshaft!

© 51435-0

Fig. 735

30-71
 Method of intervention
Refitting the high-pressure fuel pump
1. m Clean the mating surfaces.
m Fit new O-rings (1).
m Slide the spacer (2).
WARNING
Make sure the assembly position is correct. The slot (3)
must be on the fuel delivery side.

© 51436-0

Fig. 736
2. m Fit the high pressure pump gear wheel (1).
WARNING
Check the installation position is correct.

(2) - Circular groove.

(3) - Marking.

© 51437-0

Fig. 737
3. WARNING
Make sure the assembly position is correct. Do not damage
the high pressure pump gear wheel. The spring pin (1) must
engage in the groove (2).
m Insert the washer (3).
m Screw in nut (4);
NOTE
Use a suitable tool.

m Hold the high pressure pump gear wheel (5).

m Tighten the nut (4): 80 Nm. © 51438-0

Fig. 738

30-72
Method of intervention
4. WARNING
Ensure that the high pressure pump is driven in the correct
direction of rotation!

Table 146

View Direction of rotation

On high pressure pump drive to the right (clockwise)

(1) Marking on gear wheel of high pressure pump.

WARNING
Never run the pump without fuel. The high pressure pump
© 51439-0
must always receive fuel under adequate pressure.
Fig. 739
Fuel pressure on feed side: at least 4.3 Bar.
5. m Fitting the high pressure pump
NOTE
The markings must be visible. The reference marking
must be aligned correctly.

(1) Marking on gear wheel of high pressure pump.

(2) - Reference marking on high pressure pump gear wheel and intermedi-
ate wheel

© 50713-0

Fig. 740
6. WARNING
Do not bend the high pressure pump.

m Tighten the nuts (1).

m Tighten the nuts (1): 21 Nm
m Fit the screw plug.
Construction unit
09

m Fit the fuel lines.

m Fit a new high pressure line. © 50714-0

Construction unit Fig. 741

21

m Connect and lock the wiring connector.

30-73
 Method of intervention
Technical data
Tightening torque
Table 147
ID no. Designation Screws type Indications/observa- Value
tions
A17 004 High pressure pump gear Hold the high pressure 80 Nm
wheel on high pressure pump gear wheel.
pump drive shaft.
A17 031 High pressure pump to 21 Nm
engine block
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.21 - Removal and refitting of the injectors

Special tools:
l SerDia 2010 diagnostic tool
l Assembly pliers: 01899050
l Torx tool set: 01899092
l Plugs and caps: 01899144
l Lever tool 02992117
l Disassembly tool: 02992127
l Extraction device: 02992138
l Slide hammer extractor: 02992294
DANGER
Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off.
In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape.
WARNING
Ensure maximum cleanliness during all work. Before proceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be worked on. Dry any wet areas with an air jet. When handling
fuel observe the safety directives and specific local regulations. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove plugs and caps only immediately prior to assembly. Collect
operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
Removal of the injectors
1. m 1 - Injector
m 2 - Seal disc
m 3 - Tightening bracket
m 4 – Screw

© 50460-0

Fig. 742

30-74
Method of intervention
2. 1600 Bar Injection system
WARNING
Note that each injector is paired with a specific cylinder. Each
injector is assigned to its respective cylinder on the basis of
its IMA code (1). The assignments are saved in the control
1
unit memory. Whenever an injector is renewed or swapped
over, it must be assigned to its respective cylinders by enter-
ing the new IMA code in the control unit memory. Note which
type of injection system is installed! The IMA coces of differ-
ent injection systems are different. The injector calibration
depends on the type of injection system installed. The cor-
rect procedure, given in the documentation indicated below, © 51243-0
must be followed precisely Fig. 743
SerDia 2010 diagnostic tool
SerDia manual

NOTE
The procedures for the removal and refitting of the fuel injec-
tors are described in the following paragraphs. These proce-
dures apply to all the injectors.
3. m Unlock and disconnect the connectors.
m Remove the fuel line from the injector.
Construction unit
21

WARNING
Position (1): if the pipe union is loosened, the injector must
be replaced.

m Hold the pipe union (1).

m Remove the injection pipe. © 50461-0

Construction unit Fig. 744

21

m Unscrew screw (2)

30-75
 Method of intervention
4. m Insert lever (1) in the retaining bracket.
m Unseat the injector by moving lever (1) in the direction of the arrow.
m Remove the injector with the retaining bracket.

© 50462-0

Fig. 745
5. WARNING
Do not attempt to clean the injector nozzle with a brush.
When removing seal (1), take care not to damage the injec-
tor nozzle.
m Grip the fixed seal (1) with the special pliers (2) and remove it by
twisting it gently.

© 51242-0

Fig. 746

Removal of the fixed seal in the cylinder head

1. m Insert removal tool (1).
NOTE
The tool (arrowed) must locate in the seal.

© 50463-1

Fig. 747

30-76
Method of intervention
2. m Screw in spindle (1) until the seal is seated on the removal tool.
NOTE
Counterhold the removal tool.

m Fit adapter (2) to the removal tool.

© 50464-1

Fig. 748
3. m Fit slide hammer puller (1) to the removal tool.
m Remove the seal.

© 50465-1

Fig. 749

Refitting the injectors

1. m Fit a new seal (1) to the injector.
WARNING
Before installing the injector, clean any carbon deposits from
the injector bore in the cylinder head. Remove any particles
of dirt.

© 50466-0

Fig. 750

30-77
 Method of intervention
2. WARNING
Note that each injector is paired with a specific cylinder.
Make sure the assembly position is correct.

m Carefully insert the injector in the cylinder head.

m Fit the retaining bracket.
m Fit screw (1).
NOTE
Tighten the screw only after having fitted the injec-
tion pipe.

m Insert the new injection pipe.

Construction unit © 50467-1

Fig. 751
21

NOTE
Do not tighten the union nuts at this stage.

3. WARNING
Position (1): if the pipe union is loosened, the injector must
be replaced.

m Tighten the screw (2): 30 Nm.

m Tighten the nuts on the injection line unions.
Construction unit
21

m Fit the fuel pipe.

WARNING © 50461-0

Disassembled, missing or bent terminals must be replaced. Fig. 752

The terminal must automatically return to the stop position.
Otherwise, replace the terminal.
Construction unit
21

m Connect and lock the wiring connector.

30-78
Method of intervention
Technical data
Tightening torque
Table 148
ID no. Designation Screws type Indications/observa- Value
tions
A19 001 Injector in cylinder head, Observe the indicated 30 Nm
retaining bracket installation sequence.
Install the injector without
applying force.
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.22 - Removal and refitting of the common rail

Readily available commercial tools:
l Open-ended wrench, wrench width 14
Special tools:
l Box spanner insert, long: 01899132
l Plugs and caps: 01899144
l Special wrench: 02992112
l Disassembly tool: 02992127
l Assembly grease: 01016496
DANGER
Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off.
In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape.
WARNING
Ensure maximum cleanliness during all work. Before proceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be worked on. Dry any wet areas with an air jet. When handling
fuel observe the safety directives and specific local regulations.
All fuel lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove the
plugs and caps only immediately prior to assembly. Collect operating materials in suitable containers and dispose of
them in compliance with the applicable regulations.
Removal of the common rail
1. m 1 - Rail
m 2 - High pressure line
m 3 - Injection pipe
m 4 - Injection pipe
m 5 - Torx screw
m 6 – Spacer

© 50552-0

Fig. 753

30-79
 Method of intervention
Remove the high pressure line.
1. m Remove the fuel return pipe.
m Unscrew the sleeve nuts (1) using the special wrench.
m Remove the cable harness mount and turn over on its side.
m Undo the sleeve nut (2) with the special wrench.
m Remove the high pressure line (3).
NOTE
Collect any leaked fuel and dispose of it properly.

© 51409-0

Fig. 754

Removal of the injection pipes

1. m Unscrew union nuts (1) using the special wrench.
WARNING
Position (3): if the pipe union is loosened, the injector must
be replaced.

m Counterhold the pipe union on the injector.

m Unscrew the union nuts (2).
m Remove the injection pipes.
Note
Collect any leaked fuel and dispose of it properly.

© 51410-0

Fig. 755
2. m Unlock the wiring connector.
m Unplug the connector.
m Remove screws (1).
m Remove the rail (2).
m Remove spacers (3).
m Carry out a visual inspection of the components.

© 51411-0

Fig. 756

30-80
Method of intervention
Removal of the pressure sensor
1. m Unscrew rail pressure sensor (1) using the long reach socket.
NOTE
Collect any leaked fuel and dispose of it properly.

© 51412-0

Fig. 757
2. WARNING
To avoid electrostatic discharge, do not touch the male con-
nectors of the rail pressure sensor with bare hands. Ensure
that the connection plug is clean.
m Carry out a visual inspection of the thread and the sealing edge (ar-
rowed) of the rail pressure sensor.

© 43017-0

Fig. 758

Refitting the pressure sensor

1. WARNING
Make sure that no foreign material enters the common rail
system. Ensure maximum cleanliness. In particular, ensure
that the threads and the mating surfaces of the rail are
clean. Consult the documentation supplied with the replace-
ment parts. The rail pressure sensor and the pressure relief
valve must be renewed together as a pair.
m Clean the threads and the mating surfaces of the rail.
m Apply a thin coating of assembly grease to the threads and around
the sealing edge of the rail pressure sensor.

© 43017-0

Fig. 759

30-81
 Method of intervention
2. WARNING
Tighten the rail pressure sensor by applying the wrench to
the hex on the body only.

m Screw in rail pressure sensor (1)

m Tighten rail pressure sensor (1) using the box spanner insert: 70
Nm.

© 51412-0

Fig. 760

Removal of the pressure cut-off valve

1. m Unscrew pressure cut-off valve (1).
NOTE
Collect any leaked fuel and dispose of it properly.

© 51413-0

Fig. 761
2. m Carry out a visual inspection of the thread and the sealing edge of
the pressure cut-off valve.

© 43253-1

Fig. 762

30-82
Method of intervention
3. m Remove the O-ring using the specific tool.

© 43335-0

Fig. 763

Refitting the pressure cut-off valve

1. WARNING
1
Make sure that no foreign material enters the common rail
system. Ensure maximum cleanliness. In particular, ensure
that the threads and the mating surfaces of the rail are
clean. Consult the documentation supplied with the replace-
ment parts. The rail pressure sensor and the pressure relief
valve must be renewed together as a pair.
m Fit a new O-ring (1).

© 43254-0

Fig. 764
2. m Apply a thin coating of assembly grease to the threads and sealing
edge of the pressure cut-off valve.

© 43254-1

Fig. 765

30-83
 Method of intervention
3. m Clean the threads and the mating surfaces of the rail.
m Screw in pressure cut-off valve (1).
m Tighten the pressure limiting valve: 100 Nm.

© 51413-0

Fig. 766

Refitting the common rail

1. m Fit rail (1) with spacers (2).
m Fit rail (1) without tightening screws (3).
NOTE
Do not tighten the screws at this stage.

© 51414-0

Fig. 767

Refitting the injection pipes

1. WARNING
Once disturbed, the injection pipes must be renewed.

NOTE
Make sure the injection pipes are positioned correctly.

m Fit the new injection pipes (1).

© 51415-0

Fig. 768

30-84
Method of intervention
2. WARNING
Check that the injection pipes are properly aligned. Do not
rest wires in the holes (1) of the sleeve nuts. Fit the injec-
tion pipe with no contact with surrounding parts and without
tightening. Guarantee sufficient distance from the surround-
ing components.
m Align the injection pipes.
m Tighten the sleeve nuts by hand.

© 51416-0

Fig. 769

Fit the high pressure line.

1. WARNING
The high pressure line must be completely replaced after
removal.

NOTE
Check the installation position is correct.

m Fit a new high pressure line (1).

© 51417-0

Fig. 770
2. WARNING
Ensure that the high pressure line is aligned correctly. Do
not insert the line in the hole (1) of the sleeve nut. Fit the
high pressure line with no contact with surrounding parts
and without tightening. Guarantee sufficient distance from
the surrounding components.
m Align the high pressure line correctly.
m Tighten the sleeve nuts by hand.

© 51418-0

Fig. 771

30-85
 Method of intervention
3. m Tighten the screws (1): 30 Nm.

© 51419-0

Fig. 772
4. m Tighten the sleeve nuts following the specific tightening sequence.
30 (+1.5, -1.5) Nm.
m Check that the injection pipes are positioned correctly.
m Check that the high-pressure pipe is positioned correctly.
m Fit the fuel return pipe.
m Fit the cable harness mount.
m Connect and lock the wiring connector.
NOTE
Check that the connection is made correctly.

© 51420-0

Fig. 773

Technical data
Tightening torque
Table 149
ID no. Designation Screws type Indications/observa- Value
tions
A21 003 Injection pipe connec- Sleeve nut Observe the assembly 30 (+1.5, - 1.5) Nm
tion to common rail and indications.
injector, high-pressure Use a new pipe
pipe connection to high-
pressure pump and com-
mon rail
A21 038 Common rail on cylinder Observe the assembly 30 Nm
head indications.
A21 039 Pressure relief valve on Apply a thin coating of 100 Nm
common rail assembly grease to the
threads and around the
sealing edge.
A21 040 Pressure sensor on rail M18x1.5 Apply a thin coating of 70 Nm
assembly grease to the
threads and around the
sealing edge.
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-86
Method of intervention
30.8.23 - Removal and refitting of the charge air duct
Removal of the charge air duct
1. m 1 - Turbocharging air duct
m 2 - Gasket
m 3 - Hex screw

© 50413-0

Fig. 774
2. m Remove the fuel return pipe.
m Unlock and detach the connectors.
m Remove screws (1).
m Remove charge air duct (2).
m Remove seal (3).
m Carry out a visual inspection of the components.

© 50414-0

Fig. 775

Refitting the charge air duct

1. m Clean the mating surfaces.
m Fit the new gasket (1).
m Insert the screws so that their threads engage the female threads in
the gaskets by a few turns.
NOTE
The gasket is held in position by the screw thread.
Check that the gasket assembly position is correct.

© 50415-0

Fig. 776

30-87
 Method of intervention
2. m Fit the charge air duct (1).
m Tighten screws (2).
NOTE
Do not move the gasket.

© 50416-0

Fig. 777
3. m Tighten the screws in the sequence indicated: 30 Nm.
WARNING
Check that the cables are positioned correctly.

m Connect and lock the wiring connector.

m Fit the fuel return pipe.

© 50417-0

Fig. 778

Technical data
Tightening torque
Table 150
ID no. Designation Screws type Indications/observa- Value
tions
A22 030 Charge air duct connect- 30 Nm
ed to cylinder head
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.24 - Removal and refitting of the charge air manifold

Readily available commercial tools:
l Circlip pliers: 01899112

30-88
Method of intervention
Removal of the charge air manifold
1. m 1 - Rubber sleeve
m 2 - Flexible pipe union
m 3 - Spring clip
m 4 - Spring clip
m 5 - Spring clip
m 6 - Gasket
m 7 - Turbocharging air manifold
m 8 - Hex screw

© 50403-0

Fig. 779
2. m Open the spring clips (1) with the spling clip pliers.
m Remove screws (2).
m Remove charge air manifold (3).
m Remove gasket (4).
m Carry out a visual inspection of the component.

© 50404-0

Fig. 780

Refitting the charge air manifold

1. m Clean the mating surfaces.
m Fit the new gasket (1).
m Fit charge air manifold (2).
m Tighten screws (3).
m Tighten the screws in alternate sequence: 30 Nm.
m Fit the spring clips (4) with the specific pliers.

© 50405-0

Fig. 781

Technical data
Tightening torque
Table 151
ID no. Designation Screws type Indications/observa- Value
tions
A22 046 Turbocharging air elbow 30 Nm
in correspondence of the
turbocharging air duct

30-89
 Method of intervention
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.25 - Intake manifold (turbocharger)

1. Readily available commercial tools:
m Circlip pliers: 01899112
m 1 - Intake manifold
m 2 - Spring clip
m 3 - Spring clip
m 4 - Hex screw: 13 Nm
m 5 - Pipe retaining clip
m 6 - Pipe
m 7 - Rubber sleeve
NOTE
Slide the pipe and rubber sleeve to the end stop.
Fit the spring clips so that they are accessible from
above. © 50384-0

Fig. 782

30.8.26 - Charge air manifold

1. m 1 - Turbocharging air manifold
m 2 - Throttle valve
m 3 - Gasket
m 4 - Hex screw: 30 Nm
m 5 - Hex screw: 13 Nm
m 6 - Gasket
NOTE
Use a new gasket.

© 51444-0

Fig. 783

Technical data
Tightening torque
Table 152
ID no. Designation Screws type Indications/observa- Value
tions
A22 046 Turbocharging air elbow 30 Nm
in correspondence of the
turbocharging air duct

30-90
Method of intervention
30.8.27 - Charge air duct
1. Special tools:
m Spring clamp pliers 01899112
m 1 - Rubber sleeve
m 2 - Flexible pipe
m 3 - Spring clip
m 4 - Spring clip
m 5 - Spring clip
m 6 - Gasket
m 7 - Turbocharging air duct
m 8 - Hex screw: 13 Nm
m 9 - Pipe retaining clip
m 10 - Hex screw 30 Nm
m 11 - Flexible pipe
m 12 - Banjo bolt 30 Nm © 51445-0

m 13 – O-ring Fig. 784

NOTE
Use a new gasket.

30.8.28 - V-belt pulley

1. m 1 - V-belt pulley
m 2 - Hex screw: 30 Nm

© 50661-0

Fig. 785

30.8.29 - Actuating elements

1. m 1 - V-belt pulley
m 2 - Hex screw: 20 Nm

© 50391-0

Fig. 786

30-91
 Method of intervention
30.8.30 - V-belt pulley
1. m 1 - V-belt pulley
m 2 - Adapter
m 3 - Hex screw: 30 Nm

© 51447-0

Fig. 787

30.8.31 - Removal and refitting of the thermostat

NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, follow the instructions provided.

Removal of the thermostat

1. m 1 - Thermostat housing
m 2 - Thermostat
m 4 – O-ring
m 5 - Hole blanking screw: 65 Nm
m 6 - Gasket
m 7 - Hex screw
m 8 - Temperature sender

© 51383-0

Fig. 788
2. m Empty, collect and dispose of the coolant in compliance with regula-
tions.
m If available: Disconnect the flexible hose from the outlet port.
m Remove screws (1).
m Remove thermostat housing (2).
m Carry out a visual inspection of the component.

© 51384-0

Fig. 789

30-92
Method of intervention
3. m Remove seal (1).
m Remove thermostat (2).
m Carry out a visual inspection of the components.

© 51385-0

Fig. 790

Refitting the thermostat

1. m Clean the mating surfaces.
m Insert the thermostat (1).

© 51389-0

Fig. 791
2. m Fit the screws (1).
m Fasten the new gasket (2) onto the thermostat housing with the
screws.

© 51386-0

Fig. 792

30-93
 Method of intervention
3. m Install thermostat housing (1).
m Tighten screws (2).
m Tighten screws (3).

© 51387-0

Fig. 793
4. m Tighten all the screws (1): 30 Nm.
m If available: slide the flexible hose over the outlet and secure it.
m Fill the cooling system as indicated in the operating instructions.
NOTE
User instructions

© 51388-0

Fig. 794

Technical data
Tightening torque
Table 153
ID no. Designation Screws type Indications/observa- Value
tions
A38 001 Thermostat housing to 30 Nm
cylinder head
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.32 - Testing the thermostat (after removal)

Readily available commercial tools:
l Thermometer
DANGER
Risk of injury! Hot water and hot thermostat.

30-94
Method of intervention
Testing the thermostat
1. m 1 - Thermostat housing
m 2 - Thermostat
m 4 – O-ring
m 5 - Hole blanking screw: 65 Nm
m 6 - Gasket
m 7 - Hex screw
m 8 - Temperature sender

© 51383-0

Fig. 795
2. m Measure dimension (a), with thermostat closed.
m Make a note of dimension (a).

© 51390-0

Fig. 796
3. m Place the thermostat in water and heat the water.
m Determine the temperature at which the thermostat starts to open.
NOTE
To ensure an accurate reading, measure the temper-
ature as near to the thermostat as possible. Do not
touch the thermostat.
To ensure that the heat is evenly distributed, the wa-
ter should be in constant motion. The temperature
should not increased at a rate of more than 1°C/min.,
otherwise opening of the thermostat will be delayed.
n Nominal value: 86 °C
© 52163-0

Fig. 797

30-95
 Method of intervention
4. m Measure the water temperature.
n Nominal value: 99 °C

m Measure dimension (b), with thermostat open.

m Make a note of dimension (b).

© 51391-0

Fig. 798
5. m Calculate the stroke of the thermostat valve.
Table 154

Calculation example:
Target: Valve stroke
Data: -
Measured value: Stroke start, dimension (a). Stroke
end, dimension (b)
Calculation: (b) - (a)
The results of all this are: = Valve stroke

m Compare this value with the nominal value.

n Nominal value: 9 mm © 51392-0

Fig. 799

Technical data
Tightening torque
Table 155
ID no. Designation Additional information Value
P38 11 Thermostat, initial opening tem- 86 °C
perature
P38 13 Thermostat, stroke at 99 °C, idling 9 mm
P38 14 Thermostat, stroke, test tem- 99 °C
perature

30.8.33 - Line
1. Readily available commercial tools:
m Circlip pliers: 01899112
Special tools:
m Plugs and caps: 01899144
m 1 - Pipe
m 2 - Spring clip
m 3 - Elbow joint
m 4 - Flexible pipe
m 5 - Hex screw: 13 Nm
m 6 - Support plate
m 7 - Pipe retaining clip
m 8 - Hex screw 8 Nm
© 50670-0

Fig. 800

30-96
Method of intervention
30.8.34 - Line
1. m 1 - Coolant pipe
m 10 - Hex screw 14 Nm

© 50554-0

Fig. 801

30.8.35 - Line
1. m 1 - Coolant pipe
m 10 - Hex screw 14 Nm
m 11 - Hex screw 14 Nm
m 12 - Washer

© 51448-0

Fig. 802

30.8.36 - Connection (crankcase, exhaust gas recovery, coolant pipe)

1. m DEUTZ AP1908 assembly product
NOTE
Collect operating materials in suitable containers and
dispose of them in compliance with the applicable
regulations. To drain and replenish the engine fluids
and lubricants, follow the instructions provided.
m 1 - Flexible pipe union
m 2 - O-ring
m 3 - Hex screw: 20 Nm
NOTE
Use a new O-ring.
© 50387-0

Fig. 803
m Apply a thin coating of assembly product DEUTZ AP1908 on the
new O-ring.

30-97
 Method of intervention
30.8.37 - Fitting compensator (exhaust pipe)
1. m 1 - Compensator
m 2 - Gasket
m 3 - Hex screw: 20 Nm
NOTE
Use a new gasket.

WARNING
Check seal tightness. Make sure the assembly position is
correct. Fit without tightening or straining.

© 50388-0

Fig. 804

30.8.38 - Pipe (thermostat housing, exhaust gas recovery, coolant pipe)

1. Readily available commercial tools:
m Torx tool set: 01899092
m Circlip pliers: 01899112
Special tools:
m Plugs and caps 01899144
NOTE
Collect operating materials in suitable containers and dis-
pose of them in compliance with the applicable regulations.
To drain and replenish the engine fluids and lubricants, fol-
low the instructions provided.
m 1 - Flexible pipe © 50385-0
m 2 - Spring clip Fig. 805
m 3 - Coolant pipe
m 4 - Torx screw: 10 Nm
m 5 - Hex screw: 8 Nm
m 6 - Pipe retaining clip
m 7 - Gasket
m 8 - Rubber sleeve
m 9 – O-ring
m 10 - Screw plug 80 Nm
NOTE
Use a new gasket. Use a new O-ring.

30-98
Method of intervention
30.8.39 - Removal and refitting of the turbocharger
Removal of the turbocharger
1. m 1 - Turbocharger
m 2 - Gasket
m 3 - Hex screw

© 50450-0

Fig. 806
2. m Disassemble the intake manifold.
Construction unit
22

m Remove the lubricating oil pipe.

m Remove the lubricating oil return pipe.
Construction unit
16

m Disassemble the exhaust manifold.

Construction unit
© 50451-0

Fig. 807
43

m Remove screw (1).

3. m Remove screws (1).
m Remove exhaust gas turbocharger (2).
m Remove seal (3).
m Carry out a visual inspection of the component.

© 50452-0

Fig. 808

30-99
 Method of intervention
Refitting the turbocharger
1. m Clean the mating surfaces.
m Fit a new O-ring (1).
m Fit turbocharger (2).
m Tighten screws (3).

© 50453-0

Fig. 809
2. m Screw in the screw (1).
m Tighten (1) the screw: 30 Nm.
m Tighten the screws (2): 30 Nm.
m Assemble the intake manifold.
Construction unit
22

m Fit the lubricating oil pipe.

m Fit the lubricating oil return pipe.
Construction unit
16
© 50454-0

Fig. 810
m Assemble the exhaust manifold.
Construction unit
43

Technical data
Tightening torque
Table 156
ID no. Designation Screws type Indications/observa- Value
tions
A43 020 Turbocharger in cor- 30 Nm
respondence of the ex-
haust gas pipe
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-100
Method of intervention
30.8.40 - Removal and refitting of the turbocharger
Removal of the turbocharger
1. m 1 - Turbocharger
m 2 - Gasket
m 3 - Hex screw

© 50565-0

Fig. 811
2. m Disassemble the intake manifold.
Construction unit
22

m Remove the lubricating oil pipe.

m Remove the lubricating oil return pipe.
Construction unit
16

m Remove screws (1).

m Remove exhaust gas turbocharger (2). © 50728-0

m Remove seal (3). Fig. 812

m Carry out a visual inspection of the component.

Refitting the turbocharger

1. m Clean the mating surfaces.
m Fit a new O-ring (1).
m Fit turbocharger (2).
m Tighten the screw (3): 30 Nm.
m Assemble the intake manifold.
Construction unit
22

m Fit the lubricating oil pipe.

m Fit the lubricating oil return pipe.
Construction unit
16 © 50729-0

Fig. 813

30-101
 Method of intervention
Technical data
Tightening torque
Table 157
ID no. Designation Screws type Indications/observa- Value
tions
A43 020 Turbocharger in cor- 30 Nm
respondence of the ex-
haust gas pipe
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.41 - Exhaust manifold (turbocharger)

1. m 1 - Exhaust manifold
m 2 - Clip
m 3 - Nut: 10 Nm
NOTE
Observe the installation position.

© 50389-0

Fig. 814

30.8.42 - Exhaust manifold (turbocharger)

1. m 1 - Exhaust pipe
m 2 - Clamp: 9 Nm
m 3 - Clamp: 9 Nm
m 4 - Gasket
NOTE
Observe the installation position. Use a new gasket.

© 51345-0

Fig. 815

30-102
Method of intervention
30.8.43 - Exhaust manifold (turbocharger)
1. m 1 - Exhaust manifold
m 2 - Clip
m 3 - Nut: 10 Nm
NOTE
Observe the installation position.

© 51481-0

Fig. 816

30.8.44 - Removing and refitting the belt tensioner (ribbed V-belt, level 1).
Removing the belt tensioner
1. m 1 - Belt tensioner
m 2 - Idler roller.
m 3 - Ribbed V-belt
m 4 - Cylindrical screw

© 50562-1

Fig. 817
2. m Remove the V-belt.
NOTE
User instructions

m Remove screw (1).

m Remove belt tensioner (2).
m Carry out a visual inspection of the component.

© 51380-0

Fig. 818

30-103
 Method of intervention
Installing the belt tensioner
1. m Fit belt tensioner (1).
m Tighten screws (2).
m Tighten the screw (2): 48 Nm.
m Fit the ribbed V-belt, checking that the rotation direction is correct.
NOTE
User instructions

© 51381-0

Fig. 819

Technical data
Tightening torque
Table 158
ID no. Designation Screws type Indications/observa- Value
tions
A44 041 Belt tensioner on gear- 48 Nm
box
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.45 - Fitting and removing the console (ribbed V-belt, level 1)

l DEUTZ DW 73 sealant
Removing the console
1. m 1 - Console
m 2 - Spring pin
m 3 - Hex screw
m 4 - Fastener bush
m 5 - Hex screw
m 244 - Sealant

© 50561-0

Fig. 820

30-104
Method of intervention
2. m Remove the V-belt.
NOTE
User instructions

m Remove the alternator (level 1).

Construction unit
44

m Remove screws (1).

m Remove bracket (2).
m Carry out a visual inspection of the components. © 50855-0

Fig. 821

Installing the console

1. m Clean the mating surfaces.
NOTE
Make sure the pin is present (arrow).

© 50856-0

Fig. 822
2. m Clean the mating surfaces.
m Apply sealant (1) evenly to the mating surface.
NOTE
Sealing edge thickness, approx. 3 mm.

© 50857-0

Fig. 823

30-105
 Method of intervention
3. m Fit the console (1) onto the fastener pins.
m Tighten screws (2).
n M8x80-10.9

m Tighten screws (3).

n M8x80-10.9

© 50858-0

Fig. 824
4. m Tighten all the screws in the sequence indicated: 30 Nm.
m Install the alternator (level 1).
Construction unit
44

m Fit the ribbed V-belt, checking that the rotation direction is correct.
NOTE
User instructions

© 50859-0

Fig. 825

Technical data
Tightening torque
Table 159
ID no. Designation Screws type Indications/observa- Value
tions
A44 013 Console connected to 30 Nm
crankcase/gearbox
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-106
Method of intervention
30.8.46 - Engine mounting
1. m 1 – Mount
m 2 - Hex screw: 260 Nm
m 3 - Installation foot
m 4 - Hex screw: 200 Nm
m 5 - Hexagonal nut
m 6 - Washer
m 7 - Washer

© 51485-0

Fig. 826

30.8.47 - Engine mounting

1. m 1 - Installation foot
m 2 - Hex screw: 200 Nm
m 3 - Washer

© 51487-0

Fig. 827

30.8.48 - Engine mounting

1. m 1 - Installation foot
m 2 - Hex screw: 200 Nm
m 3 - Washer
m 4 - Rubber pad
m 5 - Bush

© 51486-0

Fig. 828

30-107
 Method of intervention
30.8.49 - Disassembly and assembly of the connector box
Disassembly of the connector box
1. m 1 - Connector box
m 2 - Hex screw
m 3 - Bush

© 50430-0

Fig. 829
2. m Remove the flywheel.
Construction unit
05

m Remove screw (1).

m Withdraw the connector box (2).
m Carry out a visual inspection of the component.

© 50431-0

Fig. 830

Assembly of the connector box

1. m Clean the support surfaces.
NOTE
Check that tightening bush (1) is present.

© 50432-0

Fig. 831

30-108
Method of intervention
2. m Position the connector box (1).
m Centre the connector box above the tightening bushes.

© 50433-0

Fig. 832
3. m Tighten screws (1).
m Tighten all screws (1) alternately: 170 Nm.
m Fit the flywheel.
Construction unit
05

© 50434-0

Fig. 833

Technical data
Tightening torque
Table 160
ID no. Designation Screws type Indications/observa- Value
tions
A52 080 Connector box in corre- Tighten alternatively 170 Nm
spondence of the crank-
case
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-109
 Method of intervention
30.8.50 - Disassembly and assembly of the connector box
Disassembly of the connector box
1. m 1 - Connector box
m 2 - Hex screw: 8.5 Nm
m 3 - Covering case
m 4 - Hex screw
m 5 - Bush

© 50662-0

Fig. 834
2. m Remove the flywheel.
Construction unit
05

m Remove screw (1).

m Withdraw the connector box (2).
m Carry out a visual inspection of the component.

© 50671-0

Fig. 835

Assembly of the connector box

1. m Clean the support surfaces.
NOTE
Check that tightening bush (1) is present.

© 50672-0

Fig. 836

30-110
Method of intervention
2. m Position the connector box (1).
m Centre the connector box above the tightening bushes.

© 50673-0

Fig. 837
3. m Tighten screws (1).
m Tighten all screws (1) alternately: 170 Nm.
m Fit the flywheel.
Construction unit
05

© 50674-0

Fig. 838

Technical data
Tightening torque
Table 161
ID no. Designation Screws type Indications/observa- Value
tions
A52 080 Connector box in corre- Tighten alternatively 170 Nm
spondence of the crank-
case
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-111
 Method of intervention
30.8.51 - Disassembly and assembly of the connector box
Disassembly of the connector box
1. m 1 - Connector box
m 2 - Hex screw
m 3 - Bush

© 51359-0

Fig. 839
2. m Remove the flywheel.
Construction unit
05

m Remove screw (1).

m Withdraw the connector box (2).
m Carry out a visual inspection of the component.

© 50431-0

Fig. 840

Assembly of the connector box

1. m Clean the support surfaces.
NOTE
Check that tightening bush (1) is present.

© 50432-0

Fig. 841

30-112
Method of intervention
2. m Position the connector box (1).
m Centre the connector box above the tightening bushes.

© 50433-0

Fig. 842
3. m Tighten screws (1).
m Tighten all screws (1) alternately: 170 Nm.
m Fit the flywheel.
Construction unit
05

© 50434-0

Fig. 843

Technical data
Tightening torque
Table 162
ID no. Designation Screws type Indications/observa- Value
tions
A52 080 Connector box in corre- Tighten alternatively 170 Nm
spondence of the crank-
case
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-113
 Method of intervention
30.8.52 - Disassembly and assembly of the connector box
Disassembly of the connector box
1. m 1 - Connector box
m 2 - Hex screw
m 3 - Bush

© 51360-0

Fig. 844
2. m Remove the flywheel.
Construction unit
05

m Remove screw (1).

m Withdraw the connector box (2).
m Carry out a visual inspection of the component.

© 50431-0

Fig. 845

Assembly of the connector box

1. m Clean the support surfaces.
NOTE
Check that tightening bush (1) is present.

© 50432-0

Fig. 846

30-114
Method of intervention
2. m Position the connector box (1).
m Centre the connector box above the tightening bushes.

© 50433-0

Fig. 847
3. m Tighten screws (1).
m Tighten all screws (1) alternately: 170 Nm.
m Fit the flywheel.
Construction unit
05

© 50434-0

Fig. 848

Technical data
Tightening torque
Table 163
ID no. Designation Screws type Indications/observa- Value
tions
A52 080 Connector box in corre- Tighten alternatively 170 Nm
spondence of the crank-
case
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-115
 Method of intervention
30.8.53 - Disassembly and assembly of the connector box
Disassembly of the connector box
1. m 1 - Connector box
m 2 - Bush

© 51358-0

Fig. 849
2. m Remove the flywheel.
Construction unit
05

m Remove screw (1).

m Withdraw the connector box (2).
m Carry out a visual inspection of the component.

© 50431-0

Fig. 850

Assembly of the connector box

1. m Clean the support surfaces.
NOTE
Check that tightening bush (1) is present.

© 50432-0

Fig. 851

30-116
Method of intervention
2. m Position the connector box (1).
m Centre the connector box above the tightening bushes.

© 50433-0

Fig. 852
3. m Tighten screws (1).
m Tighten all screws (1) alternately: 170 Nm.
m Fit the flywheel.
Construction unit
05

© 50434-0

Fig. 853

Technical data
Tightening torque
Table 164
ID no. Designation Screws type Indications/observa- Value
tions
A52 080 Connector box in corre- Tighten alternatively 170 Nm
spondence of the crank-
case
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-117
 Method of intervention
30.8.54 - Connector casing
1. m 1 - Connector box
m 2 - Hex screw: 8.5 Nm
m 3 - Covering case
m 4 - Screw plug 80 Nm
m 5 – O-ring
NOTE
Use a new O-ring.

© 51356-0

Fig. 854

30.8.55 - Console
1. m 1 - Console
m 2 - Hex screw: 60 Nm

© 51337-0

Fig. 855

30.8.56 - Removing and fitting hydraulic pump drive

l DEUTZ DW 73 sealant
Disassembly of the hydraulic pump drive
1. m 1 - Hydraulic pump drive
m 3 - Hex screw
m 4 - Hex screw
m 244 - Sealant

© 50821-0

Fig. 856

30-118
Method of intervention
2. m Remove screw (1).
m Remove screws (2).
m Remove the hydraulic pump drive (3).

© 50822-0

Fig. 857

Assembly of the hydraulic pump drive

1. m Apply sealant (1) evenly to the mating surface.
NOTE
Sealing edge thickness, approx. 0.5 - 0.6 mm.

© 50823-0

Fig. 858
2. m Fit the hydraulic pump drive (1).
m Tighten screws (2).
m Tighten screws (3).

© 50824-0

Fig. 859

30-119
 Method of intervention
3. m Tighten all the screws in the sequence indicated: 30 Nm.

© 51335-0

Fig. 860

Technical data
Tightening torque
Table 165
ID no. Designation Screws type Indications/observa- Value
tions
A83 003 Hydraulic pump on 30 Nm
crankcase/gearbox
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.57 - Engine flywheel (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,

5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.10.1 - Engine torsional sprin... - page 30-187
Removal
1. Undo the screws (1) and remove the engine flywheel (2).

1
2

Fig. 861

30-120
Method of intervention
Refitting
1. Fit the flywheel in its seat and tighten the fastener screws in three steps:
Step 1 - tighten to 30 Nm.
Step 2 - loosen to 10 Nm.
Step 3 - tighten by an angle of 60°± 4°.
Completion
l See para. 30.10.1 - Engine torsional sprin... - page 30-187
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.8.58 - Engine
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.12.5 - Separating front carri... - page 30-514
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.2 - Catalytic converter - page 30-148
Removal
1. Remove the retainer fork (1) and disconnect the engine wiring loom con-
1
nector (2) from the mounting bracket (3).

Fig. 862
2. Disconnect the brake fluid level sensor connector (4).
3. Undo the screw (5) on the mounting bracket and detach the brake fluid
reservoir (6), securing it to the cab.

6
5

Fig. 863
4. Open the clamps (7) and disconnect the cab heating lines (8), noting their
7
respective positions for subsequent reconnection.

Fig. 864

30-121
 Method of intervention
5. Undo the screws (9) fastening the right and left hand lower cab guards (10).
6. Undo the unions (11) and disconnect the A/C system refrigerant lines (12).
10
9

12
11

Fig. 865
7. Disconnect the engine ECU connectors (13), undo the nuts fastening the two clamps (14) and free the wiring loom (15).
8. Remove the cap (16), undo the nut and disconnect the starter motor cables
13
(17).
17

16

15

14

Fig. 866
9. Disconnect the coolant sensor connector (18), open the clamp (19) and
move the wiring looms aside (20).
18

20

19

Fig. 867
10. Disconnect the water in fuel filter sensor (21), open the clamp (22) and dis-
connect the fuel delivery line (23), noting its correct position for subsequent
reconnection.
22

23

21

Fig. 868
11. Disconnect the fuel pump connector (24).
12. Undo the unions (25) and disconnect the transmission oil delivery and return lines (26) from the radiator.
13. Open the clamp (27) and disconnect the fuel return line (28), marking its correct position for subsequent reconnection.

30-122
Method of intervention
14. Secure the lines together with a cable tie and move them aside.
24
25

28

27

26

Fig. 869
15. Disconnect the engine wiring loom connectors (29).

29

Fig. 870
16. Undo the nut (30), disconnect the ground cables (31), undo the second
nut (32), retrieving the spacer, and disconnect the third ground cable (33).
32

30

31 33

Fig. 871
17. Place a stand under the transmission, with a block of wood in between.
18. Fit and tighten the two eye-bolts (34) to the engine.
19. Connect the engine lifting beam to a hoist and bring it into position.
34
34

Fig. 872

30-123
 Method of intervention
20. Undo the two lower nuts (35) fastening the engine to the transmission.
35

Fig. 873
21. Undo the two upper nuts (36) fastening the engine to the transmission.

36

Fig. 874
22. Undo the lateral screws (37) (3 on right and 3 on left) fastening the engine
to the transmission.

37
37

Fig. 875
23. Using the hoist, move the engine (38) forward to disengage it from the stud
bolts on the transmission (39).

38

39

Fig. 876

30-124
Method of intervention
Refitting
1. Follow the procedure for separating the engine in reverse order, noting the following additional instructions for the steps indi-
cated.
2. Fit and hand-tighten all the screws fastening the engine to the transmission.
3. Tighten the (shorter) upper and central lateral screws (37) to a torque of 96.3 to 117.7 Nm.
4. Tighten the (longer) lower lateral screws (37) to a torque of 148.5 to 181.5 Nm.
5. Tighten the upper (36) and lower (35) nuts to a torque of 158.4 to 193.6 Nm.
Completion
l See para. 30.9.2 - Catalytic converter - page 30-148
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.5 - Separating front carri... - page 30-514
l See para. 30.12.4 - 4WD shaft () - page 30-513
Bleed the hydraulic steering and braking circuits as indicated in the respective procedures.
30.8.59 - A/C compressor belt
Removal
1. Undo the check nut (1) and loosen the tensioner (2) to slacken the belt.

Fig. 877
2. Loosen the two bolts (3) fastening the A/C compressor.

Fig. 878
3. Remove the belt (4), lifting it over the fan blades (5).
5

Fig. 879

30-125
 Method of intervention
Refitting
1. Follow the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
m adjust the belt tension,
m tighten the bolt (3) fastening the A/C compressor to a torque of 40.4 Nm.

30.8.60 - Alternator / water pump belt

Preliminary operations
l See para. 30.8.59 - A/C compressor belt - page 30-125
Removal
1. Fit a ½” square socket bit in the relative seat (1) on the tensioner (2).

Fig. 880
2. Turn the tensioner (2) and remove the belt (3), lifting it over the fan blades.

Fig. 881

Refitting
1. Carry out the removal operations in reverse order.
Completion
l See para. 30.8.59 - A/C compressor belt - page 30-125

30.8.61 - Connecting rod drum check (L3)

Readily available commercial tools:
l Palmer
l Internal bore meter
Special tools:
l Rotation angle gauge: 01899093
l Dial gauge: 01899126
WARNING
The allocation of the connecting rod drum and flanged bearing cover must be maintained. If the connecting rod drum
and the flanged bearing cover are switched when assembled, the connecting rod drum will not be usable! Do not dam-
age the breaking surfaces of the connecting rod drum and flanged bearing cover!

30-126
Method of intervention
Check the connecting rod small end bush
1. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-
nal bore meter.
n Set the bracket measurement screw to 34 mm.
n Apply the internal bore meter between the test surfaces of
the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 882
2. m
Note
Measurement diagram of the connecting rod small
end bush in points “a” and “b” in surfaces “1” and “2”.

Fig. 883
3. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
n Nominal value: 34.010 - 34.028 mm

Note
Pressed connecting rod small end bush. Mea-
surement points, see diagram.

m Make a note of the measured value, dimension A.

Note
Dimension A is used to determine the piston pin
clearance. Fig. 884

30-127
 Method of intervention
Checking big end
1. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-
nal bore meter.
n Adjust the palmer to 37 mm.
n Apply the internal bore meter between the test surfaces of
the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 885
2. Note
Measurement diagram of the connecting rod small end bush
in points “a” and “b” in surfaces “1” and “2”.

Fig. 886
3. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
n Nominal value: 37 (+0.025, 0) mm

Fig. 887

30-128
Method of intervention
Calculate the piston pin clearance
Note
The clearance of the piston pin results from the difference between the inner diameter of the connecting rod small end
bush (dimension A) and the diameter of the piston pin (dimension B).

Construction unit
07

l m Nominal value: 0.010 - 0.031 mm

Table 166
Calculation example:
Target: Piston pin clearance
Data:
Measured value: (a) = 40.045 mm
Calculation: (b) = 40.006 mm
Dimension (a) - dimension (b)
The results of all this are: = 0.039 mm
Check the connecting rod bearing hole
1. m Apply the flanged bearing cover.
WARNING
Pay attention to coupling the flanged bearing cover. The nu-
meric marks (1) on the connecting rod drum and on the con-
necting rod bearing cover must be identical and positioned
in front of each other during assembly.

Fig. 888
2. m Alternatively tighten the screws with the rotation angle gauge and
the box spanner insert.
n Stage 1: 20 Nm

n Stage 2: 30°
n Stage 3: 60°

Fig. 889

30-129
 Method of intervention
3. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-
nal bore meter.
n Adjust the palmer to 72 mm.
n Apply the internal bore meter between the test surfaces of
the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 890
4. Note
Measurement diagram of the connecting rod bearing hole in
points “a” and “b” in surfaces “1” and “2”.

Fig. 891
5. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
n Nominal value: 71.500 - 71.519 mm

Note
If the measured values diverse minimally, take
additional measurements with new bearing
shells.

Fig. 892

30-130
Method of intervention
Check the internal diameter of the connecting rod bearing shells
1. m Insert the connecting rod bearing shell into the connecting rod drum.
WARNING
Take care to couple the bearing shells. The anti-twist safety
(1) must enter the groove (2). The allocation of the connect-
ing rod drum and flanged bearing cover must be maintained.
If the connecting rod drum and the flanged bearing cover
are switched when assembled, the connecting rod drum will
not be usable! Do not damage the breaking surfaces of the
connecting rod drum and flanged bearing cover!

Fig. 893
2. m Insert the connecting rod bearing shell into the relative flanged bear-
ing cover.
WARNING
Take care to couple the bearing shells. The anti-twist safety
(1) must enter the groove (2).

Fig. 894
3. m Apply the flanged bearing cover.
WARNING
The numeric marks (1) on the connecting rod drum and on
the connecting rod bearing cover must be identical and po-
sitioned in front of each other during assembly.

Fig. 895

30-131
 Method of intervention
4. m Alternatively tighten the screws with the rotation angle gauge and
the box spanner insert.
n Stage 1: 20 Nm

n Stage 2: 30°
n Stage 3: 60°

Fig. 896
5. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-
nal bore meter.
n Adjust the palmer to 68 mm.
n Apply the internal bore meter between the test surfaces of
the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 897
6. Note
Measurement diagram of the internal diameter of the con-
necting rod bearing shells in points “a” and “b” in surfaces
“1” and “2”.

Fig. 898

30-132
Method of intervention
7. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
n Nominal value: 67.981 - 68.000 mm

Note
If the values lie up to a maximum of 0.015 mm above
the tolerances for the bearing, the connecting rod
drum can still be used. If the limit is reached, the con-
necting rod drum must be replaced.
m Insert the measured value, measure (C).
Note
The dimension (C) is required to define the connect- Fig. 899
ing rod bearing clearance.

Determine the clearance of the connecting rod bearing

Note
The clearance of the connecting rod bearing results from the difference between the inner diameter of the connecting
rod bearing shell (C) and the diameter of the main journal (D).

l m Nominal value: 0.026 - 0.076 mm

Table 167
Calculation example:
Target: Clearance of the connecting rod bearing
Data:
Measured value: (C) = 70.030 mm
Calculation: D = 69.994 mm
Dimension (a) - dimension (b)
The results of all this are: = 0.036 mm
Technical data
Test data and settings
Table 168
ID no. Designation Additional information Value
P06 43 Small end, inner diameter From assembled 34.010 - 34.028 mm
P06 45 Theoretical free play between 0.010 - 0.031 mm
piston pin and small end
P06 49 Big end, inner diameter 37 (+0.025, 0) mm
P06 51 Connecting rod bearing shell 25.25 - 25.75 mm
above and below, width
P06 52 Big end bearing shells, inner From assembled 67.981 - 68.000 mm
diameter
P06 54 Connecting rod bearing shells, two degrees of undersizing, 0.25 mm
inner diameter each
P06 55 Connecting rod, bearing slot, in- 71.500 - 71.519 mm
ner diameter
P06 56 Theoretical free play between 0.026 - 0.076 mm
big end bearing and main jour-
nal

30-133
 Method of intervention
Tightening torque
Table 169
ID no. Designation Screws type Indications/observa- Value
tions
A06 020 Connecting rod bearing Stage 1: Where certified 20 Nm
cover in correspondence in writing, screws may be
of the connecting rod used up to 3 times. Oth-
drum erwise, replace with new
screws after each remov-
al. OIled screws.
A06 020 Connecting rod bearing Stage 2: 30°
cover in correspondence
of the connecting rod
drum
A06 020 Connecting rod bearing Stage 3: 60°
cover in correspondence
of the connecting rod
drum
Note
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.8.62 - Removing and fitting pistons (L3)

Piston disassembly
1. m 1 – Piston
m 3 - Piston pin
m 2 - Circlip
m 4 - Set of piston rings

Fig. 900
2. m Disassemble the connecting rod drum.
Construction unit
06

m Remove circlip (1).

m Pressure remove the piston pin.
m Remove the connecting rod shank.

Fig. 901

30-134
Method of intervention
3. m Remove circlip (1).
m Visually check the wear of the components.

Fig. 902

Piston assembly
1. m Insert a new circlip.
Note
Check the installation position is correct.

Fig. 903
2. m Insert the connecting rod drum.
WARNING
The ventilation (1) and identification (2) pockets must face
the same direction.

Fig. 904

30-135
 Method of intervention
3. m Lightly oil the piston pin.
m Pressure insert the piston pin.
m Insert a new circlip.
Note
Check the installation position is correct.

m Assemble the connecting rod drum.

Construction unit
06

Fig. 905

30.8.63 - Check the piston (L3)

Readily available commercial tools:
l Palmer
l Internal bore meter
l Feeler gauges
Special tools:
l Dial gauge: 01899126
l Trapezoidal groove wear gauge: 02992166
Note
If the piston wear limit was reached, replace it.

Check piston ring groove

1. m Clean the piston.
m Inspect the piston.
m Visually inspect the piston grooves.
m Measure the race of the first piston ring using a trapezoidal race
wear gauge.

Fig. 906

30-136
Method of intervention
2. m
Note
If there is a distance “S” between the trapezoidal S
race wear gauge and the piston, the piston can still
be used.

Fig. 907
3. m
Note
If the trapezoidal race wear gauge rests on the piston
(arrow) the latter must be replaced.

Fig. 908

Check the endfloat of the piston ring

1. Note
Perform the check with new piston rings. If the piston wear
limit was reached, replace it.

m Check the endfloat between the piston and the groove of the piston
ring using the feeler gauge.
n 2. Piston ring: 0.065 - 0.110 mm

n 3. Piston ring: 0.040 - 0.080 mm

Fig. 909

30-137
 Method of intervention
Check the piston diameter
1. Note
Measurement diagram of the piston diameter in points “1, 2
and 3”, transversal to the piston pin hole.

m n Measurement point 1: 15 mm 3
n Measurement point 2: 50 mm
2
n Measurement point 3: 80.5 mm
1

Fig. 910
2. m Measure the clearance of the piston pin with the palmer.
n Measurement point 1: 97,900 (+ 0.007, − 0.007) mm

n Measurement point 2: 97,970 (+ 0.009, − 0.009) mm

n Measurement point 3: 97.350 (+ 0.010, − 0.010) mm
Note
Measurement points, see diagram.

Fig. 911

Check of the piston pin hole

1. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-
nal bore meter.
n Set the bracket measurement screw to 40 mm.
n Apply the internal bore meter between the test surfaces of
the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 912

30-138
Method of intervention
2. Note
Measurement diagram of the piston pin hole in points “a”
and “b” in surfaces “1” and “2”.

Fig. 913
3. m Insert the internal bore meter in the piston pin hole.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer: 34 (+0.011, 0.005) mm
Note
Measurement points, see diagram.

Fig. 914

Check the diameter of the piston pin

1. m Measure the piston pin with the palmer: 34 (+0, -0.006) mm
m Make a note of the measured value, dimension B.
Note
Dimension B is used to determine the piston pin
clearance.

Fig. 915

Technical data
Test data and settings
Table 170
ID no. Designation Additional information Value
P07 61 Piston pin, external diameter 34 (+ 0, − 0.006) mm
P07 62 Bearing play between piston pin 0.005 - 0.017 mm
and piston
P07 71 Piston, diameter, standard Measuring point 1 = height 15 97,900 (+ 0.007, − 0.007) mm
mm

30-139
 Method of intervention
ID no. Designation Additional information Value
P07 72 Piston, diameter, standard Measuring point 2 = height 50 97,790 (+ 0.009, − 0.009) mm
mm
P07 73 Piston, diameter, standard Measuring point 3 = height 80.5 97.350 (+ 0.010, − 0.010) mm
mm
P07 78 Piston pin, hole 34 (+0.011, + 0.005) mm
P07 88 Piston ring 2, conical section 0.065 - 0.110 mm
ring, endfloat
P07 89 Piston ring 3, oil scraper ring, 0.040 - 0.080 mm
endfloat

30.8.64 - Removing and fitting piston rings (L3)

Special tools:
l Universal pliers for piston rings: 02992155
Removing piston rings
1. m Set the universal pliers for the rings based on the piston diameter.
m Disassemble the piston ring with universal pliers.
WARNING
Do not damage the pistons during disassembly.

Fig. 916
2. 2.1. Piston ring = dual trapezoid section rings
2.2. Piston ring = conical section ring
2.3. Piston ring = oil scraper ring
m Clean the piston.
m Clean the piston ring grooves.

Fig. 917

30-140
Method of intervention
Assembly of the piston ring
1. m Fit the piston rings with the marking “TOP” facing towards the com-
bustion chamber.
Note
Offset the flexible coupling of the oil scraper ring by
180° with respect to the ring coupling.

m Assemble the piston ring with universal pliers.

WARNING
Do not damage the pistons during disassembly.

Fig. 918

30.8.65 - Checking piston rings (L3)

Readily available commercial tools:
l Palmer
l Feeler gauges
Check the coupling clearance of the piston rings
1. m Insert the piston ring (1) in the cylinder.
m Align the rings, pushing the piston into the cylinder.

Fig. 919
2. m Measure the coupling clearance of the piston rings with the feeler
gauge.
n Piston ring: 0.20 - 0.35 mm

n Piston ring: 1.5 - 2.0 mm

n Piston ring: 0.30 - 0.60 mm
Note
The piston ring wear limit was reached, replace it.

Fig. 920

30-141
 Method of intervention
Checking piston ring thickness
1. m Check the thickness of the piston ring with the palmer.
n Piston ring: 2.03 (- 0.005, - 0.030) mm

n Piston ring: 3 (- 0.01, - 0.03) mm

Fig. 921

Technical data
Test data and settings
Table 171
ID no. Designation Additional information Value
P07 81 Piston ring, first ring, double Standard external diameter/in- 98/89.8 x 3 mm
trapezoidal ring ner diameter x height
P07 82 Piston ring, second ring, ta- Standard external diameter/in- 98/89.8 x 2.03 mm
pered ring ner diameter x height
P07 83 Piston ring, third ring, oil scrap- Standard external diameter/in- 98/90.7 x 3 mm
er ring with spiral spring ner diameter x height
P07 84 Piston ring 1, gap free play Indication of TOP in direction of 0.20 - 0.35 mm
the combustion chamber
P07 85 Piston ring 2, gap free play Indication of TOP in direction of 1.5 - 2.0 mm
the combustion chamber
P07 86 Piston ring 3, gap free play Indication of TOP in direction of 0.30 - 0.60 mm
the combustion chamber
P07 91 Piston ring 1, thickness Nominal value 3 mm
P07 92 Piston ring 2, thickness 2.03 (- 0.005, - 0.030) mm
P07 93 Piston ring 3, thickness 3 (- 0.01, - 0.03) mm

30.8.66 - Disassembly and assembly the cylinder head (fastening elements) (L3)
Special tools:
l Torx box spanner insert: E14 01899060
l Rotation angle gauge: 01899093

30-142
Method of intervention
Disassembly of the cylinder head
1. 1.1. Cylinder head seal
1.2. Locating dowel Cylinder head screw

Fig. 922
2. m Disassemble the guide.
n Construction unit: 21

m Remove the injectors.

n Construction unit: 19

m Disassemble the turbocharging air duct.

n Construction unit: 22

m Disassemble the exhaust pipe.

n Construction unit: 41

m Disassemble the coolant pump.

n Construction unit: 37

m Remove the rocker.

m Remove the pushrods.
n Construction unit: 11

m Remove cable tie. Fig. 923

m Unscrew the cylindrical head screws using the Torx E14 box span-
ner insert.
WARNING
Do not place the cylinder head on the sealing surface.

3. m Remove the cylinder head seal (1).

m Remove the tightening bushes (2).

Fig. 924

30-143
 Method of intervention
Assembly of the cylinder head
1. m Clean the mating surfaces.
m Measure the piston protrusion.
n Construction unit: 08

m Insert the tightening bushes (1).

m Apply the cylinder head sealing gasket (2).
Note
The mating surfaces must be clean, dry and free of
grease or other contaminants. The mark IN ALTO /
TOP is facing the direction of the cylinder head.
m Carefully place the cylinder head on the crankcase.

Fig. 925
2. m Tighten the cylinder head screws.
Note
In the case of written certification, the cylinder head
screws can be used a maximum of 3 times.

m Tighten all the cylindrical head screws according to the tightening

sequence.
n Stage 1: 30 Nm

n Stage 2: 30 Nm
n Stage 3: 150°

Fig. 926

30-144
Method of intervention
3. m Insert pushrods.
m Fit the rocker.
Construction unit
11

m Assemble the coolant pump.

Construction unit
37

m Assemble the exhaust pipe.

Construction unit
41

m Assemble the turbocharging air duct.

Construction unit
22

m Assemble the guide.

Construction unit
21

m Fix the cable tie.

4. m Insert pushrods.
m Assemble the distribution valve.
n Construction unit: 11

m Assemble the exhaust pipe.

n Construction unit: 41

m Assemble the turbocharging air duct.

n Construction unit: 22

m Fit the thermostat housing

n Construction unit: 38

m Assemble the guide.

m Fit the fuel lines.
n Construction unit: 21

30-145
 Method of intervention
Technical data
Test data and settings
Table 172
ID no. Designation Screws type Indications/observa- Value
tions
A08 001 Cylinder head in corre- Stage 1: Where certified 30 Nm
spondence of the crank- in writing, the cylindri-
case cal head screws may
be used up to 3 times.
Otherwise, replace with
new screws after each
removal. OIled screws.
Observe the indicated
tightening sequence.
A08 001 Cylinder head in corre- Stage 2: 30 Nm
spondence of the crank-
case
A08 001 Cylinder head in corre- Stage 3: 150°
spondence of the crank-
case
Note
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-146
Method of intervention
30.9 - C0 - Engine accessories
30.9.1 - Intercooler
Preliminary operations
l See para. 30.9.8 - Air filter container - page 30-154
l See para. 30.13.2 - Condenser - page 30-526
l See para. 30.14.8 - Transmission oil radiator - page 30-551
Removal
1. Undo the clamp (1) and disconnect the intercooler inlet hose (2).

Fig. 927
2. Undo the clamp (3) and disconnect the intercooler outlet hose (4).
4

Fig. 928
3. Undo the clamps (5) and disconnect the fuel lines (6).

6
6

5 5

Fig. 929
4. Undo the two screws (7) and remove the intercooler (8) with the fuel radia-
tor (9).
9

7 7

Fig. 930

30-147
 Method of intervention
5. Undo the two screws (10) and remove the fuel radiator (9).

10

10

Fig. 931

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the screws (10) fastening the fuel radiator (9) to a torque of 20 Nm.
Completion
l See para. 30.14.8 - Transmission oil radiator - page 30-551
l See para. 30.13.2 - Condenser - page 30-526
l See para. 30.9.8 - Air filter container - page 30-154

30.9.2 - Catalytic converter

Removal
1. Undo and remove the fastener screw (1), then open the clamp (2) and move it aside.
2. Undo and remove the fastener screw (3), then open and remove the clamp (4).
3. Undo the screws (5) and open the clamps (6).
2
1

4 6

Fig. 932
4. Recover gaskets (7).
5. Remove the catalytic converter (8).
7

Fig. 933

30-148
Method of intervention
Refitting
1. Refit by following the procedure for removal in reverse order.

30.9.3 - Coolant fluid radiator

Preliminary operations
l See para. 30.9.8 - Air filter container - page 30-154
l See para. 30.9.9 - Radiator assembly - page 30-155
Removal
1. Place the radiator assembly on a work bench.
2. Unscrew screws (1)
1

Fig. 934
3. From the opposite side, undo the screws (1) and separate the radiator (2),
1
complete with duct, from the unit consisting of the remaining radiators (con-
denser, transmission oil, fuel and intercooler).
2

Fig. 935
4. Undo the screws (3) and remove the plate (4).
5. Remove the remaining plates with the same procedure.

Fig. 936

30-149
 Method of intervention
6. Remove the expansion plugs (5) and remove the air duct (6).

5 6

Fig. 937
7. Undo the two lateral bolts (7) and remove the upper moulding (8).
8

Fig. 938

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the screws (1) fastening the radiator assembly to the coolant fluid radiator (2) to a torque of 20 Nm.
Completion
l See para. 30.9.9 - Radiator assembly - page 30-155
l See para. 30.9.8 - Air filter container - page 30-154

30.9.4 - Fuel radiator

Removal
1. Undo the clamps (1) and disconnect the fuel lines (2).

Fig. 939

30-150
Method of intervention
2. Undo the screws (3) and remove the fuel radiator (4).

4
3

Fig. 940

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the screws (3) fastening the fuel radiator (4) to a torque of 20 Nm.

30.9.5 - Fuel tank

Preliminary operations
l See para. 30.13.7 - Cab access steps - page 30-531
Removal
1. Drain all the fuel from the tank.
2. From underneath the vehicle, undo the bolt (1) fastening the tank.

Fig. 941
3. Place a trolley under the tank.
4. Undo the lateral tank mounting pin (2).

Fig. 942

30-151
 Method of intervention
5. Undo the screw (3) fastening the front pin and rest the tank (4) on the trol-
ley.

Fig. 943
6. Open the clamp (5) and disconnect the breather pipe (6).

6
5

Fig. 944
7. Lower the trolley to allow access to disconnect the lines.
8. Disconnect the fuel level sensor (7).
9. Open the clamps, disconnect the delivery (8) and return (9) lines, and re-
8 9
move the tank (4). 7

Fig. 945

30-152
Method of intervention
Refitting
1. Carry out the removal operations in reverse order.
2. Tighten the front pin fastener screws to a torque of 8 Nm.
3. Tighten the lower fastener bolt to a torque of 38.6 Nm.
Completion
l See para. 30.13.7 - Cab access steps - page 30-531

30.9.6 - Exhaust pipe

Removal
1. Undo and remove the fastener screw (1), open the clamp (2), move it aside
and retrieve the gasket. 2
1

Fig. 946
2. Undo the two nuts (3) fastening the carrier bracket.

Fig. 947
3. Undo the fastener bolt (4) and remove the exhaust pipe (5).

Fig. 948

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Fit the exhaust pipe in its seat and tighten the bolt (4) to a torque of 20.4 Nm.
3. Tighten the nuts (3) to a torque of 40.4 Nm.

30-153
 Method of intervention
30.9.7 - Viscostatic fan
Removal
1. Fit a wrench (1) with a square socket bit in the seat on the automatic belt tensioner.
2. Apply a wrench (2) to the fan hub to prevent it from turning under wrench (1).
3. Place a 48 mm wrench (3) on the fan fastener nut (4).

3
4

2 3

Fig. 949
4. Turn wrench (3) in the direction indicated by the arrow to undo the fastener
nut, then remove the fan (5).
3
Important
The fastener nut has a left-handed thread.

Fig. 950

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply a drop of Loctite 270 to the thread of the nut (4) fastening the fan, and tighten to a torque of 100 Nm.
Important
The fastener nut has a left-handed thread.

30.9.8 - Air filter container

Removal
1. Loosen the clamp (1) and disconnect air hose (2).
2. Loosen the clamp (3) and disconnect the ejector tube (4).
3. Unscrew the filter clogging sensor (5). 1 2

3
4

Fig. 951

30-154
Method of intervention
4. Undo the two screws (6) and remove the air filter container together with
its mounting bracket.

6 6

Fig. 952

Refitting
1. Carry out the removal operations in reverse order.

30.9.9 - Radiator assembly

Preliminary operations
l See para. 30.9.8 - Air filter container - page 30-154
Removal
1. Undo the clamp (1) and disconnect and remove the air hose (2).

Fig. 953
2. Undo the clamps (3) and disconnect the fuel lines (4).

Fig. 954
3. Undo the clamp (5) and disconnect the line (6) connecting with the expansion tank.

30-155
 Method of intervention
4. Undo the clamp (7) and disconnect the intercooler outlet hose (8).
8 7

6 5

Fig. 955
5. Undo the unions (9) and disconnect the transmission oil delivery and return
lines from the oil radiator.

Fig. 956
6. Loosen the clamp (10) and disconnect the coolant delivery line (11) leading to the radiator.
7. Loosen the clamp (12) and disconnect the coolant return line (13) leading from the radiator.
8. Undo the clamp (14) and disconnect the intercooler inlet hose (15).

10 11
15

14

13

12

Fig. 957
9. Disconnect the A/C system pressure switch connection (16).
10. Undo the screws (17) fastening the inlet and outlet unions (18).
11. Pull out the lines from the upper pipe grommet, and lay on the engine.

16

18

17

17

Fig. 958

30-156
Method of intervention
12. Undo the screws (19) fastening the radiator assembly mounting bracket
(20).

19
20

19

Fig. 959
13. On both sides, undo the lower screws (21) fastening the radiator assembly.

21

Fig. 960
14. Remove the radiator assembly (22) with the dehydrator filter (23), the trans-
22
mission oil lines (24) and the dust ejector pipes (25).
24

23
25

Fig. 961

30-157
 Method of intervention
Refitting
1. Carry out the removal operations in reverse order.
Completion
l See para. 30.9.8 - Air filter container - page 30-154

30.9.10 - Disassembling the radiator assembly

Removal
1. Undo the screws (1) fastening the sliding system and remove the condens-
er (2) with the dehydrator filter (3).

1 1

2 3

Fig. 962
2. If fitted, undo the clamp (4) and remove the dust ejector pipe (5).

Fig. 963
3. Undo the fastener screws (6) and remove the transmission oil radiator (7) with the oil inlet and outlet lines (8).
4. Remove the oil lines if necessary.

6 8

8
6

Fig. 964

30-158
Method of intervention
5. Undo the fastener screws (9) and separate the intercooler (10) and the fuel
radiator (11) from the coolant radiator (12). 9

11

9
12

10

Fig. 965
6. Undo the fastener screws (13) and separate the fuel radiator (11) from the
intercooler (10).
13 11

13

10

Fig. 966
7. Undo the screw (14) and remove the plate (15).
8. Remove the remaining plates with the same procedure.

14

14

15

Fig. 967
9. Remove the expansion plugs (16) and remove the air duct (17).

16 17

Fig. 968

30-159
 Method of intervention
10. Undo the two lateral bolts (18) and remove the upper moulding (19).
19

18

Fig. 969

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Tighten the screws (13) fastening the fuel radiator (11) to the intercooler (10) to a torque of 20 Nm.
3. Tighten the screws (9) fastening the fuel radiator (11) and the intercooler (10) to a torque of 20 Nm.
4. Tighten the screws (6) fastening the transmission oil radiator (7) to a torque of 20 Nm.

30.9.11 - Fuel prefilter

1. DANGER
Never work on the fuel system when the engine is running.
The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several
hundred bar even after the engine has been switched off. In
this case, the fuel pressure can only be reduced by opening
the fuel system to allow fuel to escape.
WARNING
Ensure maximum cleanliness during all work. Before start-
ing with disassembly, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. When handling © 50549-0

Fig. 970
fuel observe the safety directives and specific local regula-
tions. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove plugs
and caps only immediately prior to assembly. Collect operat-
ing materials in suitable containers and dispose of them in
compliance with the applicable regulations.
m 1 - Fuel pre-filter
m 2 - Console
m 3 - Sensor: 1.6 Nm
m 4 – O-ring
NOTE
Use a new O-ring. Bleed the fuel system following
the instructions provided.

n Fuel prefilter
NOTE
User instructions

30-160
Method of intervention
30.9.12 - Fuel filter
1. DANGER
Never work on the fuel system when the engine is running.
The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several
hundred bar even after the engine has been switched off. In
this case, the fuel pressure can only be reduced by opening
the fuel system to allow fuel to escape.
WARNING
Ensure maximum cleanliness during all work. Before start-
ing with disassembly, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. When handling © 50551-0

Fig. 971
fuel observe the safety directives and specific local regula-
tions. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove plugs
and caps only immediately prior to assembly. Collect operat-
ing materials in suitable containers and dispose of them in
compliance with the applicable regulations.
m 1 - Replacement fuel filter
m 2 – Filter head
m 3 - Pressure transducer: 25 Nm
m 4 - Hex screw: 42 Nm
m 5 - O-ring
NOTE
Use a new O-ring.

30-161
 Method of intervention
30.9.13 - Fuel line
1. Special tools:
m Pliers for hose clips: 01899037
m Circlip pliers: 01899112
m Plugs and caps: 01899144
DANGER
Never work on the fuel system when the engine is running.
The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several
hundred bar even after the engine has been switched off. In
this case, the fuel pressure can only be reduced by opening
the fuel system to allow fuel to escape.
WARNING © 50548-0

Fig. 972
Ensure maximum cleanliness during all work. Before start-
ing with disassembly, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. When handling
fuel observe the safety directives and specific local regula-
tions. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove plugs
and caps only immediately prior to assembly. Collect operat-
ing materials in suitable containers and dispose of them in
compliance with the applicable regulations.
m 1 - Flexible pipe
m 2 - Banjo bolt: 20 Nm
m 3 – O-ring
m 4 - Clip
m 5 - Clip
NOTE
Use new seals.

2. WARNING
Make sure the assembly position is correct. Route the flex-
ible pipe without friction or tension points.

m Dimension X: 15 mm (+3 -1 mm)

© 51299-0

Fig. 973

30-162
Method of intervention
30.9.14 - Fuel delivery pump
1. Special tools:
m Plugs and caps: 01899144
DANGER
Never work on the fuel system when the engine is running.
The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several
hundred bar even after the engine has been switched off. In
this case, the fuel pressure can only be reduced by opening
the fuel system to allow fuel to escape.
WARNING
Ensure maximum cleanliness during all work. Before start- © 50547-0

ing with disassembly, remove any paint residue or debris. Fig. 974
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. When handling
fuel observe the safety directives and specific local regula-
tions. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove plugs
and caps only immediately prior to assembly. Collect operat-
ing materials in suitable containers and dispose of them in
compliance with the applicable regulations.
m 1 - Delivery pump
n Fastening screws: 4 x M5-8.8 (7.5 Nm)

30.9.15 - Oil measuring device

1. m 1 - Oil dipstick
m 2 - Ball
m 3 - Closing plug
m 4 - Sleeve
m 5 - O-ring
NOTE
Use a new O-ring.

© 50392-0

Fig. 975

30.9.16 - Removing and fitting fuel line (injector, rail, high pressure pump)
Special tools:
l Circlip pliers: 01899112
l Plugs and caps: 01899144
l Disassembly tool: 02992127
DANGER
Never work on the fuel system when the engine is running. The fuel system is under high pressure - risk of death. The
pressure in the fuel system may still be as high as several hundred bar even after the engine has been switched off.
In this case, the fuel pressure can only be reduced by opening the fuel system to allow fuel to escape.

30-163
 Method of intervention
WARNING
Ensure maximum cleanliness during all work. Before proceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be worked on. Dry any wet areas with an air jet. When handling
fuel observe the safety directives and specific local regulations. All fuel lines and unions should be closed immediately
after opening using new, clean plugs or caps. Remove the plugs and caps only immediately prior to assembly. Collect
operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
Removal of the fuel line
1. m 1 - Return line
m 2 - Hose mount
m 3 - Fuel line
m 4 - Flexible pipe
m 5 - Pipe retaining clip
m 6 - Hex screw
m 7 - Spring clip

© 50550-0

Fig. 976
2. WARNING
Disassembled, missing or bent terminals must be replaced.
The terminal must automatically return to the stop position.
Otherwise, replace the terminal.
m Fit the terminal (1) fully into its seat.
m Remove the return line (2).
2
1

© 51304-0

Fig. 977
3. m Remove seal (1) using the removal tool.

© 51305-0

Fig. 978

30-164
Method of intervention
4. m Remove the return line (1) from the hose mount (2).
m Release and disconnect the connector plug (3).
m Unscrew screws (4)

© 51306-0

Fig. 979
5. m Loosen hose clip (1) with the special pliers.
m Remove the flexible hose (2).
m Remove the return line.
m Carry out a visual inspection of the components.

© 51307-0

Fig. 980

Fitting the fuel line

1. WARNING
Make sure the assembly position is correct.

2
m Install circlip (1) using the circlip pliers. 1
n Dimension X: 4 (+ 2, - 2) mm

m Fit flexible pipe (2).

X

© 51308-0

Fig. 981

30-165
 Method of intervention
2. m Fit the return line.
m Fit the return line (1) in the hose mount (2).
m Locate hose clips (3).
m Tighten screws (4).
m Connect and fasten the connector plug (5).

© 51309-0

Fig. 982
3. WARNING
Disassembled, missing or bent terminals must be replaced.
The terminal must automatically return to the stop position.
Otherwise, replace the terminal.
m Fit the new O-ring (2).
m Arrange the return line (1) at right angles to the injector.
m Fit the return line (1) into the injector by hand.
WARNING 1

Make sure the assembly position is correct. The return line 2

must click audibly when connected.
© 51310-0

Fig. 983
4. m Tighten the screws (1): 30 Nm.

© 51311-0

Fig. 984

30-166
Method of intervention
Technical data
Tightening torque
Table 173
ID no. Designation Screws type Indications/observa- Value
tions
A12 095 Pipe retaining clips, fixing 30 Nm
screw
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.17 - Blower fan

1. m 1 - Blower fan
m 2 - Hex screw 30 Nm

© 51338-0

Fig. 985

30.9.18 - Removal and refitting of the exhaust manifold

Removal of the exhaust manifold
1. m 1 - Exhaust pipe
m 2 - Gasket
m 3 - Hex screw

© 50418-0

Fig. 986

30-167
 Method of intervention
2. m Remove the turbocharger.
Construction unit
43

m Disassemble the cooler.

Construction unit
41

m Remove all the screws (1).

m Remove exhaust manifold (2).
m Remove seal (3). © 50419-0

Fig. 987

Refitting the exhaust manifold

1. m Carry out a visual inspection of the components.
m Clean the mating surfaces.
m Tighten the screws (arrowed).
m Fasten the new gasket (1) with the screws to the exhaust gas pipe.

© 50420-0

Fig. 988
2. m Clean the mating surfaces.
m Fit exhaust pipe (1).
NOTE
Observe the installation position.

m Screw in all the screws (2).

© 50421-0

Fig. 989

30-168
Method of intervention
3. m Tighten the screws in the sequence indicated: 30 Nm.
m Fit the turbocharger.
Construction unit
43

m Fit the cooler.

Construction unit
41

© 50734-0

Fig. 990

Technical data
Tightening torque
Table 174
ID no. Designation Screws type Indications/observa- Value
tions
A41 001 Exhaust pipe connected Observe the indicated 30 Nm
to the cylinder head tightening sequence.
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.19 - Removal and refitting of the exhaust manifold

Removal of the exhaust manifold
1. m 1 - Exhaust pipe
m 2 - Gasket
m 3 - Hex screw

© 50564-0

Fig. 991

30-169
 Method of intervention
2. m Remove the turbocharger.
Construction unit
43

m Disassemble the cooler.

Construction unit
41

m Remove all the screws (1).

m Remove exhaust manifold (2).
m Remove seal (3). © 50730-0

Fig. 992

Refitting the exhaust manifold

1. m Carry out a visual inspection of the components.
m Clean the mating surfaces.
m Tighten the screws (arrowed).
m Fasten the new gasket (1) with the screws to the exhaust gas pipe.

© 50731-0

Fig. 993
2. m Clean the mating surfaces.
m Fit exhaust pipe (1).
NOTE
Observe the installation position.

m Screw in all the screws (2).

© 50732-0

Fig. 994

30-170
Method of intervention
3. m Tighten the screws in the sequence indicated: 30 Nm.
m Fit the turbocharger.
Construction unit
43

m Fit the cooler.

Construction unit
41

© 50733-0

Fig. 995

Technical data
Tightening torque
Table 175
ID no. Designation Screws type Indications/observa- Value
tions
A41 001 Exhaust pipe connected Observe the indicated 30 Nm
to the cylinder head tightening sequence.
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.20 - Removing and fitting the alternator (retainer bracket)

Removal of the alternator
1. m 1 - Retainer clamp
m 2 - Threaded element
m 3 - Hex screw
m 4 - Washer
m 5 - Hex screw
m 6 - Hex screw
m 7 - Spacer bush
m 8 - Hex screw
m 9 - Hexagonal nut

© 50563-0

Fig. 996

30-171
 Method of intervention
2. m Disconnect the leads from the negative terminal of the battery.
m Disassemble the positive cable.
m Unplug cable connector (1).

© 50693-0

Fig. 997
3. m Loosen screw (1).
m Keep the nut (2).
m Unscrew screw (3)
m Loosen screws (4).
m Tilt the alternator (5) in the direction of the arrow.
m Remove the V-belt.

© 50694-0

Fig. 998
4. m Remove screw (1).
m Remove alternator (2)
m Carry out a visual inspection of the components.

© 50695-0

Fig. 999

30-172
Method of intervention
Refitting the alternator
1. m Fit alternator (1).
m Tighten screws (2).
m Fit the screw (3).
m Screw in nut (4);

© 50696-0

Fig. 1000
2. m Fit the V-belt.
m Tension V-belt (1) by screwing in tensioner screw (2).
m Check the V-belt tension.
NOTE
User instructions

© 50697-0

Fig. 1001
3. m Restrain screw (2).
m Tighten the nut (1): 30 Nm.
m Tighten the screw (3): 42 Nm.
m Tighten the screw (4): 30 Nm.

© 50698-0

Fig. 1002

30-173
 Method of intervention
4. m Reconnect wiring connector (1).
m Assemble the positive cable.
m Re-connect the lead to the negative terminal of the battery.

© 50693-0

Fig. 1003

Technical data
Tightening torque
Table 176
ID no. Designation Screws type Indications/observa- Value
tions
A44 012 Alternator on the console 42 Nm
A44 015 Alternator connected to 30 Nm
the hose clip
A44 017 Retainer clamp on gear- 30 Nm
box
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.21 - Removing and fitting the alternator (fastener elements)

Removal of the alternator
1. m 1 - Hex screw
m 2 - Hex screw

© 50660-0

Fig. 1004

30-174
Method of intervention
2. m Remove the V-belt.
NOTE
User instructions

m Disconnect the leads from the negative terminal of the battery.

m Disassemble the positive cable.
m Unlock and detach connectors (1).

© 50699-0

Fig. 1005
3. m Remove screws (1).
m Remove alternator (2)
m Carry out a visual inspection of the components.

© 50700-0

Fig. 1006

Refitting the alternator

1. m Fit alternator (1).
m Tighten the screws (2): 42 Nm.

© 50701-0

Fig. 1007

30-175
 Method of intervention
2. m Fit and secure connector (1).
m Assemble the positive cable.
m Re-connect the lead to the negative terminal of the battery.
m Fit the ribbed V-belt.
NOTE
User instructions

© 50699-0

Fig. 1008

Technical data
Tightening torque
Table 177
ID no. Designation Screws type Indications/observa- Value
tions
A44 012 Alternator on the console 42 Nm
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.22 - Disassembly and assembly of the starter

Disassembly of the starter
1. m 1 - Starter
m 2 - Hex screw

© 50399-0

Fig. 1009

30-176
Method of intervention
2. m Disconnect the leads from the negative terminal of the battery.
m Disassemble the positive cable.
m Unlock and disconnect wiring connectors (1).
m Remove cable tie.

© 50400-0

Fig. 1010
3. m Remove screws (1).
m Remove the starter (2).
m Carry out a visual inspection of the component.

© 50401-0

Fig. 1011

Assembly of the starter

1. m Insert the starter (1).
m Tighten the screws (2): 60 Nm.

© 50402-0

Fig. 1012

30-177
 Method of intervention
2. m Fit and secure connector (1).
m Fix the cable tie.
m Assemble the positive cable.
m Re-connect the lead to the negative terminal of the battery.

© 50400-0

Fig. 1013

Technical data
Tightening torque
Table 178
ID no. Designation Screws type Indications/observa- Value
tions
A44 001 Starter on the connector 60 Nm
box
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.23 - Disassembly and assembly of the starter

Disassembly of the starter
1. m 1 - Starter
m 2 - Hex screw

© 51440-0

Fig. 1014

30-178
Method of intervention
2. m Disconnect the leads from the negative terminal of the battery.
m Disassemble the positive cable.
m Unlock and disconnect the connectors.
m Remove screws (1).
m Remove the starter (2).
m Carry out a visual inspection of the components.

© 51441-0

Fig. 1015

Assembly of the starter

1. m Insert the starter (1).
m Fit the screws (2).
m Tighten the screws (2): 60 Nm.
WARNING
Route the cables without friction or tension points.

m Connect and lock the wiring connector.

m Assemble the positive cable.
m Re-connect the lead to the negative terminal of the battery.

© 51442-0

Fig. 1016

Technical data
Tightening torque
Table 179
ID no. Designation Screws type Indications/observa- Value
tions
A44 001 Starter on the connector 60 Nm
box
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30-179
 Method of intervention
30.9.24 - Alternator
1. m 1 - Alternator
m 2 - Fan
m 3 – Shim
m 4 - Washer
m 5 - Hexagonal nut: 90 Nm
m 6 - Tension adjuster
m 8 - V-belt pulley
m 9 - Ring
m 10 - Ring

© 51394-0

Fig. 1017

30.9.25 - Alternator
1. m 1 - Alternator
m 2 - Tension adjuster
m 3 - Hexagonal nut 90 Nm
m 4 - Washer
m 5 - V-belt pulley

© 51348-0

Fig. 1018

30.9.26 - Camshaft speed sensor

1. WARNING
Ensure maximum cleanliness during all work. Before pro-
ceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. All fuel lines
and unions should be closed immediately after opening us-
ing new, clean plugs or caps. Remove plugs and caps only
immediately prior to assembly.
m 1 - Speed sensor
m 2 - Hex screw 8.5 Nm
m Clean the mating surfaces.
NOTE © 51375-0

Use a new O-ring. Fig. 1019

30-180
Method of intervention
30.9.27 - Removal and refitting of the glowplugs
Readily available commercial tools:
l Crow’s foot wrench, 10 mm
Special tools:
l Handle with preset torque 01899184
l Long insert mount 01899185
Removal of the glowplugs
1. m 1 - Glow plug
m 2 - Connector guide
m 3 - Fastener nut

© 51400-0

Fig. 1020
2. m Disconnect the battery.
m Unscrew nuts (1).
m Remove the connector guide (2).

© 51401-0

Fig. 1021
3. m Remove the glow plugs (1).
m Carry out a visual inspection of the components.

© 51402-0

Fig. 1022

30-181
 Method of intervention
Refitting the glowplugs
1. m Screw in the glow plugs (1).
WARNING
Make sure the assembly position is correct.

m Tighten the glow plugs (1): 13.5 Nm.

© 51402-0

Fig. 1023
2. m Fit the connector guide (1).
m Tighten new nuts (2).
WARNING
Check that the connection is made correctly.

m Tighten the nuts (2): 2.25 Nm.

© 51403-0

Fig. 1024

Technical data
Tightening torque
Table 180
ID no. Designation Screws type Indications/observa- Value
tions
A63 032 Glow plug on cylinder 13.5 Nm
head
A63 033 Connector guide on glow Use a new lock nut. 2.25 Nm
plug
NOTE
When tightening fasteners to the specified torque using a torque wrench, a torque dispersion of +/- 10 % is permitted.

30.9.28 - Pressure transducer (L3)

Technical data
1. Readily available commercial tools:
m Multimeter
m Measurement prods

30-182
Method of intervention
2. Measurement size: Pressure
Medium: Fluid

Fig. 1025

Wiring diagram
1. Power supply voltage (UDC): 5 (± 5%) V
Signal (UDC): 0.5 - 4.5 V
Measurement interval: 0 - 700 kPa
Table 181

Diagnostics V (+) 1

Overpressure Signal (UDC) ≤ 4.75 (S) 2

3
Negative pressure Signal (UDC) ≥ 0.25
(-) 4
Ground Signal (UDC) ≥ 4.8

Fig. 1026

Connector configuration
1. Table 182

Pin / socket 4 1
(-) (+)
1 Supply voltage
2 Signal
3 not used
4 Ground

(S) 3
2

Fig. 1027

30.9.29 - Pressure sensor (L3)

30-183
 Method of intervention
Technical data
1. Readily available commercial tools:
m Multimeter
m Measurement prods

2. Measurement size: Pressure/Temperature

Medium: Air
Type: NTC

1 2 3 4
Fig. 1028

Wiring diagram
1. Temperature sender (S1)
Power supply voltage (UDC): 5 (± 5%) V
Signal (UDC): 0.5 - 4.5 V
Measurement interval: -40 - 130 °C (-) 1

Pressure transducer (S2) (S1) 2

Power supply voltage (UDC): 5 (± 5%) V

(+) 3
Measurement range 50 - 400 kPa
(S2) 4

Fig. 1029

Connector configuration
1. Table 183

4 3 2 1
Pin / socket (S1) (-)
(S2) (+)
1 Ground
2 Signal
3 Supply voltage
4 Signal

DANGER
Hot components! Burn hazard!

Fig. 1030

30-184
Method of intervention
2. m Measurement
n Temperature sender

Table 184

Temperature Pin / socket Pin / socket Nominal

°C kΩ
-40 1 2 48,150 (± 5%)
-20 1 2 15,610 (± 5%)
0 1 2 5,880 (± 5%)
20 1 2 2,510 (± 5%)
50 1 2 0.850 (± 5%)
100 1 2 0.186 (± 5%)
Measurement
l With ambient pressure of 100 kPa
l Pressure transducer
Table 185
Pressure Pin / socket Pin / socket Nominal
kPa kΩ
100 3 4 5.1 (± 8%)

30.9.30 - Speed indicator (L3)

Technical data
1. Readily available commercial tools:
m Multimeter
m Measurement prods

2. Measurement size: Speed

passive: without power supply

Fig. 1031

30-185
 Method of intervention
Wiring diagram
1. Signal (UDC): 1.65 V

(S1) 1

(S2) 2

Fig. 1032

Connector configuration
1. Table 186
1 2
Pin / socket (S1) (S2)
1 Signal
2 Signal

m Measurement
n Speed indicator

Table 187

Condition Pin / socket Pin / socket Nominal

°C Ω
20 1 2 880 (±10%) Fig. 1033

DANGER
Beware of rotating parts! Risk of injury!

m Measurement
n Speed indicator

Table 188

Condition Pin / socket Pin / socket Nominal Polarity

V
The crank- 1 2 1.65 +
shaft turns
with a num-
ber of starter
revolutions

30-186
Method of intervention
30.10 - D0 - Transmission
30.10.1 - Engine torsional spring plate (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.8.1 - Separating engine from... - page 30-30
Pedal Release
1. Separate the engine from the transmission
2. Undo the screws (1) and remove the engine torsional spring plate (2).
1

Fig. 1034

Refitting
1. Fit the torsional spring plate in its seat and tighten the fastener screws to a torque of 57 Nm ± 0.5 Nm.
Completion
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.10.2 - Shuttle unit - Complete assembly (5100 C -> ZKDY480200TD10001)

Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.8.1 - Separating engine from... - page 30-30
Pedal Release
1. Important
Drain all the oil from the transmission.

2. Remove all the screws (1) and the two grub screws (2). 1

2
2

Fig. 1035

30-187
 Method of intervention
3. Fit and tighten two service screws (A), and start pulling out the shuttle unit
(3).

Fig. 1036
4. Using the tool (B), connect the shuttle unit (3) to a hoist and remove.
B

Fig. 1037
5. Remove the hydraulic oil passage union tubes (4) and remove the O-rings
(5).

Fig. 1038

30-188
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply a bead of Loctite 510 sealant around all the holes (6) on the cover
before fitting the gearbox shuttle unit.
6

Fig. 1039
3. Tighten the screws (1) fastening the hydraulic reverse shuttle unit to a torque of 40.4 Nm.
4. Apply a drop of Loctite 243 sealant to the grub screws (2), and screw into
the centre of their seats without tightening. 1
2

Fig. 1040

Completion
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.10.3 - Shuttle unit - Complete assembly (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.8.1 - Separating engine from... - page 30-30
Pedal Release
1. Important
Drain all the oil from the transmission.

30-189
 Method of intervention
2. Remove all the screws (1) and the two grub screws (2). 1

2
2

Fig. 1041
3. Fit and tighten two service screws (A), and start pulling out the shuttle unit
(3).

Fig. 1042
4. Using the tool (B), connect the shuttle unit (3) to a hoist and remove.
B

Fig. 1043
5. Remove the hydraulic oil passage union tubes (4) and remove the O-rings
(5).

Fig. 1044

30-190
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply a bead of Loctite 510 sealant around all the holes (6) on the cover
before fitting the gearbox shuttle unit. 6

Fig. 1045
3. Tighten the screws (1) fastening the hydraulic reverse shuttle unit to a torque of 40.4 Nm.
4. Apply a drop of Loctite 243 sealant to the grub screws (2), and screw into
the centre of their seats without tightening. 1
2

Fig. 1046

Completion
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.10.4 - Disassembling the shuttle unit (5100 C -> ZKDY480200TD10001)

Removal
1. Place the shuttle unit (1) on a suitable support and undo the screws (2)
(q.ty 7).

2
1

Fig. 1047

30-191
 Method of intervention
2. Remove cover (3).
Important
Mark the cover (3) and the casing to facilitate subsequent
reassembly.
3

Fig. 1048
3. Undo the screws (4) (q.ty 10).

Fig. 1049
4. Remove the forward drive clutch unit (5).

Fig. 1050
5. Retrieve the springs (6) and the relative pins.
6. Remove the needle roller thrust bearing (7).
7. Remove the O-rings (8).
6
Important
Fit new O-rings after each removal. 8

Fig. 1051

30-192
Method of intervention
Installation
1. Fit the new O-rings (8), lubricating with grease.
2. Ensure that the final friction disc (9) engages correctly with the hub.
3. Fit the needle roller thrust bearing (7) on the hub, lubricating with grease.
4. Fit the springs (6) and the relative pins in the clutch unit. 6

Fig. 1052
5. Fit the clutch unit (5), aligning the springs in the holes and aligning the cen-
tring pin with the relative hole in the clutch housing.

Fig. 1053
6. Apply a drop of Loctite 242 to the threads and tighten the screws (4) fasten-
ing the forward drive clutch to a torque of 20 Nm.
Important
Tighten the screws in alternating order in a cross pattern.

Fig. 1054
7. Fit the cover (3), aligning the markings made during removal.
Important
Lubricate the lip of the seal ring with hydraulic oil.

Fig. 1055

30-193
 Method of intervention
8. Apply a drop of Loctite 242 to the threads and tighten the screws (2) fasten-
ing the cover to a torque of 40 Nm.

2
1

Fig. 1056

30.10.5 - Disassembling the shuttle unit (5110 C -> ZKDY520200TD10001, 5120 C -> ZK-
DY560200TD10001)
Removal
1. Place the shuttle unit (1) on a suitable support and undo the screws (2)
(q.ty 7).
1

Fig. 1057
2. Remove cover (3).
Important
Mark the cover (3) and the casing to facilitate subsequent
reassembly.
3

Fig. 1058
3. Undo the screws (4) (q.ty 10).

Fig. 1059

30-194
Method of intervention
4. Remove the forward drive clutch unit (5).

Fig. 1060
5. Retrieve the springs (6) and the relative pins.
6. Remove the needle roller thrust bearing (7).
7. Remove the O-rings (8).
6
Important
Fit new O-rings after each removal. 8

Fig. 1061

Installation
1. Fit the new O-rings (8), lubricating with grease.
2. Ensure that the final friction disc (9) engages correctly with the hub.
3. Fit the needle roller thrust bearing (7) on the hub, lubricating with grease.
4. Fit the springs (6) and the relative pins in the clutch unit.
6

Fig. 1062
5. Fit the clutch unit (5), aligning the springs in the holes and aligning the cen-
tring pin with the relative hole in the clutch housing.

Fig. 1063

30-195
 Method of intervention
6. Apply a drop of Loctite 242 to the threads and tighten the screws (4) fasten-
ing the forward drive clutch to a torque of 20 Nm.
Important
Tighten the screws in alternating order in a cross pattern.

Fig. 1064
7. Fit the cover (3), aligning the markings made during removal.
Important
Lubricate the lip of the seal ring with hydraulic oil.

Fig. 1065
8. Apply a drop of Loctite 242 to the threads and tighten the screws (2) fasten-
ing the cover to a torque of 40 Nm.
1

Fig. 1066

30-196
Method of intervention
30.10.6 - Disassembling cover assembly (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. Remove the seal rings (1) and the outer O-ring (2).
2

Fig. 1067
2. Remove the circlip (3) and remove the gasket (4).
3
Important
4
Always replace the seal ring with a new component after
removing.

Fig. 1068
3. Remove the circlip (5), then remove the roller bearing cage (6) with a suit-
5
able presser or extractor tool.
6

Fig. 1069

Installation
1. Reassemble following the procedure for disassembly in reverse order, noting the following additional instructions:
2. Ensure that the seal ring (4) is installed the right way round.
3. Lubricate the seal rings (1) before refitting.

Fig. 1070

30-197
 Method of intervention
30.10.7 - Removing the forward drive clutch unit (5100 C -> ZKDY480200TD10001)
Forward drive clutch unit section

7 6 1

14

5
13

11

12

10

Fig. 1071

30-198
Method of intervention
Removal
1. Remove the 2 screws (1) and remove the plate (2).
1
2
Important
Mark the installation hole for the pin (3).

Fig. 1072
2. Remove the complete clutch pack, consisting of 4 corrugated springs (4), 4
friction discs (5), 3 steel discs (6) measuring 3 mm in thickness and 1 steel 4
5
disc (7) measuring 6.5 mm in thickness.
6
Important
Ensure that the friction discs and steel discs are kept in the
correct order during removal.
7

Fig. 1073
3. Remove the hub (8) and retrieve the Belleville washer (9).

Fig. 1074
4. Turn the hub (8) over and remove the bearing (10) with a suitable extractor.

10

Fig. 1075
5. Tighten two screws in the relative holes (see arrow) and extract the piston (11).

30-199
 Method of intervention
6. Check the condition of O-rings (12 and 13), and replace if necessary.
11

12

13

Fig. 1076

Installation
1. Fit the O-rings (12 and 13) in the clutch housing, lubricating the rings beforehand with hydraulic oil.
Important
To facilitate installation of O-ring (13), stretch it slightly at several points around their circumference so that the
entire circumference is held in place in the respective seat.

2. Fit the piston (11) in the clutch housing, ensuring that it is installed fully in
its seat. 11

12

13

Fig. 1077
3. Install the bearing (10) in the hub (8) with a suitable presser tool.

10

Fig. 1078
4. Fit the Belleville washer (9) in the clutch housing (14).
Important
Ensure that the Belleville washer (9) is oriented correctly.

30-200
Method of intervention
5. Mount the hub (8) and ensure that the bearing (10) is fully installed onto the
Belleville washer (9).

10 9
8 9

Fig. 1079
6. Fit the first steel disc (7), the friction disc (5) and the corrugated spring (4), lubricating beforehand with hydraulic oil.
Important
The steel disc (7) is the disc measuring 6.5 mm in thickness.

7. Complete assembly of the clutch pack, installing the discs in the following
sequence: one steel disc (6), one friction disc (5) and one corrugated spring 4
5
(4).
6

Fig. 1080
8. Fit the disc (2) and tighten the fastener screws (1) to a torque of 20.4 Nm.
1
2
Important
Position the plate correctly so that the pin (3) installs in the
hole marked during disassembly.

Fig. 1081

30-201
 Method of intervention
30.10.8 - Removing the forward drive clutch unit (5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001)
Forward drive clutch unit section

2
7 6
1

14 4

13
5

11

8
12

10

Fig. 1082

30-202
Method of intervention
Removal
1. Remove the 2 screws (1) and remove the plate (2).
2
Important
1
Mark the installation hole for the pin (3).

Fig. 1083
2. Remove the complete clutch pack, consisting of 6 corrugated springs (4), 6
friction discs (5), 5 steel discs (6) measuring 3 mm in thickness and 1 steel
4
disc (7) measuring 6.5 mm in thickness.
5
Important 6
Ensure that the friction discs and steel discs are kept in the
correct order during removal.
7

Fig. 1084
3. Remove the hub (8) and retrieve the Belleville washer (9).

Fig. 1085
4. Turn the hub (8) over and remove the bearing (10) with a suitable extractor.

10

Fig. 1086
5. Tighten two screws in the relative holes (see arrow) and extract the piston (11).

30-203
 Method of intervention
6. Check the condition of O-rings (12 and 13), and replace if necessary.
11

12

13

Fig. 1087

Installation
1. Fit the O-rings (12 and 13) in the clutch housing, lubricating the rings beforehand with hydraulic oil.
Important
To facilitate installation of O-ring (13), stretch it slightly at several points around their circumference so that the
entire circumference is held in place in the respective seat.

2. Fit the piston (11) in the clutch housing, ensuring that it is installed fully in
11
its seat.

12 13

Fig. 1088
3. Install the bearing (10) in the hub (8) with a suitable presser tool.

10

Fig. 1089
4. Fit the Belleville washer (9) in the clutch housing (14).
Important
Ensure that the Belleville washer (9) is oriented correctly.

30-204
Method of intervention
5. Mount the hub (8) and ensure that the bearing (10) is fully installed onto the
Belleville washer (9).
8
10 9

14

Fig. 1090
6. Fit the first steel disc (7), the friction disc (5) and the corrugated spring (4), lubricating beforehand with hydraulic oil.
Important
The steel disc (7) is the disc measuring 6.5 mm in thickness.

7. Complete assembly of the clutch pack, installing the discs in the following
sequence: one steel disc (6), one friction disc (5) and one corrugated spring
4
(4).
5

Fig. 1091
8. Fit the disc (2) and tighten the fastener screws (1) to a torque of 20.4 Nm.
2
Important
1
Position the plate correctly so that the pin (3) installs in the
hole marked during disassembly.

Fig. 1092

30-205
 Method of intervention
30.10.9 - Disassembling the reverse drive clutch unit (5100 C -> ZKDY480200TD10001)
Reverse drive clutch unit section

3
4

10

5
8

6 7

13

15
16
12

11

2 14

Fig. 1093

30-206
Method of intervention
Removal
1. Remove the complete clutch pack, consisting of 4 corrugated springs (1), 4 friction discs (2), 3 steel discs (3) measuring 3 mm
in thickness and 1 steel disc (4) measuring 6.5 mm in thickness.
2. Important 1
Ensure that the friction discs and steel discs are kept in the 2
correct order during removal. 3

Fig. 1094
3. Remove the hub (5)

Fig. 1095
4. Only if necessary, remove the bearing (6) from the hub (5) with an extractor.

Fig. 1096
5. Blow compressed air at low pressure through the hole (A) in the mount (7)
to expel the piston (8).
A
DANGER
Restrain piston (8) as it could be expelled at high speed and
be damaged. 7

Fig. 1097

30-207
 Method of intervention
6. Check the condition of the O-rings (10 and 9), and replace if necessary.

10 9

Fig. 1098
7. Remove the circlips (11 and 12).
8. Remove the circlip (13). 13

11

12

Fig. 1099
9. Remove the clutch housing (14) from the support (7).

14

Fig. 1100
10. Remove the bearing (15) from the clutch housing (14) using a soft mallet.

14

15

Fig. 1101

30-208
Method of intervention
11. Remove the seal rings (16) from the mount (7).
16

Fig. 1102

Installation
1. Fit the seal rings (16) on the mount (7), lubricating beforehand with hydrau-
lic oil. 16

Fig. 1103
2. Fit the bearing (15) on the clutch housing (14).
15

14

Fig. 1104
3. Fit the clutch housing (14) on the support (7).

14

Fig. 1105

30-209
 Method of intervention
4. Fit the circlip (13) and the circlips (12 and 11). 13

11

12

Fig. 1106
5. Fit the O-rings (9 and 10) in the clutch housing (14), lubricating the rings beforehand with hydraulic oil.
6. Important
To facilitate installation of O-ring (10), stretch it slightly at several points around their circumference so that the
entire circumference is held in place in the respective seat.

7. Fit the piston (8) in the clutch housing, ensuring that it is installed fully in
its seat.
8

10

Fig. 1107
8. Install the bearing (6) on the hub (5) with the press.

Fig. 1108
9. Fit the hub (5) on the clutch housing.

Fig. 1109
10. Fit the first steel disc (4), the friction disc (2) and the corrugated spring (1).
11. Complete assembly of the clutch pack, installing the discs in the following sequence: one steel disc (3), one friction disc (2)
and one corrugated spring (1).

30-210
Method of intervention
12. Important 1
Lubricate the friction discs with hydraulic oil. 2
3

Fig. 1110

30.10.10 - Disassembling the reverse drive clutch unit (5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
Reverse drive clutch unit section

30-211
 Method of intervention

3 3
4

10

5
9

6 7

15 16

13

11

12 14

Fig. 1111

Removal
1. Remove the complete clutch pack, consisting of 6 corrugated springs (1), 6 friction discs (2), 5 steel discs (3) measuring 3 mm
in thickness and 1 steel disc (4) measuring 6.5 mm in thickness.

30-212
Method of intervention
2. Important
1
Ensure that the friction discs and steel discs are kept in the 2
correct order during removal. 3

Fig. 1112
3. Remove the hub (5)

Fig. 1113
4. Only if necessary, remove the bearing (6) from the hub (5) with an extractor.

Fig. 1114
5. Blow compressed air at low pressure through the hole (A) in the mount (7)
to expel the piston (8).
A
DANGER
Restrain piston (8) as it could be expelled at high speed and
be damaged. 7

Fig. 1115

30-213
 Method of intervention
6. Check the condition of the O-rings (10 and 9), and replace if necessary.
9
10

Fig. 1116
7. Remove the circlips (11 and 12).
8. Remove the circlip (13).
13

11

12

Fig. 1117
9. Remove the clutch housing (14) from the support (7).

14

Fig. 1118
10. Remove the bearing (15) from the clutch housing (14) using a soft mallet.

14

15

Fig. 1119

30-214
Method of intervention
11. Remove the seal rings (16) from the mount (7).
16

Fig. 1120

Installation
1. Fit the seal rings (16) on the mount (7), lubricating beforehand with hydrau-
lic oil. 16

Fig. 1121
2. Fit the bearing (15) on the clutch housing (14).
15

14

Fig. 1122
3. Fit the clutch housing (14) on the support (7).

14

Fig. 1123

30-215
 Method of intervention
4. Fit the circlip (13) and the circlips (12 and 11).
13

11

12

Fig. 1124
5. Fit the O-rings (9 and 10) in the clutch housing (14), lubricating the rings beforehand with hydraulic oil.
6. Important
To facilitate installation of O-ring (10), stretch it slightly at several points around their circumference so that the
entire circumference is held in place in the respective seat.

7. Fit the piston (8) in the clutch housing, ensuring that it is installed fully in
its seat. 8

10

Fig. 1125
8. Install the bearing (6) on the hub (5) with the press.

Fig. 1126
9. Fit the hub (5) on the clutch housing.

Fig. 1127
10. Fit the first steel disc (4), the friction disc (2) and the corrugated spring (1).
11. Complete assembly of the clutch pack, installing the discs in the following sequence: one steel disc (3), one friction disc (2)
and one corrugated spring (1).

30-216
Method of intervention
12. Important
1
Lubricate the friction discs with hydraulic oil. 2
3

Fig. 1128

30.10.11 - Input shaft assembly and tone wheel (5100 C -> ZKDY480200TD10001)
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.10.2 - Shuttle unit - Complet... - page 30-187
Removal
1. Detach the retainer ring (1).

Fig. 1129
2. Remove the reverse drive input shaft (2), the forward drive input shaft (3) and the PTO shaft (4).
3. Remove the tone wheel (5) with its bearing, and retrieve the O-ring (6).

5 2

Fig. 1130

30-217
 Method of intervention
4. Remove the retainer ring (7) and remove the bearing (8) from the tone 5
wheel (5). 8

Fig. 1131
5. Remove oil seal (9).

Fig. 1132

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Fit the oil seal (9), ensuring that it is installed the right way around and
pushing completely into its seat.

Fig. 1133

Completion
l See para. 30.10.2 - Shuttle unit - Complet... - page 30-187
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.10.12 - Input shaft assembly and tone wheel (5110 C -> ZKDY520200TD10001, 5120 C
-> ZKDY560200TD10001)
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.10.3 - Shuttle unit - Complet... - page 30-189

30-218
Method of intervention
Pedal Release
1. Detach the retainer ring (1).

Fig. 1134
2. Remove the reverse drive input shaft (2), the forward drive input shaft (3) and the PTO shaft (4).
3. Remove the tone wheel (5) with its bearing, and retrieve the O-ring (6).

5 2

Fig. 1135
4. Remove the retainer ring (7) and remove the bearing (8) from the tone 5
wheel (5). 8

Fig. 1136
5. Remove oil seal (9).

Fig. 1137

30-219
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Fit the oil seal (9), ensuring that it is installed the right way around and
pushing completely into its seat.

Fig. 1138

Completion
l See para. 30.10.3 - Shuttle unit - Complet... - page 30-189
l See para. 30.8.1 - Separating engine from... - page 30-30
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.10.13 - DT shaft in transmission

Removal
1. Remove the retainer ring (1).
2. Remove the oil seal (2).
3. Remove the bush (3).
4. Remove the DT shaft (4) complete with bearing (5).

1
2
3
4

Fig. 1139
5. Remove the retainer rings (6) on the two sides of the bearing.

6
6

Fig. 1140

30-220
Method of intervention
6. Use the press to remove the bearing (5) from the DT shaft (4).

Fig. 1141
7. Remove the O-ring (7) and the retainer ring (8).
7
8

Fig. 1142

Refitting
1. Follow the procedure for removal in reverse order.

30.10.14 - Clutch housing - Separation from transmission

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
Separation
1. Disconnect the unions and/or remove any lines of the hydraulic system interfering with the following operations.
2. Undo the lower screws (1) (q.ty 4).

1
Fig. 1143

30-221
 Method of intervention
3. Place a trolley jack (A) under the clutch housing and a place a stand (B)
under the transmission.
Force a stand (C) under the tow hook to prevent the transmission from
toppling over.

C
B
A

Fig. 1144
4. For versions with HI-LO only: undo the union (2) and disconnect the line (3).
5. Undo the screws (4) and remove the cover (5).

5
4

Fig. 1145
6. Unscrew nut (6).

Fig. 1146
7. Undo the remaining screws (7) fastening the clutch housing to the transmis-
sion.

Fig. 1147

30-222
Method of intervention
8. Push both front wheels forward to separate the clutch (8) housing from the 9
transmission (9). 8

Fig. 1148

Connection
1. To connect the clutch housing, follow the procedure for separation in reverse order, noting the following additional instructions
for the steps indicated:
2. Tighten the screws (7) fastening the clutch housing to a torque of 67 Nm.
3. Tighten the nut (6) fastening the clutch housing to a torque of 73 Nm.
4. For versions with HI-LO only: fit a new O-ring (10) on the inner union of the
cover (5).
6

10
5

Fig. 1149
5. Tighten the screws (4) fastening the cover (5) to a torque of 8 Nm.
6. For versions with HI-LO only: connect the line (3) and tighten the union (2)
to a torque of 40 Nm.
5
4

Fig. 1150

Completion
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30-223
 Method of intervention
30.10.15 - Range selector assembly
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
Removal
1. Disconnect the unions and/or remove any lines of the hydraulic system interfering with the following operations.
2. Replace the screw (1) and disconnect the range actuator lever (2).

2 1

Fig. 1151
3. Detach the spring (3) and remove.
4. Undo the screws (4) and remove the complete range gear selector as-
sembly (5).
3

Fig. 1152

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply a thin layer of Silastic on the mating surface and around the holes for
the fastener screws.

Fig. 1153
3. Tighten the pair of screws (4) fastening the gear selector unit to a torque of 20.4 Nm.
Completion
l See para. 30.18.1 - Rear wheels - page 30-602

30-224
Method of intervention
30.10.16 - Disassembling the range selector assembly
Removal
1. Remove the springs (1) and the pins (2).

1
Fig. 1154
2. Undo the screw (3) and remove the hub (4).
3. Undo the pin (5) and remove the lever (6).
5
6

Fig. 1155
4. Undo the screws (7) and remove the mount (8).
8

Fig. 1156
5. Undo the screws (9) and remove the plate (10).

10

Fig. 1157

30-225
 Method of intervention
6. Unscrew screw (11).

11

Fig. 1158
7. Remove the rod (12) and remove the fork (13).

12

13

Fig. 1159
8. Remove the rod (14).

14

Fig. 1160
9. Remove the O-rings (15) from the lever mount (8).
8

15

Fig. 1161

30-226
Method of intervention
Installation
1. Reassemble by following the procedure for removal in reverse order and noting the following additional instructions for the
steps indicated:
Tighten the screws (11) to a torque of 20.4 Nm.
Apply a bead of Silastic on the mating surface of the mount (8).

30.10.17 - Gearbox internal cover

Removal
1. Remove the unions (1 and 2) and then the pipe (3).
Note
Replace the copper gaskets when remounting.

1 3

Fig. 1162
2. Remove the screws (4) and then the cover (5).

Fig. 1163
3. Remove the circlip (6).

Fig. 1164
4. Remove the screws (7) and then the cover (8).

7
8

Fig. 1165

30-227
 Method of intervention
5. Remove the special seal ring (9) from the cover (8).
9

Fig. 1166

Refitting
Refit by following the procedure for removal in reverse order, noting the following additional steps and instructions:
l Mount the new seal ring by the new tool (A) which allows an easier and
appropriate insertion of the seal by press.
CODE TITLE TEXT IMAGE
5.9035.620.0 Presser tool for Tool for installing the special
10
A

seal ring input shaft seal ring on the

gearbox cover (version with B

Hi-Lo).
Fig. 1167
It consists of two parts: pressor
tool (A) and support (B).
A

CAUTION
Place the seal ring (10) on the tool (A) taking care to place the seal- Fig. 1168
ing lip with its spring turned upwards.

l Insert the tool (B) under the cover (8).

8

Fig. 1169

l Insert the seal ring (10) in the cover (8) by using a soft mallet.
Note 8

Place the two parts of the tool (A and B) as shown in the picture.

10

Fig. 1170

30-228
Method of intervention
l Complete the seal ring installation using a press. The tool is made with an
end stroke that stops the seal to be pressed at about 1 mm from the seat
bottom, to prevent the deformation of the seal body.
Note
Keep the two parts of the tool (A and B) as shown in the picture.

Fig. 1171

l Reassembly all parts following the removal procedure in reverse order and lubricate the new seal ring, not with grease but
transmission oil.
CAUTION
Beware when reassembling the clutch housing to the rear housing that they mate absolutely freely. There has to be
absolutely no interference with the Hi-Lo body which otherwise could possibly cause a misalignment of the input shaft.
Make sure to insert the input and PTO shaft together into the clutch housing and take care to place a lamp inside the
clutch housing to have a good visibility to center the seal ring.

30.10.18 - HI-LO unit (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
Removal
1. Note
Drain all the oil from the transmission.

2. Remove the plug (1).

Fig. 1172

30-229
 Method of intervention
3. Undo the unions (2) and (3), and remove the line (4).
Important
Renew the copper washers on reassembly.

2 4

Fig. 1173
4. Undo the screws (5) and remove the cover (6).

Fig. 1174
5. Remove the circlip (7).

Fig. 1175
6. Undo the screws (8) and remove the cover (9).

8
9

Fig. 1176

30-230
Method of intervention
7. Undo the screws (10) (q.ty 6) and remove the complete HI range clutch
housing (11).
10

11

Fig. 1177
8. Remove the spacer (12) and the first steel disc (13).
Important 13

Note the thickness of the steel disc (5 mm). 12

Fig. 1178
9. Remove the LO range clutch disc pack, consisting of 3 friction discs (14)
and 3 steel discs (15). 15

14

Fig. 1179
10. Remove the circlip (16) and retrieve the shims (17).

16

17

Fig. 1180

30-231
 Method of intervention
11. Remove the hub (18) and the planetary gear carrier (19).
19

18

Fig. 1181
12. Undo the screws (20) and the nuts (21).

20

21

Fig. 1182
13. Remove the HI-LO unit casing (22) and remove the gasket (23).
23
Important
Replace the gasket (23) with a new component after each 22
removal.

Fig. 1183

30-232
Method of intervention
Refitting
1. Refit the HI-LO unit following the procedure for removal in reverse order, noting the following additional instructions for the
steps indicated:
2. Tighten the screws (20) and the nuts (21) fastening the HI-LO unit casing to
a torque of 40.4 Nm and 42.7 Nm respectively.

20

21

Fig. 1184
3. Important
If the HI-LO unit was removed in order to service the clutches or the piston, refit by following the procedure for
removal in reverse order. In all other cases, adjust the endfloat of the planet gear units of the planetary reduc-
tion unit (for details, see “Adjusting endfloat of planetary reduction unit gears”).
4. Fit the planetary gear carrier (19) with the planet gear units aligned cor-
rectly with sun gear S1 on the secondary shaft, with the notches (arrows) 19

on one tooth of each of the planet gear units all converging towards the
centre when the planetary gear carrier is in place.

S1

Fig. 1185
5. Then fit the planetary gear carrier (19) on the secondary shaft.
6. Fit the hub (18)
19

18

Fig. 1186
7. Fit a steel disc (15) and a friction disc (14) and repeat to complete the LO
range clutch pack. 15

14

Fig. 1187

30-233
 Method of intervention
8. Fit the first steel disc (13) (5.0 mm in thickness) and the spacer (12).
13

12

Fig. 1188
9. Fit the HI range clutch housing (11) and tighten the fastener screws (10) to
a torque of 20.4 Nm.
10

11

Fig. 1189
10. Apply a bead of Loctite 518 to the mating surface of the cover (9).
Tighten the screws (8) fastening the cover to a torque of 20.4 Nm.

8
9

Fig. 1190
11. Temporarily fit the cover (6) and hold in position with the screws (5).
12. Insert a service screw (24) (M12x45) into the threaded hole of the shaft (25)
on the HI range clutch housing and tighten the screw to pull the HI range 6
clutch housing and allow access to the circlip seat.

24

25

Fig. 1191

30-234
Method of intervention
13. Remove the cover and fit the circlip (7).

Fig. 1192
14. Apply a bead of Loctite 518 to the mating surface of the cover (6).
15. Tighten the screws (5) fastening the cover (6) to a torque of 20.4 Nm.

Fig. 1193

Completion
See para. 30.10.14 - Clutch housing - Separ... - page 30-221
See para. 30.13.1 - Cab - page 30-520
See para. 30.9.6 - Exhaust pipe - page 30-153
See para. 30.9.5 - Fuel tank - page 30-151
See para. 30.13.7 - Cab access steps - page 30-531
See para. 30.12.4 - 4WD shaft () - page 30-513
See para. 30.18.1 - Rear wheels - page 30-602
Adjusting endfloat of planetary reduction unit gears
1. Fit the hub (18) on the HI-LO unit output shaft (26) and fasten in position
with the circlip (16).
18

16

26

Fig. 1194

30-235
 Method of intervention
2. Using a feeler gauge (27), check the endfloat “R” between the hub (18) and
28
planet gear S1 (28).

27

18

Fig. 1195
3. The thickness S of the shims (17) which must be installed between the hub (18) and the circlip (16) is the difference between
the endfloat measured R and the desired endfloat value F of 0.4 ±0.2 mm.
For example, if the endfloat measured R is 1.30 mm, the thickness S of the shim pack necessary is:
S = R - F = 1.30 - 0.40 = 0.90 mm.

30.10.19 - HI-LO unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001,

5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
Pedal Release
1. Note
Drain all the oil from the transmission.

2. Remove the plug (1).

Fig. 1196
3. Undo the unions (2) and (3), and remove the line (4).
Important
Renew the copper washers on reassembly.

2 4

Fig. 1197

30-236
Method of intervention
4. Undo the screws (5) and remove the cover (6).

Fig. 1198
5. Remove the circlip (7).

Fig. 1199
6. Undo the screws (8) and remove the cover (9).

8
9

Fig. 1200
7. Undo the screws (10) (q.ty 6) and remove the complete LO range clutch
housing (11).
10

11

Fig. 1201

30-237
 Method of intervention
8. Remove the spacer (12) and the first steel disc (13).
Important 13

Note the thickness of the steel disc (5 mm). 12

Fig. 1202
9. Remove the HI range clutch disc pack, consisting of 3 friction discs (14)
and 3 steel discs (15). 15

14

Fig. 1203
10. Remove the circlip (16) and retrieve the shims (17).

16

17

Fig. 1204
11. Remove the hub (18) and the planetary gear carrier (19).
19

18

Fig. 1205

30-238
Method of intervention
12. Undo the screws (20) and the nuts (21).

20

21

Fig. 1206
13. Remove the HI-LO unit casing (22) and remove the gasket (23).
23
Important
Replace the gasket (23) with a new component after each 22
removal.

Fig. 1207

Refitting
1. Refit the HI-LO unit following the procedure for removal in reverse order, noting the following additional instructions for the
steps indicated:
2. Tighten the screws (20) and the nuts (21) fastening the HI-LO unit casing to
a torque of 40.4 Nm and 42.7 Nm respectively.

20

21

Fig. 1208
3. Important
If the HI-LO unit was removed in order to service the clutches or the piston, refit by following the procedure for
removal in reverse order. In all other cases, adjust the endfloat of the planet gear units of the planetary reduc-
tion unit (for details, see “Adjusting endfloat of planetary reduction unit gears”).
4. Fit the hub (18) on the planetary gear carrier (19) with the planet gear units
aligned correctly with the hub (19) - with the notches (arrows) on one tooth 19
of each of the gears all converging towards the centre when the hub is in
place.

18

Fig. 1209

30-239
 Method of intervention
5. Fit the planetary gear carrier (19) complete with hub (18) on the HI-LO unit
output shaft. 19

18

Fig. 1210
6. Fit a steel disc (15) and a friction disc (14) and repeat to complete the HI
range clutch pack. 15

14

Fig. 1211
7. Fit the first steel disc (13) (5.0 mm in thickness) and the spacer (12).
13

12

Fig. 1212
8. Fit the LO range clutch housing (11) and tighten the fastener screws (10)
to a torque of 20.4 Nm.
10

11

Fig. 1213

30-240
Method of intervention
9. Apply a bead of Loctite 518 to the mating surface of the cover (9).
Tighten the screws (8) fastening the cover to a torque of 20.4 Nm.

8
9

Fig. 1214
10. Temporarily fit the cover (6) and hold in position with the screws (5).
11. Insert a service screw (24) (M12x45) into the threaded hole of the shaft (25)
on the LO range clutch housing and tighten the screw to pull the LO range 6
clutch housing and allow access to the circlip seat.

24

25

Fig. 1215
12. Remove the cover and fit the circlip (7).

Fig. 1216
13. Apply a bead of Loctite 518 to the mating surface of the cover (6).
14. Tighten the screws (5) fastening the cover (6) to a torque of 20.4 Nm.

Fig. 1217

30-241
 Method of intervention
Completion
See para. 30.10.14 - Clutch housing - Separ... - page 30-221
See para. 30.13.1 - Cab - page 30-520
See para. 30.9.6 - Exhaust pipe - page 30-153
See para. 30.9.5 - Fuel tank - page 30-151
See para. 30.13.7 - Cab access steps - page 30-531
See para. 30.12.4 - 4WD shaft () - page 30-513
See para. 30.18.1 - Rear wheels - page 30-602
Adjusting endfloat of planetary reduction unit gears
1. Fit the hub (18) on the HI-LO unit output shaft (26) and fasten in position
with the circlip (16).
18

16

26

Fig. 1218
2. Using a feeler gauge (27), check the endfloat “R” between the hub (18) and
28
planet gear S1 (28).

27

18

Fig. 1219
3. The thickness S of the shims (17) which must be installed between the hub (18) and the circlip (16) is the difference between
the endfloat measured R and the desired endfloat value F of 0.4 ±0.2 mm.
For example, if the endfloat measured R is 1.30 mm, the thickness S of the shim pack necessary is:
S = R - F = 1.30 - 0.40 = 0.90 mm.

30.10.20 - Disassembling the HI range clutch housing (5090 C -> ZKDY360200TD10001,

5100 C -> ZKDY400200TD10001)
HI range clutch housing section

30-242
Method of intervention

4
5

7
6

8
10 9

15

11

23

13

12

22

14

16
21

18 17 19
2 20

Fig. 1220

Removal
1. DANGER
A
The special tool (A) 5.9030.676.0 must be used for this dis-
assembly procedure.

Fig. 1221
2. Fit and fasten the clutch housing (1) on the special tool (A).

30-243
 Method of intervention
3. Note
Align the notch (2) on the shaft with the lug on the tool.
1

Fig. 1222
4. Bend up the chamfered edges and remove the ring nut (3) using the special
B
wrench (B) 5.9030.603.0.
3
Note
Renew the ring nut on reassembly.
A

Fig. 1223
5. Remove the bearing (4).

Fig. 1224
6. Remove the shim pack (5) and the bush (6).
5
Note
Note the total thickness A of the shims (5). 6

Fig. 1225

30-244
Method of intervention
7. Remove the Belleville washers (7)
7

Fig. 1226
8. Remove the shim pack (8) and the spacer (9).
8
Note
Note the total thickness B of the shim pack (8).
9

Note
Do not accidentally swap the shim pack (5) with the shim
pack (8), and note the respective positions of the two shim
packs relative to the spacer (6).
Fig. 1227
9. Blow compressed air at low pressure into the upper hole (see arrow) in the
shaft to expel the piston (10) of the HI range clutch.
DANGER 10

Restrain piston (10) as it could be expelled at high speed

and be damaged.

Fig. 1228
10. Remove the O-ring (11) from the piston (10).

11

10

Fig. 1229

30-245
 Method of intervention
11. Remove the friction discs (12) (q.ty 5) and the steel discs (13) (q.ty 4) of
the HI range clutch. 12

13

Fig. 1230
12. Remove spacer (14).

14

Fig. 1231
13. Remove O-ring (15).
15

Fig. 1232
14. Remove the complete shaft (17) from the clutch cylinder (16) and remove
the spring (18).
16

17
18

Fig. 1233

30-246
Method of intervention
15. Remove the O-ring (19) and remove the plate (20).
19

20

Fig. 1234
16. Insert two cylindrical blocks of soft material in the holes (see arrows) on
the clutch cylinder (16) to expel the piston (21) from the LO range clutch.

16

21

Fig. 1235
17. Remove the O-ring (22) from the piston (21).

22

21

Fig. 1236
18. Check that the check valve (23) functions correctly and that the orifice (F)
is clear of debris. F

23

Fig. 1237

30-247
 Method of intervention
Installation
1. Lubricate all the O-rings with hydraulic oil before fitting.
2. Fit the O-ring (22) on the LO range clutch piston (21).

22

21

Fig. 1238
3. Fit the piston in (21) in the clutch cylinder (16), and push fully into its seat.

21

16

Fig. 1239
4. Fit the plate (20) and the O-ring (19) on the shaft.
19

20

Fig. 1240
5. Fit the spring (18) on the shaft (17).
6. Fit the shaft (17) in the clutch cylinder (16).

16

17
18

Fig. 1241

30-248
Method of intervention
7. Fit the O-ring (15) on the clutch cylinder.
15

Fig. 1242
8. Fit the spacer (14).

14

Fig. 1243
9. Assemble the HI range clutch pack, fitting a friction disc (12) and a steel
disc (13). Complete the clutch pack, ending with a friction disc (12). 12

13

Fig. 1244
10. Fit the O-ring (11) on the HI range clutch piston (10).

11

10

Fig. 1245

30-249
 Method of intervention
11. Fit the complete HI range clutch piston (10) on the clutch housing.

10

Fig. 1246
12. Fit the spacer (9) and the shim pack (8) of the thickness B measured during
removal or calculated when adjusting the Belleville spring washer preload 8
(see “Adjusting spring preload”).
9

Fig. 1247
13. Important
Adjust the spring preload if the Belleville spring washers have been replaced (see “Adjusting spring preload”
for details).

Important
If the shim packs (5 and 8) have become accidentally mixed up or swapped, or if the measurements A and B
were not noted during removal, replace the springs with a new pack and adjust the spring preload (see “Adjust-
ing spring preload”) before continuing assembly.
14. Fit the Belleville washers (7)
7

Fig. 1248

30-250
Method of intervention
15. Note
Ensure that the Belleville washers (7) are oriented correctly.
7

Fig. 1249
16. Fit the spacer (6) and the shim pack (5) of the thickness A measured during
5
removal or calculated when adjusting the Belleville spring washer preload
(see “Adjusting spring preload”).
6

Fig. 1250
17. Fit and fasten the clutch housing (1) on the special tool (A) 5.9030.676.0.
Note
Align the notch (2) on the shaft with the lug on the tool.

18. Fit the bearing (4), with the seat of the circlip facing upwards.
Note
4
Remove the circlip when fitting a new bearing. The circlip
will be refitted again afterwards. 1
2

Fig. 1251
19. Fit the special tool (B) for aligning the steel discs. Alternatively, the cover of the HI-LO clutch unit may be used instead of the
special tool.
20. Apply a drop of Loctite 243 to the thread of the ring nut.
21. Fit the ring nut (3) and tighten with the special wrench (B) to a torque of 147 Nm.
22. Chamfer the ring nut (3).
23. Remove the special tool (C) (or the cover).

30-251
 Method of intervention
24. Remove the special tool (A).

B C

Fig. 1252

Adjusting spring preload

1. DANGER
Adjustment is necessary whenever the Belleville washers are replaced, and if the shim packs (5 and 8) have
been accidentally mixed up or swapped, or if the measurements A and B were not noted.
2. Measure and note the dimension “D” of the bush (6).
m Example: D = 21.50 mm

Fig. 1253
3. Assemble a shim pack (24) with a total thickness “S” which, when added
to the dimension “D” of the bush (6), equals the nominal value “F” of 25.25 6
mm.
Note
This shim pack (24) will be subsequently split into two parts
D
F

to form the shim packs 8 and 5, installed under and above

the spacer (6) respectively.
Example:
D = 21.50 mm
S

m 24
m F = 25.25 mm Fig. 1254
m S = F - D = 25.25 - 21.50 = 3.75 mm

Assemble the shim pack (24) with:

m 4 shims measuring 0.50 mm = 2.00 mm
m 5 shims measuring 0.20 mm = 1.00 mm
m 5 shims measuring 0.15 mm = 0.75 mm

30-252
Method of intervention
4. Important
After assembling the shim pack, check that the summed
thickness of the bush (6) and the shim pack (24) is effec-
tively equal to the nominal value “F”.
6

24

Fig. 1255
5. Fit the spacer (9) and the bush (6) on the clutch cylinder.
6

Fig. 1256
6. While keeping the piston (10) compressed, measure the dimensions C and
L

L C
10

Fig. 1257
7. Calculate the dimension M as follows: M = C – L
Note
The dimension M is the space occupied by the Belleville washer.

8. Example:
m C =20.32 mm
m L=3.52 mm
m M = 20.32 - 3.52 = 16.80 mm 6
10
9
16

Fig. 1258

30-253
 Method of intervention
9. Calculate the thickness “B” of the shim pack (8) to be installed under the
bush (6) with the following formula: B = 17.70 - M where the value 17.70
mm is a fixed value corresponding to the thickness of the Belleville washer
under a load of 500 Kg.
Example:
8
m B = 17.70 - 16.80 = 0.90 mm
Assemble the disc pack (8) with a thickness B, using part of the shims mak-
ing up the shim pack (24).

Fig. 1259
10. Fit the shim pack (8) under the bush (6), and check that the new measure-
ment M is between 17.65 and 17.75 mm. 6

Note 8

If the value M is not within the specified range, reassemble

the shim pack (8) accordingly to achieve the correct mea- C
surement.
Note
If the measurement M is within the specified range, continue
with assembly of the range LO clutch housing, starting by
installing the Belleville washers (7) after removing the bush Fig. 1260
(6).
The remainder of the shim pack (24) constitutes the new shim pack (5),
which must be installed above the bush (6).

30.10.21 - Disassembling the LO range clutch housing (5100 C -> ZKDY480200TD10001,

5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)
Removal
1. LO range clutch housing section
3

4
5

7
6

8
10 9

15

11

23

13

12

22

14

16
21

18 17 19
2 20

Fig. 1261

30-254
Method of intervention
2. DANGER
A
The special tool (A) 5.9030.676.0 must be used for this dis-
assembly procedure.

Fig. 1262
3. Fit and fasten the clutch housing (1) on the special tool (A).
4. Note
Align the notch (2) on the shaft with the lug on the tool.
1

Fig. 1263
5. Bend up the chamfered edges and remove the ring nut (3) using the special
B
wrench (B) 5.9030.603.0.
3
Note
Renew the ring nut on reassembly.
A

Fig. 1264
6. Remove the bearing (4).

Fig. 1265

30-255
 Method of intervention
7. Remove the shim pack (5) and the bush (6).
5
Note
Note the total thickness A of the shims (5). 6

Fig. 1266
8. Remove the Belleville washers (7)
7

Fig. 1267
9. Remove the shim pack (8) and the spacer (9).
8
Note
Note the total thickness B of the shim pack (8).
9

Note
Do not accidentally swap the shim pack (5) with the shim
pack (8), and note the respective positions of the two shim
packs relative to the spacer (6).
Fig. 1268
10. Blow compressed air at low pressure into the upper hole (see arrow) in the
shaft to expel the piston (10) of the LO range clutch.
DANGER 10

Restrain piston (10) as it could be expelled at high speed

and be damaged.

Fig. 1269

30-256
Method of intervention
11. Remove the O-ring (11) from the piston (10).

11

10

Fig. 1270
12. Remove the friction discs (12) (q.ty 5) and the steel discs (13) (q.ty 4) of
the LO range clutch. 12

13

Fig. 1271
13. Remove spacer (14).

14

Fig. 1272
14. Remove O-ring (15).
15

Fig. 1273

30-257
 Method of intervention
15. Remove the complete shaft (17) from the clutch cylinder (16) and remove
the spring (18).
16

17
18

Fig. 1274
16. Remove the O-ring (19) and remove the plate (20).
19

20

Fig. 1275
17. Insert two cylindrical blocks of soft material in the holes (see arrows) on the
clutch cylinder (16) to expel the piston (21) from the HI range clutch.

16

21

Fig. 1276
18. Remove the O-ring (22) from the piston (21).

22

21

Fig. 1277

30-258
Method of intervention
19. Check that the check valve (23) functions correctly and that the orifice (F)
is clear of debris. F

23

Fig. 1278

Installation
1. Lubricate all the O-rings with hydraulic oil before fitting.
2. Fit the O-ring (22) on the HI range clutch piston (21).

22

21

Fig. 1279
3. Fit the piston in (21) in the clutch cylinder (16), and push fully into its seat.

21

16

Fig. 1280
4. Fit the plate (20) and the O-ring (19) on the shaft.
19

20

Fig. 1281
5. Fit the spring (18) on the shaft (17).

30-259
 Method of intervention
6. Fit the shaft (17) in the clutch cylinder (16).

16

17
18

Fig. 1282
7. Fit the O-ring (15) on the clutch cylinder.
15

Fig. 1283
8. Fit the spacer (14).

14

Fig. 1284
9. Assemble the LO range clutch pack, fitting a friction disc (12) and a steel
disc (13). Complete the clutch pack, ending with a friction disc (12). 12

13

Fig. 1285

30-260
Method of intervention
10. Fit the O-ring (11) on the LO range clutch piston (10).

11

10

Fig. 1286
11. Fit the complete LO range clutch piston (10) on the clutch housing.

10

Fig. 1287
12. Fit the spacer (9) and the shim pack (8) of the thickness B measured during
removal or calculated when adjusting the Belleville spring washer preload 8
(see “Adjusting spring preload”).
9

Fig. 1288
13. Important
Adjust the spring preload if the Belleville spring washers have been replaced (see “Adjusting spring preload”
for details).

Important
If the shim packs (5 and 8) have become accidentally mixed up or swapped, or if the measurements A and B
were not noted during removal, replace the springs with a new pack and adjust the spring preload (see “Adjust-
ing spring preload”) before continuing assembly.

30-261
 Method of intervention
14. Fit the Belleville washers (7)
7

Fig. 1289
15. Note
Ensure that the Belleville washers (7) are oriented correctly.
7

Fig. 1290
16. Fit the spacer (6) and the shim pack (5) of the thickness A measured during
5
removal or calculated when adjusting the Belleville spring washer preload
(see “Adjusting spring preload”).
6

Fig. 1291
17. Fit and fasten the clutch housing (1) on the special tool (A) 5.9030.676.0.
Note
Align the notch (2) on the shaft with the lug on the tool.

18. Fit the bearing (4), with the seat of the circlip facing upwards.
Note
4
Remove the circlip when fitting a new bearing. The circlip
will be refitted again afterwards. 1
2

Fig. 1292
19. Fit the special tool (B) for aligning the steel discs. Alternatively, the cover of the HI-LO clutch unit may be used instead of the
special tool.
20. Apply a drop of Loctite 243 to the thread of the ring nut.

30-262
Method of intervention
21. Fit the ring nut (3) and tighten with the special wrench (B) to a torque of 147 Nm.
22. Chamfer the ring nut (3).
23. Remove the special tool (C) (or the cover).
24. Remove the special tool (A).

B C

Fig. 1293

Adjusting spring preload

1. DANGER
Adjustment is necessary whenever the Belleville washers are replaced, and if the shim packs (5 and 8) have
been accidentally mixed up or swapped, or if the measurements A and B were not noted.
2. Measure and note the dimension “D” of the bush (6).
m Example: D = 21.50 mm

Fig. 1294
3. Assemble a shim pack (24) with a total thickness “S” which, when added
to the dimension “D” of the bush (6), equals the nominal value “F” of 25.25 6
mm.
Note
This shim pack (24) will be subsequently split into two parts
D
F

to form the shim packs 8 and 5, installed under and above

the spacer (6) respectively.
Example:
D = 21.50 mm
S

m 24
mF = 25.25 mm Fig. 1295
m S = F - D = 25.25 - 21.50 = 3.75 mm

Assemble the shim pack (24) with:

m 4 shims measuring 0.50 mm = 2.00 mm
m 5 shims measuring 0.20 mm = 1.00 mm
m 5 shims measuring 0.15 mm = 0.75 mm

30-263
 Method of intervention
4. Important
After assembling the shim pack, check that the summed
thickness of the bush (6) and the shim pack (24) is effec-
tively equal to the nominal value “F”.
6

24

Fig. 1296
5. Fit the spacer (9) and the bush (6) on the clutch cylinder.
6

Fig. 1297
6. While keeping the piston (10) compressed, measure the dimensions C and
L

L C
10

Fig. 1298
7. Calculate the dimension M as follows: M = C – L
Note
The dimension M is the space occupied by the Belleville washer.

8. Example:
m C =20.32 mm
m L=3.52 mm
m M = 20.32 - 3.52 = 16.80 mm 6
10
9
16

Fig. 1299

30-264
Method of intervention
9. Calculate the thickness “B” of the shim pack (8) to be installed under the
bush (6) with the following formula: B = 17.70 - M where the value 17.70
mm is a fixed value corresponding to the thickness of the Belleville washer
under a load of 500 Kg.
Example:
8
m B = 17.70 - 16.80 = 0.90 mm
Assemble the disc pack (8) with a thickness B, using part of the shims mak-
ing up the shim pack (24).

Fig. 1300
10. Fit the shim pack (8) under the bush (6), and check that the new measure-
ment M is between 17.65 and 17.75 mm. 6

Note 8

If the value M is not within the specified range, reassemble

the shim pack (8) accordingly to achieve the correct mea- C
surement.
Note
If the measurement M is within the specified range, continue
with assembly of the range LO clutch housing, starting by
installing the Belleville washers (7) after removing the bush Fig. 1301
(6).
The remainder of the shim pack (24) constitutes the new shim pack (5),
which must be installed above the bush (6).

30.10.22 - Disassembling the HI-LO planetary reduction gearbox (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001)
Removal
1. Planetary gear carrier assembly section
2
1

3
5

Fig. 1302
2. Remove the pins (1) and retrieve the balls (2).
2

Fig. 1303

30-265
 Method of intervention
3. Remove the complete planet gear units (3) and the shims (4).

Fig. 1304
4. Remove the roller bearings (5) from the planet gear units (3).
3

Fig. 1305

Installation
1. Fit the planetary reduction gearbox, following the procedure for removal in reverse order and noting the following additional
instructions for the steps indicated:
2. Fit the planet gear units (3) with the largest gear facing towards the front (from side with recesses for pin locator balls).
3. Rotate the planet gear units (3) so that the notches on one tooth of each of
the gears all converge towards the centre, to prepare for subsequent as-
sembly with the sun gear S1 (6) on the secondary shaft (see reassembly
6
of HI-LO unit).
3

Fig. 1306

30.10.23 - Disassembling the HI-LO planetary reduction gearbox (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
Removal
1. Planetary gear carrier assembly section 2
1

3
5

Fig. 1307

30-266
Method of intervention
2. Remove the pins (1) and retrieve the balls (2). 2

Fig. 1308
3. Remove the complete planet gear units (3) and the shims (4).

Fig. 1309
4. Remove the roller bearings (5) from the planet gear units (3).
3

Fig. 1310

30-267
 Method of intervention
Installation
1. Fit the planetary reduction gearbox, following the procedure for removal in reverse order and noting the following additional
instructions for the steps indicated:
2. Fit the planet gear units (3) with the smallest gear facing towards the front (from side with recesses for pin locator balls).
3. Rotate the planet gear units (3) so that the notches on one tooth of each
of the gears all converge towards the centre, to prepare for subsequent
6
assembly with the HI range clutch hub (6) (see reassembly of HI-LO unit).

Fig. 1311

30.10.24 - HML unit (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,

5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
Removal
1. Undo the unions (1) and remove the oil line (2).
2

Fig. 1312
2. Secure the HML (3) to a rope.
3. Undo the six screws (4) and the three hex socket head cap screws (5)
fastening the HML (3). 3
4

Fig. 1313

30-268
Method of intervention
4. Separate the HML (3) from the outer HML casing (6).
6

Fig. 1314
5. Retrieve the HML shaft endfloat adjuster ring (7).

Fig. 1315

Adjusting endfloat of HML shaft

1. Use a depth gauge to measure the distance X between the end of the sec- 6
ondary shaft and the outer HML casing.

8
Fig. 1316
2. Measure as indicated:
Example: X = 142.30 mm
Note
6
Clean the mating surface of the outer HML casing (6) to pre-
vent residue of sealant from influencing the measurement.

Fig. 1317

30-269
 Method of intervention
3. Remove the union (9) from the HML.

Fig. 1318
4. Tighten a service screw (10) to engage the HML shaft and take up any
endfloat.
10

Fig. 1319
5. Measure the distance between surface A and surface B on the planetary
gear carrier (11) with a digital vernier calliper, then zero the calliper. B

A 11

Fig. 1320
6. Turn the HML unit upright and measure the distance Y between surface B
and surface C with the gauge placed on surface A.
B

Note
Take measurements in several points and calculate the av-
Y

erage.

Example: Y = 139.20 mm 3

Note
C

Clean the mating surface of the HML casing (3) to prevent

residue of sealant from influencing the measurement. Fig. 1321

7. Bearing in mind that a free play of 1 mm must be left, calculate the thickness of the shim necessary SP with the following
formula: Sp = X-Y-1.
Example: Sp = 142.30 - 139.20 - 1 = 2.10 mm.

30-270
Method of intervention
8. Fit a shim (7) of the next size smaller than the value calculated.
Note
The available shim thicknesses are: 2-2.2-2.4-2.6-2.8-3-3.2-
3.4-3.6-3.8-4 7

In this case, a 2 mm thick shim is installed.

Fig. 1322
9. Remove the service screw (10) and tighten the union (9) into its seat.
Note
Apply a drop of Loctite 554 to the threads of the union (9).

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace the three O-rings (12) installed on the mating surface between the
HML and the outer HML casing.

12

Fig. 1323
3. Apply a thin layer of Loctite 518 to the mating surface of the outer HML
casing (6).
6

Fig. 1324
4. Tighten the screws (4) to a torque of 20.4±1 Nm.
5. Tighten the hex socket head cap screws (5) to a torque of 20.4±1 Nm.
Completion
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.18.1 - Rear wheels - page 30-602

30-271
 Method of intervention
30.10.25 - Disassembling the HML unit
Removal
1. Undo the five Allen screws (1) and remove the cover (2).

Fig. 1325
2. Remove the circlip (3) and remove the L clutch hub (4).
3

Fig. 1326
3. Remove the circlip (5).

Fig. 1327
4. From the opposite side, pull out the planetary reduction gearbox (6) com-
plete with drive shaft.
6

Fig. 1328

30-272
Method of intervention
5. Remove oil seal (7) (this will damage the seal irreparably).

Fig. 1329
6. Tighten two separator screws to separate the L-M clutch housing (8) from
8
the H clutch housing (9).

Fig. 1330

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Remove and replace the O-rings (10).

10

Fig. 1331
3. Use the L clutch hub (4) to correctly align the splines on the inner diameter of the M clutch friction discs.
4. Immobilise the discs (11) by inserting two screwdrivers as shown in the
4 4
figure, then remove the L clutch hub (4).

11

Fig. 1332

30-273
 Method of intervention
5. Apply a thin layer of Loctite 518 sealant on the mating surface between the
H clutch housing (9) and the L-M clutch housing.

Fig. 1333
6. Fit the L-M clutch housing (8), engaging the friction discs of the M clutch correctly with the relative hub.
7. After ensuring that the friction discs have engaged correctly with the M
clutch hub, remove the two screwdrivers. 8

Fig. 1334
8. Fit the oil seal (7) using tool (A) 5.9035.540.0.

Fig. 1335
9. Note
Ensure that the oil seal (7) is installed the correct way
around. 7

Fig. 1336

30-274
Method of intervention
10. Apply a thin layer of Loctite 518 sealant for the mating surface of the cover
(2) before fitting

Fig. 1337
11. Tighten the screws (1) fastening the cover (2) to a torque of 20.8 Nm.

Fig. 1338

30.10.26 - Disassembling M-L clutches (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. Remove the circlip (1) on the L clutch side.
1

Fig. 1339
2. Remove the L clutch disc pack, consisting of two thrust plates (2), six fric-
tion discs (3) and five intermediate discs (4).

4
2

2
3

Fig. 1340

30-275
 Method of intervention
3. Remove the circlip (5) on the M clutch side.
5

Fig. 1341
4. Remove the M clutch disc pack, consisting of two thrust plates (6), three
friction discs (7) and two intermediate discs (8).
8

6
6

Fig. 1342
5. Place the M-L clutch housing (9) in the press and compress the belleville spring washers on the M clutch side, pressing with
tool (A) 5.9035.521.0 as shown in the figure.
6. Remove the circlip (10).
A
DANGER
Do not remove the circlip before compressing the belleville
9
spring washers, as the unopposed preload of these springs
may force them violently and uncontrollably out of the hous-
ing.

Fig. 1343
7. Remove the thrust ring (11) and decompress the belleville spring washers,
A
removing the tool (A).

11

Fig. 1344

30-276
Method of intervention
8. Remove the belleville spring washer pack (12) on the M clutch side.
12

Fig. 1345
9. Turn the M-L clutch housing (9) upside down, and proceed as described previously to remove the circlip (13) from the L clutch
side, using tool (A) 5.9035.521.0 to compress the belleville spring washers.
10. DANGER
A
Do not remove the circlip before compressing the belleville
spring washers, as the unopposed preload of these springs 9
may force them violently and uncontrollably out of the hous-
ing.

13

Fig. 1346
11. Remove the ring (14) and decompress the belleville spring washers, re-
moving the tool (A).
A 14

Fig. 1347
12. Remove the belleville spring washer pack (15) on the L clutch side.
15

Fig. 1348

30-277
 Method of intervention
13. Blow compressed air into the oil passage holes (arrow) to push out the 17
pistons of the M (16) and L (17) clutches. 16

Fig. 1349
14. Remove and replace the O-rings (18 and 19) on the pistons.
18

19

Fig. 1350

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Lubricate the O-rings with suitable grease before fitting.
3. Use a mallet and the bush (B) 5.9035.557.0 to drive the pistons (16 and
17) into their seats.
Note B
16

Refit the pistons with the smooth part facing towards the M
- L clutch housing (9). 9

Fig. 1351
4. Fit the M clutch belleville spring washers (12), oriented correctly as shown in the figure.
5. Fit the thrust ring (11).

12 11

Fig. 1352
6. Compress the M clutch side belleville spring washers by pressing with tool (A) 5.9035.521.0 as shown in the figure.

30-278
Method of intervention
7. Fit circlip (10)
A

10

Fig. 1353
8. Fit the L clutch belleville spring washers (15), oriented correctly as shown in the figure.
9. Fit the thrust ring (14).

14
15

Fig. 1354
10. Compress the L clutch side belleville spring washers by pressing with tool (A) 5.9035.521.0 as shown in the figure.
11. Fit circlip (13)

13

Fig. 1355
12. Install the M clutch disc pack, then fit the circlip (5), rotated so that the gap
5
between its two ends (arrows) are not aligned with the apertures on the M-L
clutch housing.

Fig. 1356

30-279
 Method of intervention
13. Install the L clutch disc pack, then fit the circlip (1), rotated so that the gap
1
between its two ends (arrows) are not aligned with the apertures on the M-L
clutch housing.

Fig. 1357

30.10.27 - Disassembling the H clutch (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. Remove the circlip (1).

Fig. 1358
2. Remove the H clutch disc pack, consisting of two thrust plates (2), three
friction discs (3) and two intermediate discs (4).

4
3

2
Fig. 1359
3. Place the H clutch housing (5) in the press and compress the belleville spring washers on the H clutch side, pressing with tool
(A) 5.90.35.550.0 as shown in the figure.
4. Remove the circlip (6).
A
DANGER
Do not remove the circlip before compressing the belleville
spring washers, as the unopposed preload of these springs
may force them violently and uncontrollably out of the hous-
5
ing. 6

Fig. 1360

30-280
Method of intervention
5. Remove the H clutch hub (7)
7

Fig. 1361
6. From the opposite side, remove the H clutch housing (8) with the splined
shaft (9), and retrieve the shim (10).

10

Fig. 1362
7. Remove the bearing (11) and retrieve the spring (12).

12

11

Fig. 1363
8. Pull the splined shaft (9) out from the H clutch housing (8).

Fig. 1364

30-281
 Method of intervention
9. Remove and replace the “Vespel” seals (13).
13

Fig. 1365
10. Blow compressed air into the oil passage holes to push out the piston (14)
of the H clutch.
14

Fig. 1366
11. Remove and replace the O-rings (15 and 16) on the H clutch piston.
15

16

Fig. 1367
12. Place the splined shaft (9) in the press and compress the belleville spring
washers (17), using tool (B) 5.9035.521.0 as shown in the figure, and re-
move the circlip (18).
B
DANGER
Do not remove the circlip before compressing the belleville
spring washers, as the unopposed preload of these springs
may force them violently and uncontrollably out of the hous- 18

ing. 17

Fig. 1368

30-282
Method of intervention
13. Remove the belleville spring washer pack (17) and the spring (19).
17

19

Fig. 1369

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Lubricate the O-rings with suitable grease before fitting on the piston.
3. Fit the ring (19) and the belleville spring washers (17) on the splined shaft
(9), in the order and orientation shown in the figure. 9 19

17

Fig. 1370
4. Compress the belleville spring washers (17) by pressing with tool (B)
5.9035.521.0 as shown in the figure, and fit the circlip (18).

18
17

Fig. 1371
5. Fit the H clutch housing H (8) on the splined shaft (9), with the holes on the
shaft aligned with the corresponding holes on the housing (arrows).
9

Fig. 1372

30-283
 Method of intervention
6. Install the H clutch disc pack, then fit the circlip (1), rotated so that the gap
between its two ends (arrows) are not aligned with the apertures on the H
clutch housing. 1

Fig. 1373

30.10.28 - Replacing the L clutch (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
L clutch section

30-284
Method of intervention

3 6 7 7

8 9

Fig. 1374
l 3 - L clutch cover
l 4 – Circlip
l 5 - L clutch hub
l 6 – Circlip
l 7 - Pressure plate
l 8 - Friction disc
l 9 – Intermediate disc

30-285
 Method of intervention
Removal
1. Important
Drain off all the oil from the transmission.

2. Undo the unions and remove the line (1).

IMPORTANT
Replace the copper washers of the hydraulic union. 1

Fig. 1375
3. Undo the eight hex socket head cap screws (2) and remove the cover (3)
of the L clutch.

Fig. 1376
4. Remove the circlip (4) and remove the L clutch hub (5) to free the housing
(6), then remove the housing.

Fig. 1377
5. Remove circlip (6).

Fig. 1378

30-286
Method of intervention
6. Remove the L clutch disc pack, consisting of two thrust plates (7), six fric-
tion discs (8) and five intermediate discs (9). 7

Fig. 1379

Refitting
1. Fit the L clutch hub (5) and the circlip (4) to facilitate installation of the discs.

Fig. 1380
2. Fit the L clutch disc pack, consisting of two thrust plates (7), six friction
discs (8) and five intermediate discs (9).
7

Fig. 1381
3. Fit the circlip (6), with the open ends (arrows) offset relative to the gaps in
the L clutch housing.

Fig. 1382

30-287
 Method of intervention
4. Apply a thin layer of Loctite 518 sealant for the mating surface of the cover
(3) before fitting. 3

Fig. 1383
5. Apply a drop of Loctite 243 to the threads of the fastener screws.
6. Fit the L clutch cover (3) and tighten the hex socket head cap screws (2) to
3
a torque of 20.4 Nm.

Fig. 1384
7. Fit the line (1) and tighten the unions to a torque of 28 Nm.

Fig. 1385
8. Important
Replace the copper washers of the hydraulic union.

30-288
Method of intervention
Completion
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.29 - Disassembly of the HML planetary reduction gearbox (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. Remove the circlips (1).
1

Fig. 1386
2. Remove the pins (2) and remove the balls (3) preventing the pins from
rotating.
2

Fig. 1387
3. Remove the planetary gear units (4) and retrieve the shims (5).

5
5

Fig. 1388
4. Remove the rollers (6) and the spacer (7) from the gears (4).

30-289
 Method of intervention
5. Note
4
Note that the rollers (6) are no longer restrained and may
drop out during disassembly. 6

Fig. 1389
6. Remove the shaft (8) with the sun gear from the planetary gear carrier (9).
9

Fig. 1390
7. Open and remove the roller bearing cages (10).

10

10

Fig. 1391
8. Use a punch to remove the shim (11) from the planet gear carrier (9).
9

11

Fig. 1392

30-290
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fix the shim (11) onto the planetary gear carrier (9) with a thin layer of
Loctite 272. 11

Fig. 1393
3. Rotate the four planet gears (4) to align the point (12) marked on each gear
with the milled notches (13) on the planetary gear carrier.
13

12

Fig. 1394

30.10.30 - Outer HML casing (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.24 - HML unit (5100 C -> ZK... - page 30-268
Removal
1. Remove circlip (1).

Fig. 1395

30-291
 Method of intervention
2. Remove the crown wheel (2).

Fig. 1396
3. Insert a shim (3) to immobilise the synchroniser, then refit the circlip (1).
Note
This step is necessary to prevent the synchroniser from ac-
cidentally falling out during removal of the outer casing. 3

Fig. 1397
4. Remove the screws (4) and the nuts (5) fastening the outer HML casing to
the gearbox flange.
4

Fig. 1398
5. Remove the outer HML housing (6) and the paper gasket (7). 7

Fig. 1399

30-292
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
Note
Renew paper gasket (7) on reassembly.

2. Tighten the nuts (5) to a torque of 42.7 Nm and tighten the screws (4) to a torque of 40.4 Nm.
Completion
l See para. 30.10.24 - HML unit (5100 C -> ZK... - page 30-268
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.31 - Gearbox and HI-LO unit

Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
Pedal Release
1. Disconnect the unions and/or remove any lines of the hydraulic system interfering with the following operations.
2. Note
Drain all the oil from the transmission.

3. Undo the screws (1) and remove the gear selector lever (2).

Fig. 1400
4. Fit an eyebolt (3) for connecting the HI-LO unit to hoist, and take up the slack in the cable.

30-293
 Method of intervention
5. Working on the left hand side, undo the two screws (4) and the two nuts (5).
3

Fig. 1401
6. Working on the right hand side, undo the two screws (4) and the two nuts
(5).

Fig. 1402
7. Remove the HI-LO unit (6), complete with flange and gearbox shafts.

Fig. 1403

30-294
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply a bead of Loctite 518 to the mating surfaces between the transmis-
sion casing and the gearbox flange.

Fig. 1404
3. Tighten the screws (4) and the nuts (5) fastening the gearbox flange to the transmission casing to 40.4 Nm and 42.7 Nm
respectively.
4. Apply a bead of 7091 DOWN CORNING sealant to the contact surface of the gear selector lever (2).
5. Tighten the fastener screws (1) to a torque of 20.4 Nm.
Completion
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.10.32 - Gearbox/HML assembly (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-

DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
Removal
1. Shift the gearbox into neutral.
2. Undo the unions (1) and remove the oil line (2).
2

Fig. 1405

30-295
 Method of intervention
3. Undo the screws (3) and remove the gear selector lever (4).

Fig. 1406
4. Fit an eye bolt (5) into the relative threaded hole for hoisting the gearbox/HML assembly with a rope.
5. Undo the screws (6) fastening the gearbox/HML assembly to the transmis-
sion casing.
5

Fig. 1407
6. Separate the gearbox/HML assembly (7) from the transmission casing (8)
and undo the nuts (9) completely (these nuts were not removable with the
assembly installed). 7

8
Fig. 1408
7. Detach the gearbox/HML assembly (7) from the transmission casing (8).

Fig. 1409

30-296
Method of intervention
Adjusting endfloat of HML shaft
1. Use a gauge to measure the distance X between the axial end stop on the
pinion shank (9) and the mating surface (10) between the transmission and
the gearbox carrier flange.
10

9
Fig. 1410
2. Reset the gauge (A) on a flat surface, then take the measurement as shown
in the figure. 9

Note 10

Take measurements in several points and calculate the av-

erage.

E.g. X = 209.74 mm A

Fig. 1411
3. Fit a test shim of a known thickness Sp (12) on the HML output shaft (11).
E.g. Sp = 2 mm
4. Fit the HML output shaft (15) into the secondary gearbox shaft (11), com-
plete with roller bearing cages (13) and the shim (14).

14
12

11

15
13

Fig. 1412
5. Use a gauge to measure the distance Y between the surface (17) of the
axial bearing on the HML output shaft and the mating surface (16) between
the transmission and the gearbox carrier flange.
17

16

Fig. 1413
6. Turn the gearbox/HML assembly into an upright position and measure the distance Y as follows.

30-297
 Method of intervention
7. Reset the gauge on the surface (17) of the axial bearing on the HML output
shaft (11).

17

11

Fig. 1414
8. Place the arm of the gauge (A) on the gear of the HML output shaft and
measure the value Y as indicated.
Note
Take measurements in several points and calculate the av-
A
erage.

E.g. Y = 208.1 mm

16

Fig. 1415
9. After measuring the values X and Y, determine the thickness S of the shim (12) with the following formula, considering that
the resulting endfloat must be 0.2 mm:
S = Sp + X - Y - 0.2
Note
If no retainer ring of the thickness calculated is available, select the retainer ring immediately below this value.

10. In this example:

S = 2 + 209.74 - 208.1 - 0.2 = 3.44 mm
Choose a shim (12) measuring 3.4 mm in thickness.
11. Once assembly is complete, the endfloat of the HML shaft must be within a range from 0.2 to 0.6 mm.

30-298
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace all the O-rings and gaskets removed during disassembly.
3. Apply Loctite 518 sealant to the mating surface of the gearbox/HML as-
sembly (7).
7

51
8
Fig. 1416
4. Tighten the nuts (9) to a torque of 42.7 ±2.1 Nm.

8
Fig. 1417
5. Tighten the fastener screws (6) to a torque of 40.4±2 Nm.

Fig. 1418
6. Apply DOW CORNING 7091 sealant and refit the gear selector lever, tight-
ening the relative fastener screws (3) to a torque of 20.4 ±1 Nm.

Fig. 1419

30-299
 Method of intervention
Completion
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.33 - Secondary shaft - Version with HI-LO (5090 C -> ZKDY360200TD10001, 5100 C
-> ZKDY400200TD10001)
Preliminary operations
1. m See para. 30.18.1 - Rear wheels - page 30-602
m See para. 30.13.7 - Cab access steps - page 30-531
m See para. 30.9.5 - Fuel tank - page 30-151
m See para. 30.13.9 - Engine cowl - page 30-532
m See para. 30.9.6 - Exhaust pipe - page 30-153
m See para. 30.13.1 - Cab - page 30-520
m See para. 30.10.14 - Clutch housing - Separ... - page 30-221
m See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
m See para. 30.10.18 - HI-LO unit (5090 C -> ... - page 30-229

Removal
1. Remove the HI-LO unit output shaft (2) from the secondary shaft (1).

Fig. 1420
2. Remove the circlip (3) and remove the gear (4).

4
3
Fig. 1421

30-300
Method of intervention
3. Using a puller, remove the bearing (5) and the bush (6).

5
6

Fig. 1422
4. Remove disc (7).

Fig. 1423
5. Undo the screw (8) and remove the 1st speed selector fork (9) and the complete synchronizer assembly (10).
6. Note
Renew screw (8) on reassembly.

7. Note
9
Note the orientation of the synchroniser.
8
10

Fig. 1424
8. Remove the 1st speed driven gear (11), then remove the stop ring (12) and the thrust washer (13).
9. Note
11 13
Ensure that the thrust washer (12) is installed the correct 12
way around, with the notch facing the gear.

Fig. 1425
10. Undo the lower plugs (14) and retrieve the springs (15) and the balls (16).

30-301
 Method of intervention
11. Note 14

Renew the copper washers on reassembly.

15

16

Fig. 1426
12. Undo the screw (17), remove the 2nd-3rd speed selector rod (18) and remove the relative fork (19).
13. Remove the 1st speed selector rod (20).
19 18

17

20

Fig. 1427
14. Undo the screw (21), remove the 4th-5th speed selector rod (22) and re-
23
move the relative fork (23).

22

21

Fig. 1428
15. Retrieve the grub screws (24), the ball (25) and the spring (26), which pre-
vent simultaneous engagement of two gears, from the gearbox mounting.
24

25

26

Fig. 1429

30-302
Method of intervention
16. Undo the screws (27) and remove the disc (28).
28

27

Fig. 1430
17. Remove the circlip (29) and retrieve the spacer (30).
30
29

Fig. 1431
18. Use the extractor tool (A) 5.9035.535.0 to remove the bearing (31).
31

Fig. 1432
19. Remove the ring bearing (32) and remove the secondary shaft (1), tilting
1
upwards.

32

Fig. 1433

30-303
 Method of intervention
Refitting
1. Install the secondary shaft, following the procedure for disassembly in reverse order and noting the following additional in-
structions for the steps indicated:
2. During installation of the secondary shaft, shim the inner ring of the bearing (31).
3. Fit a suitable spacer (30), selected from the choice available from 2 to 2.45
mm in thickness, between the circlip (29) and the bearing (31) to eliminate 30 31
any free play.
29

Fig. 1434
4. Versions with mechanical reverse shuttle.
5. Fit the shafts in the gearbox shaft carrier flange and measure the distance
“X” while pushing the bearing (31) towards the rear of the transmission. 31
Select the shims (33) necessary to eliminate the endfloat.

33

Fig. 1435
6. Fit the disc (28) in its seat and tighten the fastener screws (27) to a torque
of 20 Nm. 28

Note 27

Apply a drop of Loctite 270 to the threads of the screws (27).

Fig. 1436
7. Fit the balls (16) and the springs (15) in their respective seats.
8. Applying a drop of Loctite 542 to the threads, fit the plugs (14) with new 14
copper washers, and tighten to a torque of 30 Nm.
15

16

Fig. 1437
9. Applying Loctite 270 beforehand, tighten the new screws (21, 17 and 8) fastening the selector forks to a torque of 32.2 Nm.

30-304
Method of intervention
Completion
l See para. 30.10.18 - HI-LO unit (5090 C -> ... - page 30-229
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.34 - Secondary shaft - Version with HI-LO (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
1. m See para. 30.18.1 - Rear wheels - page 30-602
m See para. 30.12.4 - 4WD shaft () - page 30-513
m See para. 30.13.7 - Cab access steps - page 30-531
m See para. 30.9.5 - Fuel tank - page 30-151
m See para. 30.9.6 - Exhaust pipe - page 30-153
m See para. 30.13.1 - Cab - page 30-520
m See para. 30.10.14 - Clutch housing - Separ... - page 30-221
m See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
m See para. 30.10.19 - HI-LO unit (5100 C -> ... - page 30-236

Removal
1. Remove the HI-LO unit output shaft (2) from the secondary shaft (1).

Fig. 1438
2. Remove the circlip (3) and remove the gear (4).

4
3
Fig. 1439

30-305
 Method of intervention
3. Using a puller, remove bearing (5).

Fig. 1440
4. Remove disc (6).

Fig. 1441
5. Undo the screw (7) and remove the 1st speed selector fork (8) and the complete synchronizer assembly (9).
6. Note
Renew screw (7) on reassembly.

7. Note
8
Note the orientation of the synchroniser.
7
9

Fig. 1442
8. Remove the 1st speed driven gear (10), then remove the stop ring (11) and the thrust washer (12).
9. Note
10 12
Ensure that the thrust washer (12) is installed the correct 11
way around, with the notch facing the gear.

Fig. 1443
10. Undo the lower plugs (13) and retrieve the springs (14) and the balls (15).

30-306
Method of intervention
11. Note 13

Renew the copper washers on reassembly.

14

15

Fig. 1444
12. Undo the screw (16), remove the 2nd-3rd speed selector rod (17) and remove the relative fork (18).
13. Remove the 1st speed selector rod (19).
18 17

16

19

Fig. 1445
14. Undo the screw (20), remove the 4th-5th speed selector rod (21) and re-
22
move the relative fork (22).

21

20

Fig. 1446
15. Retrieve the grub screws (23), the ball (24) and the spring (25), which pre-
vent simultaneous engagement of two gears, from the gearbox mounting.
23

24

25

Fig. 1447

30-307
 Method of intervention
16. Undo the screws (26) and remove the disc (27).
27

26

Fig. 1448
17. Remove the circlip (28) and retrieve the spacer (29).
29
28

Fig. 1449
18. Use a specific extractor tool (30) to remove the bearing (31).
31

30

Fig. 1450
19. Remove the ring bearing (32) and remove the secondary shaft (1), tilting
1
upwards.

32

Fig. 1451

30-308
Method of intervention
Refitting
1. Install the secondary shaft, following the procedure for disassembly in reverse order and noting the following additional in-
structions for the steps indicated:
2. During installation of the secondary shaft, shim the inner ring of the bearing (31).
3. Fit a suitable spacer (29), selected from the choice available from 2 to 2.45
mm in thickness, between the circlip (28) and the bearing (31) to eliminate
any free play. 29 31

28

Fig. 1452
4. Fit the shafts in the gearbox shaft carrier flange and measure the distance
“X” while pushing the bearing (31) towards the rear of the transmission.
Select the shims (33) necessary to eliminate the endfloat.

33

X 31

Fig. 1453
5. Fit the disc (27) in its seat and tighten the fastener screws (26) to a torque
of 20 Nm. 27

Note 26

Apply a drop of Loctite 270 to the threads of the screws (26).

Fig. 1454
6. Fit the balls (15) and the springs (14) in their respective seats.
7. Applying a drop of Loctite 542 to the threads, fit the plugs (13) with new 13
copper washers, and tighten to a torque of 30 Nm.
14

15

Fig. 1455
8. Applying Loctite 270 beforehand, tighten the new screws (20, 16 and 7) fastening the selector forks to a torque of 32.2 Nm.

30-309
 Method of intervention
Completion
l See para. 30.10.19 - HI-LO unit (5100 C -> ... - page 30-236
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.35 - Secondary shaft - Version with HML (5100 C -> ZKDY480200TD10001, 5110 C
-> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.32 - Gearbox/HML assembly ... - page 30-295
l See para. 30.10.24 - HML unit (5100 C -> ZK... - page 30-268
l See para. 30.10.30 - Outer HML casing (5100... - page 30-291
Removal
1. Detach the HML unit output shaft (2) from the secondary shaft (1).

Fig. 1456
2. Undo the screw (3) and remove the 1st speed selector fork (4) and the complete synchronizer assembly (5).
3. Note
Renew screw (3) on reassembly.

4. Note
8
Note the orientation of the synchroniser.
7
9

Fig. 1457
5. Remove the 1st speed driven gear (6), then remove the stop ring (7) and the thrust washer (8).

30-310
Method of intervention
6. Note
10 12
Ensure that the thrust washer (8) is installed the correct way 11
around, with the notch facing the gear.

Fig. 1458
7. Undo the lower plugs (9) and retrieve the springs (10) and the balls (11).
8. Note 13

Renew the copper washers on reassembly.

14

15

Fig. 1459
9. Undo the screw (12), remove the 2nd-3rd speed selector rod (13) and remove the relative fork (14).
10. Remove the 1st speed selector rod (15).
18 17

16

19

Fig. 1460
11. Undo the screw (16), remove the 4th-5th speed selector rod (17) and re-
22
move the relative fork (18).

21

20

Fig. 1461

30-311
 Method of intervention
12. Retrieve the grub screws (19), the ball (20) and the spring (21), which pre-
vent simultaneous engagement of two gears, from the gearbox mounting.
23

24

25

Fig. 1462
13. Undo the screws (22) and remove the disc (23).
27

26

Fig. 1463
14. Remove the circlip (24) and retrieve the spacer (25).
29
28

Fig. 1464
15. Use the specific extractor tool 5.9035.535.0 (26) to remove the bearing
31
(27).
30

Fig. 1465

30-312
Method of intervention
16. Remove the ring bearing (28) and remove the secondary shaft (1), tilting
1
upwards.

32

Fig. 1466

Refitting
1. Install the secondary shaft, following the procedure for disassembly in reverse order and noting the following additional in-
structions for the steps indicated:
2. During installation of the secondary shaft, shim the inner ring of the bearing (27).
3. Fit a suitable spacer (25), selected from the choice available from 2 to 2.45
mm in thickness, between the circlip (24) and the bearing (27) to eliminate
any free play. 29 31

28

Fig. 1467
4. Fit the shafts in the gearbox shaft carrier flange and measure the distance
“X” while pushing the bearing (27) towards the rear of the transmission.
Select the shims (29) necessary to eliminate the endfloat.

33

X 31

Fig. 1468
5. Fit the disc (23) in its seat and tighten the fastener screws (22) to a torque
of 20 Nm. 27

Note 26

Apply a drop of Loctite 270 to the threads of the screws (22).

Fig. 1469
6. Fit the balls (11) and the springs (10) in their respective seats.

30-313
 Method of intervention
7. Applying a drop of Loctite 542 to the threads, fit the plugs (13) with new 13
copper washers, and tighten to a torque of 30 Nm.
14

15

Fig. 1470
8. Applying Loctite 270 beforehand, tighten the new screws (16, 12 and 3) fastening the selector forks to a torque of 32.2 Nm.
Completion
l See para. 30.10.30 - Outer HML casing (5100... - page 30-291
l See para. 30.10.24 - HML unit (5100 C -> ZK... - page 30-268
l See para. 30.10.32 - Gearbox/HML assembly ... - page 30-295
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.36 - Primary shaft (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,

5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.19 - HI-LO unit (5100 C -> ... - page 30-236
l See para. 30.10.34 - Secondary shaft - Vers... - page 30-305
Pedal Release
1. Undo the screws (1) and move the flange (2) aside.
2. Note
The rear of the input shaft (A) is now free to leave its seat,
permitting removal of the primary shaft.

A
2

Fig. 1471

30-314
Method of intervention
3. Remove the retainer ring (3).

Fig. 1472
4. Using a soft mallet, detach the bearing and remove the primary shaft (4).
4

Fig. 1473

Refitting
1. Refit the primary shaft following the procedure for removal in reverse order.
Completion
l See para. 30.10.34 - Secondary shaft - Vers... - page 30-305
l See para. 30.10.19 - HI-LO unit (5100 C -> ... - page 30-236
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.37 - Disassembling the gearbox input shaft (5100 C -> ZKDY480200TD10001, 5110
C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.19 - HI-LO unit (5100 C -> ... - page 30-236
l See para. 30.10.34 - Secondary shaft - Vers... - page 30-305
l See para. 30.10.36 - Primary shaft (5100 C ... - page 30-314

30-315
 Method of intervention
Removal
1. Note
3 10 11
6 12
5
The second section of the gearbox input shaft is removed 4

during this procedure.

9
1 8
2 7

Fig. 1474
2. Remove the retainer ring (1).
1

Fig. 1475
3. Using a soft mallet, drive out the first section (2) of the gearbox input shaft
and remove the roller bearing (3). 2

Fig. 1476
4. Remove the retainer ring (4) and the spacer (5).
5. Use the press to remove the bearing (6).
4

Fig. 1477

30-316
Method of intervention
6. Remove the retainer ring (8) and the spacer (9) from the second section
(7) of the gearbox input shaft, which was removed during the procedure to 8
separate the primary shaft. 9

Fig. 1478
7. Use the press to remove the bearing (10).
8. Remove the stop flange (11).
10

11

Fig. 1479
9. On the opposite side, use the press to remove the bearing (12).
12

Fig. 1480

30-317
 Method of intervention
Installation
1. To assemble, follow the procedure for disassembly in reverse order.
2. Note
The second section of the gearbox input shaft is installed during the procedure to reinstall the primary shaft.

Completion
l See para. 30.10.36 - Primary shaft (5100 C ... - page 30-314
l See para. 30.10.34 - Secondary shaft - Vers... - page 30-305
l See para. 30.10.19 - HI-LO unit (5100 C -> ... - page 30-236
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.38 - Disassembly of secondary shaft - Version with HI-LO (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001)
Secondary shaft

4 6 8 10 12 13 15 16
2

A
5 7 B 9 11 C 14 17 D

Fig. 1481
Key
l A: 2nd gear
l B: 3rd gear
l S: 4th gear
l D: 5th gear

30-318
Method of intervention
Removal
1. Remove the circlip (1) and the 2nd speed gear (2).
1

Fig. 1482
2. Remove the needle roller bearing cage (3) and the synchroniser ring (4).
3

Fig. 1483
3. Remove the circlip (5) retaining the synchroniser (6).
5
IMPORTANT
Renew the circlip on reassembly
6

Remove the synchroniser (6) complete with the second synchroniser ring.
IMPORTANT
Note which way round the synchroniser sleeve is installed.

Fig. 1484
4. Remove the circlip (7) and the 3rd speed gear (8).
7
IMPORTANT
Renew the circlip on reassembly
8

Fig. 1485

30-319
 Method of intervention
5. Remove spacer (9) and circlip (10).
9
IMPORTANT
10
Note the orientation of the lubrication recesses.

Fig. 1486
6. Remove the spacer (11) and the 4th speed gear (12).
11
IMPORTANT
Note the orientation of the lubrication recesses. 12

Fig. 1487
7. Remove the synchroniser ring (13) and the circlip (14).
13
IMPORTANT
14
Renew the circlip on reassembly

Fig. 1488
8. Remove the synchroniser (15) complete with the second synchroniser ring.
15
IMPORTANT
Note which way round the synchroniser sleeve is installed. 16

Remove the 5th speed gear (16).

Fig. 1489

30-320
Method of intervention
9. Remove circlip (17). 17
IMPORTANT
Renew the circlip on reassembly

Fig. 1490
10. Remove the bush (18).

18

Fig. 1491

Installation
1. Fit the circlips (5, 7, 14 and 17) in tool 5.9035.532.0.
2. Remove the conical part (A) from the tool.
3. Fit the cylindrical part (B) of the tool onto the secondary shaft and fit the
circlip (17) it its seat.
17
14
7
5

A
B

B
17

Fig. 1492
4. Assemble by following the procedure for disassembly in reverse order, using tool 5.9035.532.0 to fit the remaining circlips, and
noting the following additional instructions for the steps indicated:
5. Position the synchroniser (15) correctly as shown in the figure.
15

Fig. 1493

30-321
 Method of intervention
6. Position the thrust washers (9) and (11) correctly as shown in the figure.

11

Fig. 1494
7. Position the synchroniser (6) correctly as shown in the figure.
6

Fig. 1495

30.10.39 - Disassembly of secondary shaft - Version with HI-LO ()

Secondary shaft

1 3 2 4 6 8 10 12 13 15 16

18 19

A B C D

5 7 9 11 14 17

Fig. 1496
Key

30-322
Method of intervention
l A: 2nd gear
l B: 3rd gear
l S: 4th gear
l D: 5th gear
Removal
1. Remove the circlip (1) and the 2nd speed gear (2).
1

Fig. 1497
2. Remove the needle roller bearing cage (3) and the synchroniser ring (4).
3

Fig. 1498
3. Remove the circlip (5) retaining the synchroniser (6).
5
IMPORTANT
Renew the circlip on reassembly
6

Remove the synchroniser (6) complete with the second synchroniser ring.
IMPORTANT
Note which way round the synchroniser sleeve is installed.

Fig. 1499
4. Remove the circlip (7) and the 3rd speed gear (8).
7
IMPORTANT
Renew the circlip on reassembly
8

Fig. 1500

30-323
 Method of intervention
5. Remove spacer (9) and circlip (10).
9
IMPORTANT
10
Note the orientation of the lubrication recesses.

Fig. 1501
6. Remove the spacer (11) and the 4th speed gear (12).
11
IMPORTANT
Note the orientation of the lubrication recesses. 12

Fig. 1502
7. Remove the synchroniser ring (13) and the circlip (14).
13
IMPORTANT
14
Renew the circlip on reassembly

Fig. 1503
8. Remove the synchroniser (15) complete with the second synchroniser ring.
15
IMPORTANT
Note which way round the synchroniser sleeve is installed. 16

Remove the 5th speed gear (16).

Fig. 1504

30-324
Method of intervention
9. Remove circlip (17). 17
IMPORTANT
Renew the circlip on reassembly

Fig. 1505
10. Remove the circlip (18) and the roller bearing cage (19).

19
18

Fig. 1506

Installation
1. Assemble following the procedure for disassembly in reverse order, noting the following additional instructions for the steps
indicated:
2. Position the synchroniser (15) correctly as shown in the figure.
15

Fig. 1507
3. Position the thrust washers (9) and (11) correctly as shown in the figure.

11

Fig. 1508

30-325
 Method of intervention
4. Position the synchroniser (6) correctly as shown in the figure.
6

Fig. 1509

30.10.40 - Disassembly of the main shaft

7
8
2 3

Fig. 1510

Removal
1. Cross-section of the primary shaft
2. Remove the circlip (1) and remove the gear (2).
1

Fig. 1511

30-326
Method of intervention
3. Remove the bearing (3) with the press and retrieve the circlip (4).
3

Fig. 1512
4. Remove the circlip (5) and remove the spacer (6).
5

Fig. 1513
5. Using a puller, remove the bearing (7) and the double gear (8).
7

Fig. 1514

30-327
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the double gear (8) to 120°C, and install on the primary shaft, pushing completely into its seat.
3. Heat the bearing (7) to 120°C and install on the primary shaft.
4. Fit the circlip (4), which will retain the bearing during reinstallation of the primary shaft.
5. Heat the bearing (3) to 120°C and install on the primary shaft.

30.10.41 - Disassembly of HI-LO unit output shaft (5090 C -> ZKDY360200TD10001, 5100
C -> ZKDY400200TD10001)
Removal
1. HI-LO unit output shaft section 3
4

2 6

7 5

Fig. 1515
2. Remove the roller bearing cages (1) and the spacer (2).

Fig. 1516
3. Remove the circlip (3).

Fig. 1517
4. Push out the bearing (4) with a suitable presser tool.

Fig. 1518

30-328
Method of intervention
5. If necessary, remove the circlip (5) and the roller bearing cage (6) from the
7
output shaft (7) of the HI-LO clutch unit.

6
5

Fig. 1519

Installation
1. To assemble, follow the procedure for disassembly in reverse order.

30.10.42 - Disassembly of HI-LO unit output shaft (5100 C -> ZKDY480200TD10001, 5110 C
-> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. HI-LO unit output shaft section 3
6 8
2

9
1
5

Fig. 1520
2. Remove the roller bearing cages (1) and the spacer (2).

Fig. 1521
3. Remove the circlip (3), the thrust washer (4) and the bearing (5).

5
4

Fig. 1522

30-329
 Method of intervention
4. Using a suitable presser tool, push the inner race (6) out from the bearing
6
(5).

Fig. 1523
5. If necessary, remove the circlip (7) and the roller bearing cage (8) from the
9
output shaft (9) of the HI-LO clutch unit.

8
7

Fig. 1524

Installation
1. To assemble, follow the procedure for disassembly in reverse order.

30.10.43 - Disassembling the HML unit output shaft (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
HML unit output shaft section
5
9 8
1

6
2 3
10
4 7

Fig. 1525

Removal
1. Remove the roller bearing cages (1) and the spacer (2).

30-330
Method of intervention
2. Remove thrust washer (3).

Fig. 1526
3. Remove the circlip (4).

Fig. 1527
4. Push out the bearing (5) with a suitable presser tool.

Fig. 1528
5. If necessary, remove the circlip (7) and the roller bearing cage (8) from the output shaft (6) of the HML unit.
6. Remove the thrust bearing (9) and the two ring bearings (10).

7
6

10

Fig. 1529

30-331
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the shim ring (3) of the thickness calculated in the procedure for adjusting the secondary shaft endfloat.
See para. 30.10.35 - Secondary shaft - Vers... - page 30-310
3. Fit the roller bearing cages (1) and the spacer (2).

Fig. 1530

30.10.44 - PTO output shaft - 2 speed version

Preliminary operations
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
Pedal Release
1. Undo the nuts (1) and remove the flange (2).
1 2

Fig. 1531
2. Undo the nuts (3) and remove the external flange shaft (4).

4
3

Fig. 1532

30-332
Method of intervention
3. Undo the nuts (5) and remove the cover (6).
6
5

Fig. 1533
4. Remove the retainer ring (7) from the inside.
5. Tighten a slide hammer extractor into the hole on the PTO output shaft (8) 7
and pull out the shaft.

Fig. 1534

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Fit the cover (6) and tighten the nuts (5) to a torque of 40.4 Nm.
6
5

Fig. 1535
3. Fit the external flange shaft (4) and tighten the nuts (3) to a torque of 40.4
Nm.

4
3

Fig. 1536

30-333
 Method of intervention
4. Fit the flange (2) and tighten the nuts (1) to a torque of 40.4 Nm.
1 2

Fig. 1537

Completion
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531

30.10.45 - PTO output shaft - 4 speed version (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001)
Preliminary operations
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
Removal
1. Undo the nuts (1) and remove the PTO output flange shaft cover PTO (2) 1
and the PTO cover (3).

3 2

Fig. 1538
2. Undo the fastener nuts and remove the lubrication line (4).

Fig. 1539
3. Undo the screw (5) and remove the PTO range control rod (6).

30-334
Method of intervention
4. Retrieve the selector lever (7) and the shoe (8).
Note 6

Renew screw (5) on reassembly.

5

Fig. 1540
5. Free the sliding sleeve (9) by pushing the circlip (10) out of its seat towards
the front of the transmission (arrow).

10

Fig. 1541
6. Move the sliding sleeve (9) towards the front of the transmission.

Fig. 1542
7. Remove the circlip (11).

11

Fig. 1543

30-335
 Method of intervention
8. Detach the clutch (12) from its seat, moving it towards the front of the trans-
mission.

12

Fig. 1544
9. Use a slide hammer extractor (A) to remove the internal PTO output shaft
(13) complete with bearing (14).
13

14

Fig. 1545
10. Use a soft mallet to remove the double gear (15).

15

Fig. 1546
11. Remove the circlip (16).
12. Using a soft mallet, drive the bearing (17) in the direction indicated by the
arrow and remove the bearing.

16

17

Fig. 1547

30-336
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply DOW CORNING 7091 sealant to the PTO output flange shaft cover (2) and to the PTO cover (3) before fitting.
3. Tighten the nuts (1) to a torque of 42.7 ±2.1 Nm. 1

3 2

Fig. 1548
4. Fit the PTO range control rod (6) and the selector lever (7).
Note
Replace the O-ring installed on the PTO range selector rod (6).

5. Replace the screw (5) with a new screw (pre-moistened with thread lock),
and tighten to a torque of 21.9±1.1 Nm. 6

Fig. 1549

Completion
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.19.1 - Tow hook sled - page 30-605

30.10.46 - PTO output shaft - 4 speed version (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584

30-337
 Method of intervention
Removal
1. Undo the nuts (1) and remove the PTO output flange shaft cover PTO (2) 1
and the PTO cover (3).

3 2

Fig. 1550
2. Undo the fastener nuts and remove the lubrication line (4).

Fig. 1551
3. Undo the screw (5) and remove the PTO range control rod (6).
4. Retrieve the selector lever (7) and the shoe (8).
Note 6

Renew screw (5) on reassembly.

5

Fig. 1552
5. Free the sliding sleeve (9) by pushing the circlip (10) out of its seat towards
the front of the transmission (arrow).

10

Fig. 1553

30-338
Method of intervention
6. Move the sliding sleeve (9) towards the front of the transmission.

Fig. 1554
7. Remove the circlip (11).

11

Fig. 1555
8. Detach the clutch (12) from its seat, moving it towards the front of the trans-
mission.

12

Fig. 1556
9. Use a slide hammer extractor (A) to remove the internal PTO output shaft
(13) complete with bearing (14).
13

14

Fig. 1557

30-339
 Method of intervention
10. Use a soft mallet to remove the double gear (15).

15

Fig. 1558
11. Open the circlip (16) with pliers and simultaneously remove the bearing
(17), tapping with a soft mallet to drive it in the direction indicated (arrow)

16

17

Fig. 1559

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply DOW CORNING 7091 sealant to the PTO output flange shaft cover (2) and to the PTO cover (3) before fitting.
3. Tighten the nuts (1) to a torque of 42.7 ±2.1 Nm. 1

3 2

Fig. 1560
4. Fit the PTO range control rod (6) and the selector lever (7).
Note
Replace the O-ring installed on the PTO range selector rod (6).

30-340
Method of intervention
5. Replace the screw (5) with a new screw (pre-moistened with thread lock),
and tighten to a torque of 21.9±1.1 Nm. 6

Fig. 1561

Completion
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.19.1 - Tow hook sled - page 30-605

30.10.47 - Disassembling the PTO output shaft - 2-speed version

Removal
1. PTO output shaft section - 2-speed version 9
7
10

4 8
2 5

Fig. 1562
2. Remove the retainer rings (1) and (2) and remove the PTO output shaft (3) from the double gear (4).
3. Retrieve the O-ring (5).

3
2

1
4

Fig. 1563
4. Remove the retainer ring (6), then remove the bearing (7) from the double gear (4) with the press.
5. Remove the spacer (8).
6

Fig. 1564

30-341
 Method of intervention
6. Open the ring (9) and remove the bearing (10) from the transmission cas-
ing.

9
10

Fig. 1565

Installation
1. To assemble, follow the procedure for disassembly in reverse order.

30.10.48 - Removing the PTO output shaft - 4 speed version (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001)
Removal
1. Remove the two roller bearing cages (1).
2. Remove the roller bearing cage (2).
3. Remove the spacer (3) and the axial bearing (4).

1
4
3
2

Fig. 1566
4. Remove the circlip (5).
5

Fig. 1567

30-342
Method of intervention
5. Use a suitable extractor tool (A) to remove the bearing (6) from the inner
PTO output shaft (7).

6
7

Fig. 1568

Installation
1. Heat the inner race of the bearing (6) to 80°C, then install in its seat on the inner PTO output shaft (7).
2. Fit the circlip (5)
5

Fig. 1569
3. Fit the axial bearing (4) and the spacer (3).
4. Fit the roller bearing cage (2).
5. Fit the two roller bearing cages (1).

1
4
3
2

Fig. 1570

30-343
 Method of intervention
30.10.49 - Removing the PTO output shaft - 4 speed version (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
Removal
1. Remove roller cage (1).
1

Fig. 1571
2. Remove the circlip (2).
2

Fig. 1572
3. Use a suitable extractor tool (A) to remove the bearing (3) from the inner
PTO output shaft (4).

3
4

Fig. 1573
4. Remove the circlip (5).

Fig. 1574

30-344
Method of intervention
5. Remove the spacer (6) and the roller cage (7).

Fig. 1575

Installation
1. Fit the roller cage (7) and the ring (6) in their seats.

Fig. 1576
2. Fit the circlip (5)

Fig. 1577
3. Heat the inner race of the bearing (3) to 80°C, then install in its seat on the inner PTO output shaft (4).
4. Fit the circlip (2)
2

Fig. 1578

30-345
 Method of intervention
5. Fit roller cage (1).
1

Fig. 1579

30.10.50 - PTO engagement clutch

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
Pedal Release
1. Undo the unions (1) and (2), undo the screws (3) and move the relative
lines aside.

Fig. 1580
2. Remove gasket (4).
Undo the screws (5) and remove the cover (6).

6
5

Fig. 1581

30-346
Method of intervention
3. Undo the unions (7) and remove the PTO control lines (8)
Undo the screw (9) fastening the connector (10).

7
7

10 9
8

Fig. 1582
4. Remove the connector (10) and the two union tubes (11) and (12).
Important
Check the condition of O-rings (13) and renew them if nec- 12

essary.
11

10

13

Fig. 1583
5. Undo the union (14) and move the line (15) aside.
Remove the pipe (16).
16

14

15

Fig. 1584
6. Undo the nuts (17) and remove the PTO cover (18).
17 18

Fig. 1585

30-347
 Method of intervention
7. Undo the nuts (19) and remove the external flange shaft (20).

20
19

Fig. 1586
8. Undo the nuts (21) and remove the cover (22).
22
21

Fig. 1587
9. Remove the retainer ring (23), screw a slide hammer extractor to the PTO
output shaft (24) and pull out the shaft to disengage the PTO clutch.

24

23

Fig. 1588
10. Detach the retainer ring (25) and push the PTO clutch (26) back (arrow).

25

26

Fig. 1589

30-348
Method of intervention
11. Remove the PTO clutch assembly (27).

27

Fig. 1590
12. Remove the retainer ring (25), the spacer (28) and the PTO clutch shaft
(26).

26
28
25

Fig. 1591

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Fit the PTO clutch shaft (26) in the clutch unit, complete with the retainer
ring (25) and spacer (28).
The spacer must always be fitted when servicing or replacing any assem-
blies or components involved in the operation of the rear PTO.
26
28
25

Fig. 1592
3. Move the PTO clutch shaft (26) towards the front of the tractor so that it
seats against the O-ring (29).
29
26

Fig. 1593

30-349
 Method of intervention
4. Using a feeler gauge, measure the residual clearance “G” between the
spacer and the circlip.
If the clearance measured “G” is less than 1.00 mm, remove the spacer.
25
28

Fig. 1594
5. Apply a bead of 7091 Down Corning to the mating surface of the cover (6).

Fig. 1595
6. Renew gasket (4) after every removal.
7. Fit the cover (6) and tighten the screws (5) to a torque of 40.4 Nm.

6
5

Fig. 1596

30-350
Method of intervention
Completion
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.51 - Disassembling PTO engagement clutch (5090 C -> ZKDY360200TD10001, 5100

C -> ZKDY400200TD10001)
Removal
1. PTO engagement clutch section 8 10
7 9 28
6
17
27
19

1
18

1
12 20
13 21
25
11
14 30
29 23
15 24
22

26

Fig. 1597
2. Using a suitable wrench, remove accumulator (1).
Note
Replace the copper washer (2) with a new component after
each removal.
1

Fig. 1598
3. If not removed previously, remove the PTO clutch shaft (3).
4. Remove the retainer ring (4) and the spacer (5).

Fig. 1599

30-351
 Method of intervention
5. Remove the circlip (6) and the spacers (7).
6

Fig. 1600
6. Remove the steel disc (8), all the friction discs (9) and the steel discs (10).
9
8

10

Fig. 1601
7. Remove the hub (11) and shim (12).

11

12

Fig. 1602
8. Using a press and a suitable presser tool, lightly compress the spring and
remove the circlip (13).

13

Fig. 1603

30-352
Method of intervention
9. Remove the disc (14) and spring (15).
14

15

Fig. 1604
10. Undo the screws (16) and remove the cover (17).
16

17

Fig. 1605
11. Remove the friction disc (18) and the disc (19).
12. Remove the circlip (20) and the thrust washer (21)
18

19

20
21

Fig. 1606
13. Blow compressed air at low pressure through the centre hole (arrow) in the clutch housing (22) to expel the piston (23).
14. DANGER
Restrain piston (23) as it could be expelled at high speed and thus damaged.

15. Remove O-ring (24) from piston (23) and O-ring (25) from clutch housing
(22). 23

24

25

22

Fig. 1607

30-353
 Method of intervention
16. Remove clutch assembly (22) from clutch housing (26).
22

26

Fig. 1608
17. Blow low pressure compressed air into the centre hole (arrow) in the clutch housing (26) to expel the piston (27).
18. Remove the piston (27), the O-ring (28) and the O-ring (29) from the hub.
19. Remove the ring seals (30) from the clutch housing (26).
28
26

30

27
29

Fig. 1609

Installation
1. Fit the PTO clutch following the procedure for removal in reverse order, lubricating the O-rings (30), all the O-rings and all the
friction discs with hydraulic oil.
2. Apply a drop of Loctite 243 to the threads of the screws (16) and tighten to a torque of 20.4 Nm.
3. Check that the free play M between the clutch disc pack and the piston (27) is between 0.8 and 2.6 mm.
4. If not, adjust the number of shims (7) to obtain the correct free play.
M
7

27

Fig. 1610
5. Check that the free play N between the friction disc (18) and the pressure
plate (19) is 0.55 mm.
18

19 N

Fig. 1611

30-354
Method of intervention
30.10.52 - Disassembling PTO engagement clutch (5100 C -> ZKDY480200TD10001, 5110 C
-> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. PTO engagement clutch section 8 10
7 9 28
6
17
27
19

1
18

1
12 20
13 21
25
11
14 30
29 23
15 24
22

26

Fig. 1612
2. Using a suitable wrench, remove accumulator (1).
Note
Replace the copper washer (2) with a new component after
each removal.
1

Fig. 1613
3. If not removed previously, remove the PTO clutch shaft (3).
4. Remove the retainer ring (4) and the spacer (5).

Fig. 1614
5. Remove the circlip (6) and the spacers (7).
6

Fig. 1615

30-355
 Method of intervention
6. Remove the steel disc (8), all the friction discs (9) and the steel discs (10).
9
8

10

Fig. 1616
7. Remove the hub (11) and shim (12).

11

12

Fig. 1617
8. Using a press and a suitable tool, lightly compress the spring and remove
the circlip (13).

13

Fig. 1618
9. Remove the disc (14) and spring (15).
14

15

Fig. 1619

30-356
Method of intervention
10. Undo the screws (16) and remove the cover (17).
16

17

Fig. 1620
11. Remove the friction disc (18) and the disc (19).
12. Remove the circlip (20) and the thrust washer (21)
18

19

20
21

Fig. 1621
13. Blow compressed air at low pressure through the centre hole (arrow) in the clutch housing (22) to expel the piston (23).
14. DANGER
Restrain piston (23) as it could be expelled at high speed and thus damaged.

15. Remove O-ring (24) from piston (23) and O-ring (25) from clutch housing
(22). 23

24
22
25

Fig. 1622
16. Remove clutch assembly (22) from clutch housing (26).
22

26

Fig. 1623
17. Blow low pressure compressed air into the centre hole (arrow) in the clutch housing (26) to expel the piston (27).
18. Remove the piston (27), the O-ring (28) and the O-ring (29) from the hub.

30-357
 Method of intervention
19. Remove the ring seals (30) from the clutch housing (26).
28
26

30

27
29

Fig. 1624

Installation
1. Fit the PTO clutch following the procedure for removal in reverse order, lubricating the seal rings (30), all the O-rings and all
the friction discs with hydraulic oil.
2. Apply a drop of Loctite 243 to the threads of the screws (16) and tighten to a torque of 20.4 Nm.
3. Check that the free play M between the clutch disc pack and the piston (27) is between 1.9 and 2.6 mm.
4. If not, adjust the number of shims (7) to obtain the correct free play.
7 M

27

Fig. 1625
5. Check that the free play N between the friction disc (18) and the pressure
plate (19) is 0.55 mm.
18

19 N

Fig. 1626

30.10.53 - Pump drive PTO - External gear

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.14.7 - Disassembling the comp... - page 30-547

30-358
Method of intervention
Removal
1. Undo the nuts (1) and remove the cover (2).

Fig. 1627
2. Use a soft mallet to drive out the hub (3) and the bearing (4).
Retrieve the fastener key.

Fig. 1628
3. Undo the screws (5) and remove the cover (6).
Important
Take care not to let the gear fall out.

6 5

Fig. 1629
4. Remove the gear (7) and retrieve the two spacers (8).
8
Remove the second bearing (9). 9

8 7

Fig. 1630

30-359
 Method of intervention
5. Drive the bearing (4) out from the hub (3) with the press.
4

Fig. 1631
6. Use a soft mallet to drive out the hub (10) and the bearing (11).
Retrieve the fastener key (12).
7. Remove the gear (13) and retrieve the two spacers (14). 14 13 15
Remove the second bearing (15). 10 11

12

14

Fig. 1632
8. Drive the bearing (11) out from the hub (10) with the press.
11

10

Fig. 1633

30-360
Method of intervention
Refitting
1. Refit by following the procedure for removal in reverse order.
2. Apply a thin layer of DOW CORNING 7091 to the mating surface, then fit the cover (6) and tighten the screws (5) to a torque
of 20.4 Nm.
3. Apply a thin layer of DOW CORNING 7091 to the mating surface, then fit the cover (2) and tighten the nuts (1) to a torque of
40.4 Nm.
Completion
l See para. 30.14.7 - Disassembling the comp... - page 30-547
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.54 - Pump drive PTO - Internal gear

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.14.7 - Disassembling the comp... - page 30-547
l See para. 30.10.53 - Pump drive PTO - Exter... - page 30-358
Removal
1. Pump drive PTO section - Internal gear

4 1

6
7

5 3

Fig. 1634

30-361
 Method of intervention
2. Remove circlip (1)

Fig. 1635
3. Use a punch in soft material to drive out the hub (2) complete with bearing (3).
4. Retrieve the key (4).
5. Retrieve the O-ring from inside the hub.

Fig. 1636
6. Remove the gear (5) from the transmission casing, then remove the bear-
ing (6).

5
6

Fig. 1637
7. Drive the bearing (3) out from the hub (2) with the press.

Fig. 1638

30-362
Method of intervention
Refitting
1. Install the internal pump drive PTO gear following the procedure for disas-
sembly in reverse order, noting the following additional instruction for the
2
step indicated:
Orient the hub correctly (2) with the recess (7) facing towards the front of
the transmission (arrow).

Fig. 1639

Completion
l See para. 30.10.53 - Pump drive PTO - Exter... - page 30-358
l See para. 30.14.7 - Disassembling the comp... - page 30-547
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.55 - Disassembling the PTO flange shaft - 2-speed version ()

Preliminary operations
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
Removal
1. PTO output flange shaft section
9
8
17
24
25 16

22
23
18

15

20
12
19 21

Fig. 1640

30-363
 Method of intervention
2. Undo the nuts (1) and remove the lubrication union (2).

Fig. 1641
3. Fit the external flange shaft (3) and tighten the nuts (4).

Fig. 1642
4. Undo the grub screw (5) fastening the fork.

Fig. 1643
5. Undo the screw (6) and remove the bracket (7).
6. Remove the engagement shaft (8) and remove the fork (9) with the relative shoes (10), retrieving the coupling key.
7. Remove O-ring (11).
9
10

11
8
6

7
Fig. 1644
8. Bend back the chamfering on the ring nut (12).

30-364
Method of intervention
9. Fit an open-ended wrench on the ring nut (12) and turn the flange shaft (3)
with a suitable wrench (13) to undo the ring nut.
13

12

Fig. 1645
10. Using a suitable tool (14) tightened into the hole on the external flange shaft
3
(3) and a hammer, partially extract the inner flange shaft (15).
15

14

Fig. 1646
11. Remove the spacer (16) and the gear (17), complete with bush (18), in the
order given.
17
18
16

Fig. 1647
12. Remove the sliding sleeve (19) and the hub (20).

19
20

Fig. 1648

30-365
 Method of intervention
13. Remove the gear (21), retrieving the two inner roller bearing cages.
21

Fig. 1649
14. Remove the retainer ring (22).

22

Fig. 1650
15. Remove the spacer (23).
16. Use the press to remove the bearing (24).

23

24

Fig. 1651
17. Remove the bearing (25) from the transmission casing.

25

Fig. 1652

30-366
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (24) with the retainer ring facing towards the rear of the inner PTO flange shaft.
3. Apply a drop of Loctite 270 to the thread of the ring nut (12), tighten to a torque of 90 ±1 Nm, then chamfer the nut.
4. Apply a drop of Loctite 243 to the thread of the grub screw (5) fastening the engagement fork, and tighten to a torque of 8.4
Nm.
5. Tighten the nuts (1) to a torque of 40.4 Nm.
Completion
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584

30.10.56 - Disassembling PTO final flange shaft - 4 speed version (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001)
Preliminary operations
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.45 - PTO output shaft - 4 s... - page 30-334
PTO final flange shaft section

15
11

13

12 17
18

1
14 16
10 19
20

Fig. 1653

30-367
 Method of intervention
Removal
1. Versions with coated PTO flange shaft:
Fit the external flange shaft (1), if removed previously, and tighten the nuts
(2).
2

Fig. 1654
2. Undo the grub screw (3) fastening the fork.
3

Fig. 1655
3. Undo the screw (4) and remove the bracket (5).

Fig. 1656
4. Remove the engagement shaft (6) and remove the fork (7) with the relative shoes (8), retrieving the coupling key.
5. Remove and replace the O-ring (9).
7

8
6

Fig. 1657
6. Bend back the chamfering on the ring nut (10).

30-368
Method of intervention
7. Fit an open-ended wrench on the ring nut (10) and turn the flange shaft (1)
with tool (A) 5.9035.545.0) to undo the ring nut. A

10

Fig. 1658
8. Fit a suitable tool (B) onto the flange shaft (1).
9. Extract the flange shaft (1) partially, tapping the tool (B) in the direction
indicated (arrow) with a mallet.
1

Fig. 1659
10. Remove the gear (11) complete with bush (12).
12 11

Fig. 1660
11. Remove the sliding sleeve (13) and the hub (14).
13
14

Fig. 1661

30-369
 Method of intervention
12. Remove the double gear (15), retrieving the two inner roller bearing cages
(16).
15
16

Fig. 1662
13. Remove circlip (17).
17

Fig. 1663
14. Remove the spacer (18).
15. Use the press to remove the bearing (19).

18

19

Fig. 1664
16. Remove bearing (20) from the transmission casing.

20

Fig. 1665

30-370
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the inner bearing race (19) to 80 °C, and fit onto the PTO flange shaft.
3. Fit the spacer (18) with the grooves (arrow) facing upwards.

18

19

Fig. 1666
4. Apply a drop of Loctite 270 to the thread of the ring nut (10), tighten to a torque of 90 ±1 Nm, then chamfer the nut.
5. Apply a drop of Loctite 243 to the thread of the grub screw (3) fastening the engagement fork, and tighten to a torque of 8.4
Nm.
6. Adjust the endfloat of the selector rod (6) as follows.
7. Tighten the grub screw (22) until there is no endfloat.
8. Undo the grub screw (22) by ¼ turn, then lock in this position by tightening
the check nut (23).

23

22

Fig. 1667

Completion
l See para. 30.10.45 - PTO output shaft - 4 s... - page 30-334
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597

30.10.57 - Disassembling PTO final flange shaft - 4 speed version (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.46 - PTO output shaft - 4 s... - page 30-337
PTO final flange shaft section

30-371
 Method of intervention

16
11

14

13 12 18
19

1
15 17
10 20
20

Fig. 1668

Removal
1. Versions with coated PTO flange shaft:
Fit the external flange shaft (1), if removed previously, and tighten the nuts
(2).
2

Fig. 1669
2. Undo the grub screw (3) fastening the fork.
3

Fig. 1670

30-372
Method of intervention
3. Undo the screw (4) and remove the bracket (5).

Fig. 1671
4. Remove the engagement shaft (6) and remove the fork (7) with the relative shoes (8), retrieving the coupling key.
5. Remove and replace the O-ring (9).
7

8
6

Fig. 1672
6. Bend back the chamfering on the ring nut (10).
7. Fit an open-ended wrench on the ring nut (10) and turn the flange shaft (1)
with tool (A) 5.9035.545.0) to undo the ring nut. A

10

Fig. 1673
8. Fit a suitable tool (B) onto the flange shaft (1).
9. Extract the flange shaft (1) partially, tapping the tool (B) in the direction
indicated (arrow) with a mallet.
1

Fig. 1674

30-373
 Method of intervention
10. Remove the gear (11) complete with bush (12) and spacer (13).
12 11

13

Fig. 1675
11. Remove the sliding sleeve (14) and the hub (15).
14
15

Fig. 1676
12. Remove the double gear (16), retrieving the two inner roller bearing cages
(17).
16
17

Fig. 1677
13. Remove circlip (18).
18

Fig. 1678
14. Remove the spacer (19).

30-374
Method of intervention
15. Use the press to remove the bearing (20).

19

20

Fig. 1679
16. Remove bearing (21) from the transmission casing.

21

Fig. 1680

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the inner bearing race (20) to 80 °C, and fit onto the PTO flange shaft.
3. Fit the spacer (19) with the grooves (arrow) facing upwards.

19

20

Fig. 1681
4. Apply a drop of Loctite 270 to the thread of the ring nut (10), tighten to a torque of 90 ±1 Nm, then chamfer the nut.
5. Apply a drop of Loctite 243 to the thread of the grub screw (3) fastening the engagement fork, and tighten to a torque of 8.4
Nm.
6. Adjust the endfloat of the selector rod (6) as follows.
7. Tighten the grub screw (22) until there is no endfloat.

30-375
 Method of intervention
8. Undo the grub screw (22) by ¼ turn, then lock in this position by tightening
the check nut (23).

23

22

Fig. 1682

Completion
l See para. 30.10.46 - PTO output shaft - 4 s... - page 30-337
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597

30.10.58 - Removing the rear pinion - 2-range version (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.5 - Rear differential (509... - page 30-490
Removal
1. Rear pinion section 14 15

10 12 13
11
6
9

7 17
16

Fig. 1683

30-376
Method of intervention
2. Unscrew and remove the oil union (1).

Fig. 1684
3. Unscrew the bushes (2).

Fig. 1685
4. Remove the selector rods (3), taking care not to drop the shoes (4) into the
transmission casing.

4
3
Fig. 1686
5. Remove circlip (5).
6. Partially remove the pinion (6) with a suitable extractor tool.

Fig. 1687
7. Bend back the chamfering on the ring nut (7).
8. Apply a suitable wrench to the ring nut (7) and hold in position.

30-377
 Method of intervention
9. Fit a suitable bush on the flange shaft (8) of the ground speed PTO and
loosen the ring nut (7) by turning the flange shaft (8) in the direction indi-
cated by the arrow.
Important
If the tractor is not equipped with a ground speed PTO, re- 8

move the cover and fit tool 5.9030.988.0, engaging with the
gear on the dual traction shaft.

Fig. 1688
10. Remove circlip (9).
11. Continue extracting the pinion (6) and remove the sleeve (10).

10

Fig. 1689
12. Remove the gear (11), complete with the lubrication union (12), from the
shaft.

12

11

Fig. 1690
13. Continue extracting the pinion and remove the ring nut (7), the gear (14)
and the inner race of the tapered roller bearing (13).
13
14

Fig. 1691

30-378
Method of intervention
14. Remove the pinion (6) from the transmission casing, with the second inner
race of the tapered roller bearing. 6

Fig. 1692
15. Using a bush and a suitable mallet, remove the outer race of the roller bear-
ing (15) and the calibrated shims from the transmission casing.

15

Fig. 1693
16. Remove spacer (16).
17. Use a press to push out the inner race (17) of the roller bearing.
16

17

Fig. 1694

30-379
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (18) on the shaft, heating the inner races to 110°C.
Note
After installation, lubricate the bearing races and rotate the
outer bearing rod by a few turns to seat the rollers correctly.
18

Fig. 1695
3. When installing the bearing (11) and the lubrication union (12), ensure that
the grooves in the two parts are oriented in the same direction as the holes
in the pinion (6) to allow oil to flow in an unobstructed path (arrow).
11
6

12

Fig. 1696
4. Fit the lubrication union (12) on the gear (11), with the nozzle turned to-
wards the PTO clutch housing as shown in the figure.

12

11

Fig. 1697
5. Replace the ring nut (7).
6. To adjust the bevel gear set
See para. 30.10.64 - Adjustment of the diff... - page 30-415
7. Tighten the ring nut (7) using a suitable wrench applied to the ground speed PTO flange shaft (8).
Important
If the tractor is not equipped with a ground speed PTO, remove the cover and fit tool 5.9030.988.0, engaging
with the gear on the dual traction shaft.

Note
Apply a drop of Loctite 270 to the thread of the ring nut (7).

8. Fit the torque wrench to the ring nut (7) and tighten to a torque of 460±20 Nm.
9. Alternatively, apply the torque wrench to the flange shaft (8) and tighten the ring nut (7) to a torque of 390±17 Nm.

30-380
Method of intervention
10. Chamfer the ring nut (7) with a punch.

Fig. 1698

Completion
l See para. 30.11.5 - Rear differential (509... - page 30-490
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.59 - Removing the rear pinion - 2-range version (5110 C -> ZKDY440200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.6 - Rear differential (511... - page 30-493
Removal
1. Rear pinion section 14 15

10 12 13
11
6
9

7 17
16

Fig. 1699

30-381
 Method of intervention
2. Unscrew and remove the oil union (1).

Fig. 1700
3. Unscrew the bushes (2).

Fig. 1701
4. Remove the selector rods (3), taking care not to drop the shoes (4) into the
transmission casing.

4
3
Fig. 1702
5. Remove circlip (5).
6. Partially remove the pinion (6) with a suitable extractor tool.

Fig. 1703
7. Bend back the chamfering on the ring nut (7).
8. Apply a suitable wrench to the ring nut (7) and hold in position.

30-382
Method of intervention
9. Fit a suitable bush on the flange shaft (8) of the ground speed PTO and
loosen the ring nut (7) by turning the flange shaft (8) in the direction indi-
cated by the arrow.
Important
If the tractor is not equipped with a ground speed PTO, re- 8

move the cover and fit tool 5.9030.988.0, engaging with the
gear on the dual traction shaft.

Fig. 1704
10. Remove circlip (9).
11. Continue extracting the pinion (6) and remove the sleeve (10).

10

Fig. 1705
12. Remove the gear (11), complete with the lubrication union (12), from the
shaft.

12

11

Fig. 1706
13. Continue extracting the pinion and remove the ring nut (7), the gear (14)
and the inner race of the tapered roller bearing (13).
13
14

Fig. 1707

30-383
 Method of intervention
14. Remove the pinion (6) from the transmission casing, with the second inner
race of the tapered roller bearing. 6

Fig. 1708
15. Using a bush and a suitable mallet, remove the outer race of the roller bear-
ing (15) and the calibrated shims from the transmission casing.

15

Fig. 1709
16. Remove spacer (16).
17. Use a press to push out the inner race (17) of the roller bearing.
16

17

Fig. 1710

30-384
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (18) on the shaft, heating the inner races to 110°C.
Note
After installation, lubricate the bearing races and rotate the
outer bearing rod by a few turns to seat the rollers correctly.
18

Fig. 1711
3. When installing the bearing (11) and the lubrication union (12), ensure that
the grooves in the two parts are oriented in the same direction as the holes
in the pinion (6) to allow oil to flow in an unobstructed path (arrow).
11
6

12

Fig. 1712
4. Fit the lubrication union (12) on the gear (11), with the nozzle turned to-
wards the PTO clutch housing as shown in the figure.

12

11

Fig. 1713
5. Replace the ring nut (7).
6. To adjust the bevel gear set
See para. 30.10.65 - Adjustment of the diff... - page 30-424
7. Tighten the ring nut (7) using a suitable wrench applied to the ground speed PTO flange shaft (8).
Important
If the tractor is not equipped with a ground speed PTO, remove the cover and fit tool 5.9030.988.0, engaging
with the gear on the dual traction shaft.

Note
Apply a drop of Loctite 270 to the thread of the ring nut (7).

8. Fit the torque wrench to the ring nut (7) and tighten to a torque of 460±20 Nm.
9. Alternatively, apply the torque wrench to the flange shaft (8) and tighten the ring nut (7) to a torque of 390±17 Nm.

30-385
 Method of intervention
10. Chamfer the ring nut (7) with a punch.

Fig. 1714

Completion
l See para. 30.11.6 - Rear differential (511... - page 30-493
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.60 - Removing the rear pinion - 2-range version (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.7 - Rear differential (510... - page 30-496
Removal
1. Rear pinion section 14 15

10 12 13
11
6
9

7 17
16

Fig. 1715

30-386
Method of intervention
2. Unscrew and remove the oil union (1).

Fig. 1716
3. Unscrew the bushes (2).

Fig. 1717
4. Remove the selector rods (3), taking care not to drop the shoes (4) into the
transmission casing.

4
3
Fig. 1718
5. Remove circlip (5).
6. Partially remove the pinion (6) with a suitable extractor tool.

Fig. 1719
7. Bend back the chamfering on the ring nut (7).
8. Apply a suitable wrench to the ring nut (7) and hold in position.

30-387
 Method of intervention
9. Fit a suitable bush on the flange shaft (8) of the ground speed PTO and
loosen the ring nut (7) by turning the flange shaft (8) in the direction indi-
cated by the arrow.
Important
If the tractor is not equipped with a ground speed PTO, re- 8

move the cover and fit tool 5.9030.988.0, engaging with the
gear on the dual traction shaft.

Fig. 1720
10. Remove circlip (9).
11. Continue extracting the pinion (6) and remove the sleeve (10).

10

Fig. 1721
12. Remove the gear (11), complete with the lubrication union (12), from the
shaft.

12

11

Fig. 1722
13. Continue extracting the pinion and remove the ring nut (7), the gear (14)
and the inner race of the tapered roller bearing (13).
13
14

Fig. 1723

30-388
Method of intervention
14. Remove the pinion (6) from the transmission casing, with the second inner
race of the tapered roller bearing. 6

Fig. 1724
15. Using a bush and a suitable mallet, remove the outer race of the roller bear-
ing (15) and the calibrated shims from the transmission casing.

15

Fig. 1725
16. Remove spacer (16).
17. Use a press to push out the inner race (17) of the roller bearing.
16

17

Fig. 1726

30-389
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (18) on the shaft, heating the inner races to 110°C.
Note
After installation, lubricate the bearing races and rotate the
outer bearing rod by a few turns to seat the rollers correctly.
18

Fig. 1727
3. When installing the bearing (11) and the lubrication union (12), ensure that
the grooves in the two parts are oriented in the same direction as the holes
in the pinion (6) to allow oil to flow in an unobstructed path (arrow).
11
6

12

Fig. 1728
4. Fit the lubrication union (12) on the gear (11), with the nozzle turned to-
wards the PTO clutch housing as shown in the figure.

12

11

Fig. 1729
5. Replace the ring nut (7).
6. To adjust the bevel gear set
See para. 30.10.65 - Adjustment of the diff... - page 30-424
7. Tighten the ring nut (7) using a suitable wrench applied to the ground speed PTO flange shaft (8).
Important
If the tractor is not equipped with a ground speed PTO, remove the cover and fit tool 5.9030.988.0, engaging
with the gear on the dual traction shaft.

Note
Apply a drop of Loctite 270 to the thread of the ring nut (7).

8. Fit the torque wrench to the ring nut (7) and tighten to a torque of 460±20 Nm.
9. Alternatively, apply the torque wrench to the flange shaft (8) and tighten the ring nut (7) to a torque of 390±17 Nm.

30-390
Method of intervention
10. Chamfer the ring nut (7) with a punch.

Fig. 1730

Completion
l See para. 30.11.7 - Rear differential (510... - page 30-496
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.61 - Removing the rear pinion - 4-range version (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.5 - Rear differential (509... - page 30-490
Rear pinion section

30-391
 Method of intervention

17 13 14 3
16
8

5 4

6
11

10 18 15

Fig. 1731

Removal
1. Unscrew and remove the oil union (1).

Fig. 1732
2. Unscrew the bushes (2).

Fig. 1733

30-392
Method of intervention
3. Remove the pinion bearing retainer circlip (3).

Fig. 1734
4. Using an extractor tool applied to the shank of the pinion, push the pinion
(4) towards the rear side of the transmission.

Fig. 1735
5. Remove the circlip (5).

Fig. 1736
6. Remove the splined connection (6) from the pinion.
7. Retrieve the shoes (7) from the range selector rod.
8. Remove the sleeve (8).

7
7
6

Fig. 1737

30-393
 Method of intervention
9. Remove the range selector rod (9).

Fig. 1738
10. Move the gears (10) towards the front of the transmission to uncover the ring nut (11).
11. Bend back the chamfering on the ring nut (11).
10

11

Fig. 1739
12. Fit a 60 mm wrench (A) on the ring nut (11).
A

11

Fig. 1740
13. Engage tool 5.9035.552.0 (B) with the splines on the pinion (4).

4
B

Fig. 1741

30-394
Method of intervention
14. Undo the ring nut as shown in the figure (arrows).
A

Fig. 1742
15. Alternative procedure for versions with ground speed PTO:
Fit tool 5.9035.545.0 on the flange shaft (12) of the ground speed PTO and
loosen the ring nut (11) by turning the flange shaft (12) of the ground speed
PTO in the direction indicated by the arrow.
12

11

Fig. 1743
16. Remove the pinion (4) from its seat, complete with one of the two tapered
roller rings and the relative inner bearing race.

Fig. 1744
17. Retrieve the double gear (10)
10

Fig. 1745

30-395
 Method of intervention
18. Retrieve the ring nut (11) and the gear (13).

11 13

Fig. 1746
19. Using a bush and a suitable mallet, remove the outer race of the bearing
(14), together with the remaining ring of tapered rollers and the relative in-
ner race. 15

Note
Retrieve the spacer rings (15) used to adjust the bevel gear 14

set.

Fig. 1747
20. Remove the circlip (16) and remove the lubrication union (17).
21. Remove and replace the “Vespel” seals (18).
16

17

18

Fig. 1748
22. Remove spacer (19).
23. Use a press to push out the inner race (20) of the tapered roller bearing.
19

20

Fig. 1749

30-396
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (14) on the shaft, heating the inner races to 110°C.
Note
After installation, lubricate the bearing races and rotate the
outer bearing race by a few turns to seat the rollers correctly.
14

Fig. 1750
3. Fit the lubrication union (17) on the gear (10), with the nozzle turned facing
upwards. After fitting the PTO clutch (21), the union must be in the position
shown in the figure.
21

17

10

Fig. 1751
4. Replace the ring nut (11).

11

Fig. 1752
5. To adjust the bevel gear set
See para. 30.10.64 - Adjustment of the diff... - page 30-415
6. Engage tool 5.9035.552.0 (B) with the splines on the pinion.
7. Note
A
Apply a drop of Loctite 270 to the thread of the ring nut (11).

Tighten the ring nut (11), using a torque wrench applied to tool (B), to a
torque of 460±20 Nm. B

Fig. 1753

30-397
 Method of intervention
8. Important
On tractors with ground speed PTO, fit tool 5.9035.545.0 onto the ground speed PTO output flange shaft.

Note
Apply a drop of Loctite 270 to the thread of the ring nut (11).

9. Apply the torque wrench to the flange shaft (12) and tighten the ring nut (11) to a torque of 390±17 Nm.
10. Chamfer the ring nut (11) with a punch.

12

11

Fig. 1754
11. Replace the copper gaskets under the bushes (2).
Note
Apply a drop of Loctite 554 to the threads of the bushes (2).

Fig. 1755
12. Replace the O-rings (22) and tighten the oil union (1).
Note
Apply a drop of Loctite 554 to the threads of the bushes (1).

22

Fig. 1756

30-398
Method of intervention
Completion
l See para. 30.11.5 - Rear differential (509... - page 30-490
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.62 - Removing the rear pinion - 4-range version (5110 C -> ZKDY440200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.6 - Rear differential (511... - page 30-493
Rear pinion section

30-399
 Method of intervention

17 13 14 3
16
8

5 4

6
11

10 18 15

Fig. 1757

Removal
1. Unscrew and remove the oil union (1).

Fig. 1758
2. Unscrew the bushes (2).

Fig. 1759

30-400
Method of intervention
3. Remove the pinion bearing retainer circlip (3).

Fig. 1760
4. Using an extractor tool applied to the shank of the pinion, push the pinion
(4) towards the rear side of the transmission.

Fig. 1761
5. Remove the circlip (5).

Fig. 1762
6. Remove the splined connection (6) from the pinion.
7. Retrieve the shoes (7) from the range selector rod.
8. Remove the sleeve (8).

7
7
6

Fig. 1763

30-401
 Method of intervention
9. Remove the range selector rod (9).

Fig. 1764
10. Move the gears (10) towards the front of the transmission to uncover the ring nut (11).
11. Bend back the chamfering on the ring nut (11).
10

11

Fig. 1765
12. Fit a 60 mm wrench (A) on the ring nut (11).
A

11

Fig. 1766
13. Engage tool 5.9035.552.0 (B) with the splines on the pinion (4).

4
B

Fig. 1767

30-402
Method of intervention
14. Undo the ring nut as shown in the figure (arrows).
A

Fig. 1768
15. Alternative procedure for versions with ground speed PTO:
Fit tool 5.9035.545.0 on the flange shaft (12) of the ground speed PTO and
loosen the ring nut (11) by turning the flange shaft (12) of the ground speed
PTO in the direction indicated by the arrow.
12

11

Fig. 1769
16. Remove the pinion (4) from its seat, complete with one of the two tapered
roller rings and the relative inner bearing race.

Fig. 1770
17. Retrieve the double gear (10)
10

Fig. 1771

30-403
 Method of intervention
18. Retrieve the ring nut (11) and the gear (13).

11 13

Fig. 1772
19. Using a bush and a suitable mallet, remove the outer race of the bearing
(14), together with the remaining ring of tapered rollers and the relative in-
ner race. 15

Note
Retrieve the spacer rings (15) used to adjust the bevel gear 14

set.

Fig. 1773
20. Remove the circlip (16) and remove the lubrication union (17).
21. Remove and replace the “Vespel” seals (18).
16

17

18

Fig. 1774
22. Remove spacer (19).
23. Use a press to push out the inner race (20) of the tapered roller bearing.
19

20

Fig. 1775

30-404
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (14) on the shaft, heating the inner races to 110°C.
Note
After installation, lubricate the bearing races and rotate the
outer bearing race by a few turns to seat the rollers correctly.
14

Fig. 1776
3. Fit the lubrication union (17) on the gear (10), with the nozzle turned facing
upwards. After fitting the PTO clutch (21), the union must be in the position
shown in the figure.
21

17

10

Fig. 1777
4. Replace the ring nut (11).

11

Fig. 1778
5. To adjust the bevel gear set
See para. 30.10.65 - Adjustment of the diff... - page 30-424
6. Engage tool 5.9035.552.0 (B) with the splines on the pinion.
7. Note
A
Apply a drop of Loctite 270 to the thread of the ring nut (11).

Tighten the ring nut (11), using a torque wrench applied to tool (B), to a
torque of 460±20 Nm. B

Fig. 1779

30-405
 Method of intervention
8. Important
On tractors with ground speed PTO, fit tool 5.9035.545.0 onto the ground speed PTO output flange shaft.

Note
Apply a drop of Loctite 270 to the thread of the ring nut (11).

9. Apply the torque wrench to the flange shaft (12) and tighten the ring nut (11) to a torque of 390±17 Nm.
10. Chamfer the ring nut (11) with a punch.

12

11

Fig. 1780
11. Replace the copper gaskets under the bushes (2).
Note
Apply a drop of Loctite 554 to the threads of the bushes (2).

Fig. 1781
12. Replace the O-rings (22) and tighten the oil union (1).
Note
Apply a drop of Loctite 554 to the threads of the bushes (1).

22

Fig. 1782

30-406
Method of intervention
Completion
l See para. 30.11.6 - Rear differential (511... - page 30-493
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.63 - Removing the rear pinion - 4-range version (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
or
See para. 30.10.32 - Gearbox/HML assembly ... - page 30-295
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.7 - Rear differential (510... - page 30-496
Rear pinion section

30-407
 Method of intervention

17 13 14 3
16
8

5 4

6
11

10 18 15

Fig. 1783

Removal
1. Unscrew and remove the oil union (1).

Fig. 1784
2. Unscrew the bushes (2).

Fig. 1785

30-408
Method of intervention
3. Remove the pinion bearing retainer circlip (3).

Fig. 1786
4. Using an extractor tool applied to the shank of the pinion, push the pinion
(4) towards the rear side of the transmission.

Fig. 1787
5. Remove the circlip (5).

Fig. 1788
6. Remove the splined connection (6) from the pinion.
7. Retrieve the shoes (7) from the range selector rod.
8. Remove the sleeve (8).

7
7
6

Fig. 1789

30-409
 Method of intervention
9. Remove the range selector rod (9).

Fig. 1790
10. Move the gears (10) towards the front of the transmission to uncover the ring nut (11).
11. Bend back the chamfering on the ring nut (11).
10

11

Fig. 1791
12. Fit a 60 mm wrench (A) on the ring nut (11).
A

11

Fig. 1792
13. Engage tool 5.9035.552.0 (B) with the splines on the pinion (4).

4
B

Fig. 1793

30-410
Method of intervention
14. Undo the ring nut as shown in the figure (arrows).
A

Fig. 1794
15. Alternative procedure for versions with ground speed PTO:
Fit tool 5.9035.545.0 on the flange shaft (12) of the ground speed PTO and
loosen the ring nut (11) by turning the flange shaft (12) of the ground speed
PTO in the direction indicated by the arrow.
12

11

Fig. 1795
16. Remove the pinion (4) from its seat, complete with one of the two tapered
roller rings and the relative inner bearing race.

Fig. 1796
17. Retrieve the double gear (10)
10

Fig. 1797

30-411
 Method of intervention
18. Retrieve the ring nut (11) and the gear (13).

11 13

Fig. 1798
19. Using a bush and a suitable mallet, remove the outer race of the bearing
(14), together with the remaining ring of tapered rollers and the relative in-
ner race. 15

Note
Retrieve the spacer rings (15) used to adjust the bevel gear 14

set.

Fig. 1799
20. Remove the circlip (16) and remove the lubrication union (17).
21. Remove and replace the “Vespel” seals (18).
16

17

18

Fig. 1800
22. Remove spacer (19).
23. Use a press to push out the inner race (20) of the tapered roller bearing.
19

20

Fig. 1801

30-412
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the bearing (14) on the shaft, heating the inner races to 110°C.
Note
After installation, lubricate the bearing races and rotate the
outer bearing race by a few turns to seat the rollers correctly.
14

Fig. 1802
3. Fit the lubrication union (17) on the gear (10), with the nozzle turned facing
upwards. After fitting the PTO clutch (21), the union must be in the position
shown in the figure.
21

17

10

Fig. 1803
4. Replace the ring nut (11).

11

Fig. 1804
5. To adjust the bevel gear set
See para. 30.10.65 - Adjustment of the diff... - page 30-424
6. Engage tool 5.9035.552.0 (B) with the splines on the pinion.
7. Note
A
Apply a drop of Loctite 270 to the thread of the ring nut (11).

Tighten the ring nut (11), using a torque wrench applied to tool (B), to a
torque of 460±20 Nm. B

Fig. 1805

30-413
 Method of intervention
8. Important
On tractors with ground speed PTO, fit tool 5.9035.545.0 onto the ground speed PTO output flange shaft.

Note
Apply a drop of Loctite 270 to the thread of the ring nut (11).

9. Apply the torque wrench to the flange shaft (12) and tighten the ring nut (11) to a torque of 390±17 Nm.
10. Chamfer the ring nut (11) with a punch.

12

11

Fig. 1806
11. Replace the copper gaskets under the bushes (2).
Note
Apply a drop of Loctite 554 to the threads of the bushes (2).

Fig. 1807
12. Replace the O-rings (22) and tighten the oil union (1).
Note
Apply a drop of Loctite 554 to the threads of the bushes (1).

22

Fig. 1808

30-414
Method of intervention
Completion
l See para. 30.11.7 - Rear differential (510... - page 30-496
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30-415
 Method of intervention
30.10.64 - Adjustment of the differential - Bevel gear set (5090 C -> ZKDY360200TD10001,
5100 C -> ZKDY400200TD10001)
Differential - Bevel gear set

3
2
A

12
13
1

8
5

7
4

11 11

10

Fig. 1809

30-416
Method of intervention
Preparations for adjustments
1. m All the procedures described in this chapter must be carried out following renewal of the transmission casing, differen-
tial support flanges, bevel gear set, differential case or the support bearings of the pinion and differential.
2. Install bearing assembly (2) on pinion shaft (1).
IMPORTANT 1
When handling bearing (2), take care not to invert the inner
races.
2

IMPORTANT
During assembly of bearing (2) on pinion shaft (1), rotate the
outer race to help seat the rollers.

IMPORTANT Fig. 1810

Lubricate the bearing with transmission oil.

3. Install a service bush “A” (Ø 65 x Ø 50 x 20) on the pinion shaft (1) and
provisionally tighten the new ring nut (3) with wrench 5.9030.984.0).
1

Fig. 1811
4. Remove the outer race of bearing (5) and relative shims (6) from flange (4)
on the crown wheel side. 5

IMPORTANT
Note the thickness “S” of the shim pack (6) (e.g. 0.80 mm). 6
4

Fig. 1812
5. Remove the outer race of bearing (8) and shims (9) from flange (7) on the
opposite side to the crown wheel. 8

9
7

Fig. 1813

30-417
 Method of intervention
6. Heat bearing inner race (5) to 80 °C and install it on the crown wheel side 5
of differential (10).
6
IMPORTANT
Check that the bearing seats against the shoulder on the 5
differential.

Install the outer race of the bearing (5) in the crown wheel side flange (4),
with a shim pack (6) measuring approximately 0.5 mm less than the mea-
10
sured thickness “S”.
4
For example, if the thickness S measured is 0.80 mm, fit a shim pack (6)
measuring 0.30 mm in thickness. Fig. 1814

7. Heat the inner race of bearing (8) to approx. 80 °C and install on differential
(10) on the side opposite to the crown wheel.
9
IMPORTANT
Check that bearing (8) seats against the shoulder on the 8 8
differential.

Install the outer race of bearing (8) and a 1.00 mm thick shim pack (9) on
flange (7) on the opposite side to the crown wheel.

10

Fig. 1815

Adjustment of the differential bearings preload

1. Locate complete differential (10) in the transmission casing.

10

Fig. 1816
2. Install the flanges (4) and (7) and secure in position by tightening the
screws (11) to a torque of 32 - 40 Nm.
Note
While tightening screws (11), rotate the differential unit to
help seat the bearings. 11

Note
Lubricate the bearings with transmission oil.

Fig. 1817

30-418
Method of intervention
3. Place a dial gauge with magnetic base (B) on the flat surface of the differen-
tial casing (12), and set it to zero on the end face of the differential while si-
12
multaneously forcing the differential towards the opposite side with a lever.
Force the differential axially towards the crown wheel side and measure
endfloat G.
IMPORTANT
If the endfloat is zero, adjust the shim pack (9) on the side
opposite the crown wheel to 0.70 mm and repeat the proce- B
dure to measure the endfloat G.

Fig. 1818
4. Add 0.10 mm to the measured endfloat value G and round up to the nearest 0.10 mm to determine the shim thickness to be
added under the outer ring of bearing (8) on the opposite side to the crown wheel.
5. For example, if the value G measured is 0.28 mm, add 0.10 mm to obtain a value of 0.38 mm.
Rounding this value up to the nearest 0.05 mm gives the real value of the shims to be added, in this case 0.40 mm.
6. Undo the screws (11) of both flanges, leaving one screw in its seat for
safety.

11

Fig. 1819
7. Using a suitable punch in soft material, separate the differential carrier
flanges (4) and (7) from the transmission casing. 7

Fig. 1820
8. Undo the last screw (11) and remove the flanges (4 and 7).

Fig. 1821

30-419
 Method of intervention
9. Attach the differential (10) to a hoist and remove.

10

Fig. 1822

Adjustment of pinion position

1. Note the value E stamped on the crest of one of the teeth of pinion (1), in
this example: + 0.15 mm
1

Fig. 1823
2. Install the pinion (1), without the shims, in the transmission casing.
1

Fig. 1824
3. Locate complete differential (10) in the transmission casing

10

Fig. 1825

30-420
Method of intervention
4. Install the flanges (4) and (7) and secure in position by tightening the
screws (11) to a torque of 32 - 40 Nm.
Note
While tightening screws (11), check for the presence of
clearance between the differential and pinion (1). If the dif- 11

ferential is seated against the pinion, adjust the shim packs

installed under the outer races of the bearings so as to re-
duce the thickness of the pack on the crown wheel side and
increase the thickness of the pack on the opposite side by
the same amount.
Fig. 1826
5. Use a feeler gauge to measure the distance D between the end face of 1
pinion (1) and the 174 mm diameter section of the differential (10) (in this
example 2.85 mm).
Calculate dimension T by adding the value E previously read on the tooth
of pinion (1) to the design value of 2.00 mm. D
If the value E is positive, as in the case shown in the figure, add it to the
design value of 2.00 mm:
m T= 2.00 + E, therefore T= 2.00 + 0.15 = 2.15 mm 10

If E is negative, subtract it from the design value of 2.00 mm

m T= 2.00 - E, therefore T= 2.00 - 0.15 = 1.85 mm
Fig. 1827
If the measured value D differs from the calculated value T, calculate the
difference between D and T. The resulting value P is the shim thickness to
be installed under bearing (2) of pinion (1).
Formula: P = D - T
m which in our example gives: P = 2.85 - 2.15 = 0.70 mm
6. Undo the screws (11) of both flanges, leaving one screw in its seat for
safety.

11

Fig. 1828
7. Using a suitable punch in soft material, separate the differential carrier
flanges (4) and (7) from the transmission casing. 7

Fig. 1829

30-421
 Method of intervention
8. Undo the last screw (11) and remove the flanges (4 and 7).

Fig. 1830
9. Attach the differential (10) to a hoist and remove.

10

Fig. 1831
10. Using a puller, remove the complete pinion (1) from the transmission cas-
ing. 1 1
Remove the ring nut (3) and the service bush (A) from the pinion (1).
3
A

Fig. 1832
11. Measure the dimension R of the shoulder of the bearing (2). In this ex-
ample, R = 4.96 mm.
R
Install the pinion (1) and the shim pack of the thickness P calculated previ-
ously, following the procedure for removal in reverse order. 2

Fig. 1833

30-422
Method of intervention
12. Secure pinion (1) in position with suitable circlip (13) selected from the
available sizes.
Select circlip (13) by applying the following formula:
Circlip thickness:
mFixed dimension K = 9.5 mm 1
Shim thickness = P
Dimension R = 4.96 mm (permissible range: 4.90-5.00mm)
13
Formula:
m A = K - P - R which in this example gives:
m A = 9.5 - 0.7 - 4.96 = 3.84 mm
The circlip to be used is therefore the one with thickness 3.80 mm. Fig. 1834

Note
Circlip (13) installed should in any case ensure pinion end-
float of less than 0.1 mm.

Adjustment of pinion and crown wheel backlash

1. Locate complete differential (10) in the transmission casing.

10

Fig. 1835
2. Install the flanges (4) and (7) and secure in position by tightening the
screws (11) to a torque of 32 - 40 Nm.
Note
While tightening screws (11), rotate differential assembly
(10) to help seat the bearings. 11

Note
Lubricate the bearings with transmission oil.

Fig. 1836
3. Apply a dial gauge with magnetic base (F), with the probe perpendicular
B
to the tooth flank on the external diameter of the crown wheel. Preload the
gauge by approx. 3 mm and measure the backlash Z between the pinion
and crown wheel teeth by turning the differential (3) back and forth in both
directions.
Take four measurements 90° apart and calculate the average; the backlash
should normally be 0.12 to 0.18 mm.

Fig. 1837

30-423
 Method of intervention
4. If the backlash Z is less than the minimum value, remove a shim from shim pack (6) (crown wheel side) and add the same
shim to shim pack (9) (side opposite to crown wheel).
If the backlash Z is greater than the maximum value, remove a shim from shim pack (9) (side opposite to crown wheel) and
add the same shim to shim pack (6) (crown wheel side).
IMPORTANT
The sum total thickness of shim packs (6) and (9) should not be different from the calculated value.

Check that the backlash Z is within the range from 0.12 to 0.18 mm.
5. If not, swap additional shims from one side to the other as described above
until the correct backlash is obtained.

6 9

Fig. 1838

30.10.65 - Adjustment of the differential - Bevel gear set (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)
Differential - Bevel gear set
Differential section - Bevel gear set

30-424
Method of intervention

3
2
A

12
13
1

8
5

7
4

11 11

10

Fig. 1839

Preparations for adjustments

1. m All the procedures described in this chapter must be carried out following renewal of the transmission casing, differen-
tial support flanges, bevel gear set, differential case or the support bearings of the pinion and differential.

30-425
 Method of intervention
2. Install bearing assembly (2) on pinion shaft (1).
IMPORTANT 1
When handling bearing (2), take care not to invert the inner
races.
2

IMPORTANT
During assembly of bearing (2) on pinion shaft (1), rotate the
outer race to help seat the rollers.

IMPORTANT Fig. 1840

Lubricate the bearing with transmission oil.

3. Install a service bush “A” (Ø 65 x Ø 50 x 20) on the pinion shaft (1) and
provisionally tighten the new ring nut (3) with wrench 5.9030.984.0).
1

Fig. 1841
4. Remove the outer race of bearing (5) and relative shims (6) from flange (4)
on the crown wheel side. 5

IMPORTANT
Note the thickness “S” of the shim pack (6) (e.g. 0.80 mm). 6
4

Fig. 1842
5. Remove the outer race of bearing (8) and shims (9) from flange (7) on the
opposite side to the crown wheel. 8

9
7

Fig. 1843

30-426
Method of intervention
6. Heat bearing inner race (5) to 80 °C and install it on the crown wheel side 5
of differential (10).
6
IMPORTANT
Check that the bearing seats against the shoulder on the 5
differential.

Install the outer race of the bearing (5) in the crown wheel side flange (4),
with a shim pack (6) measuring approximately 0.5 mm less than the mea-
10
sured thickness “S”.
4
For example, if the thickness S measured is 0.80 mm, fit a shim pack (6)
measuring 0.30 mm in thickness. Fig. 1844

7. Heat the inner race of bearing (8) to approx. 80 °C and install on differential
(10) on the side opposite to the crown wheel.
9
IMPORTANT
Check that bearing (8) seats against the shoulder on the 8 8
differential.

Install the outer race of bearing (8) and a 1.00 mm thick shim pack (9) on
flange (7) on the opposite side to the crown wheel.

10

Fig. 1845

Adjustment of the differential bearings preload

1. Locate complete differential (10) in the transmission casing.

10

Fig. 1846
2. Install the flanges (4) and (7) and secure in position by tightening the
screws (11) to a torque of 32 - 40 Nm.
Note
While tightening screws (11), rotate the differential unit to
help seat the bearings. 11

Note
Lubricate the bearings with transmission oil.

Fig. 1847

30-427
 Method of intervention
3. Place a dial gauge with magnetic base (B) on the flat surface of the differen-
tial casing (12), and set it to zero on the end face of the differential while si-
12
multaneously forcing the differential towards the opposite side with a lever.
Force the differential axially towards the crown wheel side and measure
endfloat G.
IMPORTANT
If the endfloat is zero, adjust the shim pack (9) on the side
opposite the crown wheel to 0.70 mm and repeat the proce- B
dure to measure the endfloat G.

Fig. 1848
4. Add 0.10 mm to the measured endfloat value G and round up to the nearest 0.01 mm to determine the shim thickness to be
added under the outer ring of bearing (8) on the opposite side to the crown wheel.
5. For example, if the value G measured is 0.28 mm, add 0.10 mm to obtain a value of 0.38 mm.
Rounding this value up to the nearest 0.05 mm gives the real value of the shims to be added, in this case 0.40 mm.
6. Undo the screws (11) of both flanges, leaving one screw in its seat for
safety.

11

Fig. 1849
7. Using a suitable punch in soft material, separate the differential carrier
flanges (4) and (7) from the transmission casing. 7

Fig. 1850
8. Undo the last screw (11) and remove the flanges (4 and 7).

Fig. 1851

30-428
Method of intervention
9. Attach the differential (10) to a hoist and remove.

10

Fig. 1852

Adjustment of pinion position

1. Note the value E stamped on the crest of one of the teeth of pinion (1), in
this example: + 0.15 mm
1

Fig. 1853
2. Install the pinion (1), without the shims, in the transmission casing.
1

Fig. 1854
3. Locate complete differential (10) in the transmission casing

10

Fig. 1855

30-429
 Method of intervention
4. Install the flanges (4) and (7) and secure in position by tightening the
screws (11) to a torque of 32 - 40 Nm.
Note
While tightening screws (11), check for the presence of
clearance between the differential and pinion (1). If the dif- 11

ferential is seated against the pinion, adjust the shim packs

installed under the outer races of the bearings so as to re-
duce the thickness of the pack on the crown wheel side and
increase the thickness of the pack on the opposite side by
the same amount.
Fig. 1856
5. Use a feeler gauge to measure the distance D between the end face of 1
pinion (1) and the 174 mm diameter section of the differential (10) (in this
example 4.85 mm).
Calculate dimension T by adding the value E previously read on the tooth
of pinion (1) to the design value of 4.00 mm. D
If the value E is positive, as in the case shown in the figure, add it to the
design value of 4.00 mm:
m T= 4.00 + E, therefore T= 4.00 + 0.15 = 4.15 mm 10

If E is negative, subtract it from the design value of 4.00 mm

m T= 4.00 - E, therefore T= 4.00 - 0.15 = 3.85 mm
Fig. 1857
If the measured value D differs from the calculated value T, calculate the
difference between D and T. The resulting value P is the shim thickness to
be installed under bearing (2) of pinion (1).
Formula: P = D - T
m which in our example gives: P = 4.85 - 4.15 = 0.70 mm
6. Undo the screws (11) of both flanges, leaving one screw in its seat for
safety.

11

Fig. 1858
7. Using a suitable punch in soft material, separate the differential carrier
flanges (4) and (7) from the transmission casing. 7

Fig. 1859

30-430
Method of intervention
8. Undo the last screw (11) and remove the flanges (4 and 7).

Fig. 1860
9. Attach the differential (10) to a hoist and remove.

10

Fig. 1861
10. Using a puller, remove the complete pinion (1) from the transmission cas-
ing. 1 1
Remove the ring nut (3) and the service bush (A) from the pinion (1).
3
A

Fig. 1862
11. Measure the dimension R of the shoulder of the bearing (2). In this ex-
ample, R = 4.96 mm.
R
Install the pinion (1) and the shim pack of the thickness P calculated previ-
ously, following the procedure for removal in reverse order. 2

Fig. 1863

30-431
 Method of intervention
12. Secure pinion (1) in position with suitable circlip (13) selected from the
available sizes.
Select circlip (13) by applying the following formula:
Circlip thickness:
mFixed dimension K = 9.5 mm 1
Shim thickness = P
Dimension R = 4.96 mm (permissible range: 4.90-5.00mm)
13
Formula:
m A = K - P - R which in this example gives:
m A = 9.5 - 0.7 - 4.96 = 3.84 mm
The circlip to be used is therefore the one with thickness 3.80 mm. Fig. 1864

Note
Circlip (13) installed should in any case ensure pinion end-
float of less than 0.1 mm.

Adjustment of pinion and crown wheel backlash

1. Locate complete differential (10) in the transmission casing.

10

Fig. 1865
2. Install the flanges (4) and (7) and secure in position by tightening the
screws (11) to a torque of 32 - 40 Nm.
Note
While tightening screws (11), rotate differential assembly
(10) to help seat the bearings. 11

Note
Lubricate the bearings with transmission oil.

Fig. 1866
3. Apply a dial gauge with magnetic base (F), with the probe perpendicular
B
to the tooth flank on the external diameter of the crown wheel. Preload the
gauge by approx. 3 mm and measure the backlash Z between the pinion
and crown wheel teeth by turning the differential (3) back and forth in both
directions.
Take four measurements 90° apart and calculate the average; the backlash
should normally be 0.20 to 0.28 mm.

Fig. 1867

30-432
Method of intervention
4. If the backlash Z is less than the minimum value, remove a shim from shim pack (6) (crown wheel side) and add the same
shim to shim pack (9) (side opposite to crown wheel).
If the backlash Z is greater than the maximum value, remove a shim from shim pack (9) (side opposite to crown wheel) and
add the same shim to shim pack (6) (crown wheel side).
IMPORTANT
The sum total thickness of shim packs (6) and (9) should not be different from the calculated value.

Check that the backlash Z is within the range from 0.20 to 0.28 mm.
5. If not, swap additional shims from one side to the other as described above
until the correct backlash is obtained.

6 9

Fig. 1868

30.10.66 - Disassembling the ground speed PTO flange output shaft

Removal
1. Check that the ground speed PTO lever (1) is in the “ON” position (turned
down) to prevent the engagement sleeve from falling into the transmission
casing. OFF

ON 1

Fig. 1869
2. Note
Mark the position of the cover (3) to prevent the risk of incorrect reassembly.

3. Undo the screws (2) and remove the cover (3).

2 3

Fig. 1870

30-433
 Method of intervention
4. Remove the ground speed PTO output shaft (4) complete with bearing (5).

Fig. 1871
5. Remove the circlip (6) and remove the spacer (7).
6

Fig. 1872
6. Use the press to remove the bearing (5) from the shaft.

Fig. 1873
7. Remove the spacer (8) and remove the circlip (9).
8

Fig. 1874

30-434
Method of intervention
8. Remove the seal ring (10) from the cover (3).

10
3

Fig. 1875

Installation
1. Assemble by following the procedure for removal in reverse order and not-
ing the following additional instructions for the steps indicated:
Check that the seal ring (10) is oriented correctly relative to the cover (3).
Lubricate the lip of the seal ring (10) with oil. 10
Apply a bead of Silastic 738 sealant to the mating surface between the 3

cover (3) and the transmission casing.

Fig. 1876

30.10.67 - Disassembling the ground speed PTO clutch engage mechanism

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.10.66 - Disassembling the grou... - page 30-433
Removal
1. Undo the screw (2), remove the control shaft (3) and retrieve the lever (4)
and the shoe (5).

5
1
3

Fig. 1877

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Replace the O-ring (6) fitted on the control shaft.

30-435
 Method of intervention
3. Replace the screw (2), tightening to a torque of 32.2 Nm.

6 2

Fig. 1878

Completion
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.68 - Disassembly of dual traction output shaft (5090 C -> ZKDY360200TD10001,

5100 C -> ZKDY400200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.11.5 - Rear differential (509... - page 30-490
l See para. 30.10.58 - Removing the rear pini... - page 30-376
l See para. 30.10.74 - Disassembling EasyShif... - page 30-461
Removal
1. 4WD output shaft section
6 8 7
4
2
5
1

10

3
9
12 11

Fig. 1879
2. Remove circlip (1).

30-436
Method of intervention
3. Remove the gaiter (2) and the retainer half-rings (3).
Note
3
Take care not to drop the half-rings (3) into the transmission
casing.

Fig. 1880
4. Remove circlip (4).

Fig. 1881
5. Tighten an extractor tool onto the threaded end of the dual traction output
5
shaft (5) and extract partially.

Fig. 1882
6. Remove the dual traction output shaft (5) complete with bearing and re- 7 8
move the gears (7 and 8) and the roller bearings (9). 9

6
5

Fig. 1883
7. Remove the circlip (10) and the spacer (11).

30-437
 Method of intervention
8. Using the press, push the bearing (12) out of the dual traction output shaft.
10

11

12

Fig. 1884

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
Heat the bearing (12) to 110 °C and fit onto the dual traction shaft.
Lubricate the roller bearings (9).
Completion
1. m See para. 30.10.74 - Disassembling EasyShif... - page 30-461
m See para. 30.10.58 - Removing the rear pini... - page 30-376
m See para. 30.11.5 - Rear differential (509... - page 30-490
m See para. 30.10.67 - Disassembling the grou... - page 30-435
m See para. 30.10.66 - Disassembling the grou... - page 30-433
m See para. 30.10.50 - PTO engagement clutch - page 30-346
m See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
m See para. 30.19.1 - Tow hook sled - page 30-605
m See para. 30.11.1 - Wheel carriers - page 30-475
m See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
m See para. 30.10.15 - Range selector assembly - page 30-224
m See para. 30.10.14 - Clutch housing - Separ... - page 30-221
m See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
m See para. 30.13.1 - Cab - page 30-520
m See para. 30.9.6 - Exhaust pipe - page 30-153
m See para. 30.9.5 - Fuel tank - page 30-151
m See para. 30.13.7 - Cab access steps - page 30-531
m See para. 30.12.4 - 4WD shaft () - page 30-513
m See para. 30.18.1 - Rear wheels - page 30-602

30.10.69 - Disassembly of dual traction output shaft (5110 C -> ZKDY440200TD10001)

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.11.6 - Rear differential (511... - page 30-493
l See para. 30.10.59 - Removing the rear pini... - page 30-381

30-438
Method of intervention
l See para. 30.10.74 - Disassembling EasyShif... - page 30-461
Removal
1. 4WD output shaft section
6 8 7
4
2
5
1

10

3
9
12 11

Fig. 1885
2. Remove circlip (1).
3. Remove the gaiter (2) and the retainer half-rings (3).
Note
3
Take care not to drop the half-rings (3) into the transmission
casing.

Fig. 1886
4. Remove circlip (4).

Fig. 1887
5. Tighten an extractor tool onto the threaded end of the dual traction output
5
shaft (5) and extract partially.

Fig. 1888

30-439
 Method of intervention
6. Remove the dual traction output shaft (5) complete with bearing and re- 7 8
move the gears (7 and 8) and the roller bearings (9). 9

6
5

Fig. 1889
7. Remove the circlip (10) and the spacer (11).
8. Using the press, push the bearing (12) out of the dual traction output shaft.
10

11

12

Fig. 1890

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
Heat the bearing (12) to 110 °C and fit onto the dual traction shaft.
Lubricate the roller bearings (9).
Completion
1. m See para. 30.10.74 - Disassembling EasyShif... - page 30-461
m See para. 30.10.59 - Removing the rear pini... - page 30-381
m See para. 30.11.6 - Rear differential (511... - page 30-493
m See para. 30.10.67 - Disassembling the grou... - page 30-435
m See para. 30.10.66 - Disassembling the grou... - page 30-433
m See para. 30.10.50 - PTO engagement clutch - page 30-346
m See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
m See para. 30.19.1 - Tow hook sled - page 30-605
m See para. 30.11.1 - Wheel carriers - page 30-475
m See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
m See para. 30.10.15 - Range selector assembly - page 30-224
m See para. 30.10.14 - Clutch housing - Separ... - page 30-221
m See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
m See para. 30.13.1 - Cab - page 30-520
m See para. 30.9.6 - Exhaust pipe - page 30-153
m See para. 30.9.5 - Fuel tank - page 30-151
m See para. 30.13.7 - Cab access steps - page 30-531
m See para. 30.12.4 - 4WD shaft () - page 30-513
m See para. 30.18.1 - Rear wheels - page 30-602

30-440
Method of intervention
30.10.70 - Disassembly of dual traction output shaft (5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.11.7 - Rear differential (510... - page 30-496
l See para. 30.10.60 - Removing the rear pini... - page 30-386
l See para. 30.10.74 - Disassembling EasyShif... - page 30-461
Removal
1. 4WD output shaft section
6 8 7
4
2
5
1

10

3
9
12 11

Fig. 1891
2. Remove circlip (1).
3. Remove the gaiter (2) and the retainer half-rings (3).
Note
3
Take care not to drop the half-rings (3) into the transmission
casing.

Fig. 1892

30-441
 Method of intervention
4. Remove circlip (4).

Fig. 1893
5. Tighten an extractor tool onto the threaded end of the dual traction output
5
shaft (5) and extract partially.

Fig. 1894
6. Remove the dual traction output shaft (5) complete with bearing and re- 7 8
move the gears (7 and 8) and the roller bearings (9). 9

6
5

Fig. 1895
7. Remove the circlip (10) and the spacer (11).
8. Using the press, push the bearing (12) out of the dual traction output shaft.
10

11

12

Fig. 1896

30-442
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
Heat the bearing (12) to 110 °C and fit onto the dual traction shaft.
Lubricate the roller bearings (9).
Completion
1. m See para. 30.10.74 - Disassembling EasyShif... - page 30-461
m See para. 30.10.60 - Removing the rear pini... - page 30-386
m See para. 30.11.7 - Rear differential (510... - page 30-496
m See para. 30.10.67 - Disassembling the grou... - page 30-435
m See para. 30.10.66 - Disassembling the grou... - page 30-433
m See para. 30.10.50 - PTO engagement clutch - page 30-346
m See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
m See para. 30.19.1 - Tow hook sled - page 30-605
m See para. 30.11.3 - Park Brake assembly (5... - page 30-484
m See para. 30.11.1 - Wheel carriers - page 30-475
m See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
m See para. 30.10.15 - Range selector assembly - page 30-224
m See para. 30.10.14 - Clutch housing - Separ... - page 30-221
m See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
m See para. 30.13.1 - Cab - page 30-520
m See para. 30.9.6 - Exhaust pipe - page 30-153
m See para. 30.9.5 - Fuel tank - page 30-151
m See para. 30.13.7 - Cab access steps - page 30-531
m See para. 30.12.4 - 4WD shaft () - page 30-513
m See para. 30.18.1 - Rear wheels - page 30-602

30.10.71 - Removing dual traction output shaft - 4-range version (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.5 - Rear differential (509... - page 30-490
l See para. 30.10.61 - Removing the rear pini... - page 30-391
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.10.75 - Disassembly of dual tr... - page 30-465
Dual traction output shaft section - 4-range version

30-443
 Method of intervention

10

12
16

7
17 19 11 6
4

19
8 18
9 15
14

13

Fig. 1897

Removal
1. Remove the range selector rod (1).
2. Retrieve the shoes (2).

Fig. 1898
3. Unscrew and remove the range gearbox speed sensors (3).

3
3

Fig. 1899

30-444
Method of intervention
4. Working from the front side of the transmission, remove the circlip (4).

Fig. 1900
5. Working from the rear side of the transmission, remove the circlip (5).
6. Remove the gaiter (6) and the two half-rings (7) retaining the DT output
shaft.
7

Fig. 1901
7. Apply a slide hammer extractor (A) to the DT output shaft flange and re-
move the shaft (8), pulling towards the front of the transmission (arrow).

8 A

Fig. 1902
8. Note
When removing the DT output shaft, set the gears down on
the bottom of the transmission casing.
8
Remove the DT output shaft (8) complete with bearing (9).

Fig. 1903

30-445
 Method of intervention
9. Retrieve the gear (10) with the inner bush (11) from the interior of the trans-
mission casing. 11
10

Fig. 1904
10. Retrieve the gear (12)
12

Fig. 1905
11. Retrieve the gear (13) and the selector sleeve (14) complete with hub.
14

13

Fig. 1906
12. Remove the bearing (15) from the transmission casing.

15

Fig. 1907

30-446
Method of intervention
13. Remove the circlip (16).

16

Fig. 1908
14. Remove the circlip (17).
15. Remove spacer (18).
16. Place the DT shaft under a press and drive out the bearing (9).
17

18

Fig. 1909
17. Remove the bushes (19) of the gear (14).
19
14

19

Fig. 1910

30-447
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the inner bearing race (9) to 80 °C, and fit onto the DT output shaft.
3. Fit the spacer (18).
4. Fit the circlip (17)
17

18

Fig. 1911
5. For versions without ground speed PTO:
Undo the nuts (19) and remove the cover (20).

19

20

Fig. 1912
6. Fit the DT output shaft (8), complete with bearing (9), in the transmission
casing.

Fig. 1913
7. When fitting the DT output shaft (8) from the front side, fit the gear (13) 12
10
with the relative bushes (19), the selector sleeve (14) complete with hub,
the gear (10) with the relative bush (11), and the gear (12) in the sequence 19 11

indicated.
Note
Ensure that the gear (12) is installed the right way round.

13 14

Fig. 1914

30-448
Method of intervention
8. Fit the ball bearing (15) in its seat.

15

Fig. 1915
9. Fit the bush (B), the shaft (C) and the guide bush (D) of tool 5.9035.547.0 as shown in the figure.
10. Drive the bearing (15) into its seat on end of the shaft (C) with a mallet.
B

15

D
Fig. 1916
11. Apply a thin layer of DOW CORNING 7091 sealant to the mating surface of the cover (20) before fitting

Completion
l See para. 30.10.75 - Disassembly of dual tr... - page 30-465
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.61 - Removing the rear pini... - page 30-391
l See para. 30.11.5 - Rear differential (509... - page 30-490
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.72 - Removing dual traction output shaft - 4-range version (5110 C -> ZK-
DY440200TD10001)

30-449
 Method of intervention
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.6 - Rear differential (511... - page 30-493
l See para. 30.10.62 - Removing the rear pini... - page 30-399
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.10.75 - Disassembly of dual tr... - page 30-465
Dual traction output shaft section - 4-range version

16 15
13
12
18
11 14 7
10
4 5

20 10 6
8
9 17
21
19

Fig. 1917

Removal
1. Remove the range selector rod (1).

30-450
Method of intervention
2. Retrieve the shoes (2).

Fig. 1918
3. Unscrew and remove the range gearbox speed sensors (3).

3
3

Fig. 1919
4. Working from the front side of the transmission, remove the circlip (4).

Fig. 1920
5. Working from the rear side of the transmission, remove the circlip (5).
6. Remove the gaiter (6) and the two half-rings (7) retaining the DT output
shaft.
7

Fig. 1921

30-451
 Method of intervention
7. Apply a slide hammer extractor (A) to the DT output shaft flange and re-
move the shaft (8), pulling towards the front of the transmission (arrow).

8 A

Fig. 1922
8. Note
11
When removing the DT output shaft, set the gears down on
12
the bottom of the transmission casing.

Remove the DT output shaft (8) complete with bearing (9), and retrieve the 10 8
roller bearing cages (10), the spacers (11) and the shim (12).

Fig. 1923
9. Retrieve the gear (13) with the inner bush (14) from the interior of the trans-
mission casing. 14
13

Fig. 1924
10. Retrieve the gear (15)
15

Fig. 1925

30-452
Method of intervention
11. Retrieve the gear (16) and the selector sleeve (17) complete with hub.
17

16

Fig. 1926
12. Remove the bearing (18) from the transmission casing.

18

Fig. 1927
13. Remove the circlip (19).

19

Fig. 1928
14. Remove the circlip (20).
15. Remove spacer (21).
16. Place the DT shaft under a press and drive out the bearing (9).
20

21

Fig. 1929

30-453
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the inner bearing race (9) to 80 °C, and fit onto the DT output shaft.
3. Fit the spacer (21).
4. Fit the circlip (20)
20

21

Fig. 1930
5. For versions without ground speed PTO:
Undo the nuts (22) and remove the cover (23).

22

23

Fig. 1931
6. Fit the roller bearing cages (10) and the spacers (11) on the DT output shaft (8).
7. Fit the shim (12) next to the bearing (9).
11
12

10 8

Fig. 1932
8. Fit the DT output shaft (8) from the front side, fitting the gear (16), the selec-
16 15
tor sleeve (17) complete with hub, the gear (13) with the relative bush (14),
13
and the gear (15) in the sequence indicated.
Note
Ensure that the gear (15) is installed the right way round.

14
17

Fig. 1933

30-454
Method of intervention
9. Fit the oscillating bearing (18) in its seat.

18

Fig. 1934
10. Fit the bush (B), the shaft (C) and the guide bush (D) of tool 5.9035.547.0 as shown in the figure.
11. Drive the bearing (18) into its seat on end of the shaft (C) with a mallet.
B

18

D
Fig. 1935
12. Apply a thin layer of DOW CORNING 7091 sealant to the mating surface of the cover (23) before fitting

Completion
l See para. 30.10.75 - Disassembly of dual tr... - page 30-465
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.62 - Removing the rear pini... - page 30-399
l See para. 30.11.6 - Rear differential (511... - page 30-493
l See para. 30.11.10 - Brake carrier (version... - page 30-504
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.73 - Removing dual traction output shaft - 4-range version (5100 C -> ZK-
DY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

30-455
 Method of intervention
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
or
See para. 30.10.32 - Gearbox/HML assembly ... - page 30-295
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.7 - Rear differential (510... - page 30-496
l See para. 30.10.63 - Removing the rear pini... - page 30-407
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.10.74 - Disassembling EasyShif... - page 30-461
Dual traction output shaft section - 4-range version

16 15
13
12
18
11 14 7
10
4 5

20 10 6
8
9 17
21
19

Fig. 1936

Removal
1. Remove the range selector rod (1).

30-456
Method of intervention
2. Retrieve the shoes (2).

Fig. 1937
3. Unscrew and remove the range gearbox speed sensors (3).

3
3

Fig. 1938
4. Working from the front side of the transmission, remove the circlip (4).

Fig. 1939
5. Working from the rear side of the transmission, remove the circlip (5).
6. Remove the gaiter (6) and the two half-rings (7) retaining the DT output
shaft.
7

Fig. 1940

30-457
 Method of intervention
7. Apply a slide hammer extractor (A) to the DT output shaft flange and re-
move the shaft (8), pulling towards the front of the transmission (arrow).

8 A

Fig. 1941
8. Note
11
When removing the DT output shaft, set the gears down on
12
the bottom of the transmission casing.

Remove the DT output shaft (8) complete with bearing (9), and retrieve the 10 8
roller bearing cages (10), the spacers (11) and the shim (12).

Fig. 1942
9. Retrieve the gear (13) with the inner bush (14) from the interior of the trans-
mission casing. 14
13

Fig. 1943
10. Retrieve the gear (15)
15

Fig. 1944

30-458
Method of intervention
11. Retrieve the gear (16) and the selector sleeve (17) complete with hub.
17

16

Fig. 1945
12. Remove the bearing (18) from the transmission casing.

18

Fig. 1946
13. Remove the circlip (19).

19

Fig. 1947
14. Remove the circlip (20).
15. Remove spacer (21).
16. Place the DT shaft under a press and drive out the bearing (9).
20

21

Fig. 1948

30-459
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the inner bearing race (9) to 80 °C, and fit onto the DT output shaft.
3. Fit the spacer (21).
4. Fit the circlip (20)
20

21

Fig. 1949
5. For versions without ground speed PTO:
Undo the nuts (22) and remove the cover (23).

22

23

Fig. 1950
6. Fit the roller bearing cages (10) and the spacers (11) on the DT output shaft (8).
7. Fit the shim (12) next to the bearing (9).
11
12

10 8

Fig. 1951
8. Fit the DT output shaft (8) from the front side, fitting the gear (16), the selec-
16 15
tor sleeve (17) complete with hub, the gear (13) with the relative bush (14),
13
and the gear (15) in the sequence indicated.
Note
Ensure that the gear (15) is installed the right way round.

14
17

Fig. 1952

30-460
Method of intervention
9. Fit the oscillating bearing (18) in its seat.

18

Fig. 1953
10. Fit the bush (B), the shaft (C) and the guide bush (D) of tool 5.9035.547.0 as shown in the figure.
11. Drive the bearing (18) into its seat on end of the shaft (C) with a mallet.
B

18

D
Fig. 1954
12. Apply a thin layer of DOW CORNING 7091 sealant to the mating surface of the cover (23) before fitting

Completion
l See para. 30.10.74 - Disassembling EasyShif... - page 30-461
l See para. 30.10.67 - Disassembling the grou... - page 30-435
l See para. 30.10.66 - Disassembling the grou... - page 30-433
l See para. 30.10.63 - Removing the rear pini... - page 30-407
l See para. 30.11.7 - Rear differential (510... - page 30-496
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.15 - Range selector assembly - page 30-224
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.50 - PTO engagement clutch - page 30-346
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.17.7 - 3-point linkage - page 30-597
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.74 - Disassembling EasyShift DT clutch system

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221

30-461
 Method of intervention
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
Removal
1. EasyShift system section 2 14 16
15 11
12
1

5
9 17
10
6
13

Fig. 1955
2. Remove the gasket (1).
Note
Replace the gasket on disassembly.
1

Fig. 1956
3. Remove circlip (2).

Fig. 1957
4. Fit a slide hammer extractor to the threaded holes (arrows), and extract the
hub (3) complete with bearing.

Fig. 1958

30-462
Method of intervention
5. Remove the circlip (4) and remove the bearing (5) from the hub (3).
4

Fig. 1959
6. Remove the bearing retainer circlip (6).

Fig. 1960
7. Undo the screws (7) and remove the lower plate (8).
Note
Remove any oil lines which may obstruct the removal pro-
cedure.

8
7

Fig. 1961
8. Immobilise the dual traction output shaft, undo the screw (9) and remove
the washer (arrow).

Fig. 1962

30-463
 Method of intervention
9. Remove the clutch (10), the spring (11) and the disc (12).

12
11
10

Fig. 1963
10. Retrieve the oil union (13).

13

Fig. 1964
11. Separate the piston (14) from the clutch (10).

14

10

Fig. 1965

30-464
Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Check the condition of the O-rings (15) on the piston (14) and replace if
necessary.

15

Fig. 1966
3. Check the condition of the O-rings (16) and (17) on the dual traction output
17 16
shaft and replace if necessary.

17 16
Fig. 1967
4. Apply a drop of Loctite 242 to the thread of the screw (9) and tighten to a torque of 40 Nm.
5. Apply a bead of DOWN CORNING 9071 sealant to the mating surface between the plate (8) and the transmission casing.
Completion
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30.10.75 - Disassembly of dual traction clutch - Easyshift with mechanical park brake
Preliminary operations
l Drain the transmission oil
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293

30-465
 Method of intervention
Removal
1. Undo the screw (1) and the hex socket head cap screw (2), and remove the
tank mounting bracket (3).

3
1

Fig. 1968
2. Undo the screw (4) and remove the retainer plate (5).
5

Fig. 1969
3. Remove the park brake lever (6) from its seat.
6

Fig. 1970
4. Undo the union (7) and remove the oil line (8).
5. Undo the screws (9) and remove the cover (10).

9
8

10

Fig. 1971

30-466
Method of intervention
6. Tighten a suitable slide hammer extractor (11) onto the brake shoe guide
(12) and remove the guide.
12

11

Fig. 1972
7. Remove the brake shoes (13), the pressure plate (14) and the retainer
block (15).

15

13

14

Fig. 1973
8. Remove the oil seal (16) on the Easyshift unit (this will damage the seal
irreparably).

16

Fig. 1974
9. Remove the Easyshift bearing retainer circlip (17).

17

Fig. 1975

30-467
 Method of intervention
10. T
Fit a slide hammer extractor (18) and remove the Easyshift hub (19) out of
its seat, complete with bearing.

19

18

Fig. 1976
11. Remove the circlip (20).

20

Fig. 1977
12. Undo the screw (21) and remove the washer (21) and the EasyShift clutch
(23).

23
22
21

Fig. 1978
13. Remove the spring (24) and the thrust ring (25).

24

25

Fig. 1979

30-468
Method of intervention
14. Remove the oil union (26).

26

Fig. 1980
15. Remove the circlip (27) and remove the park brake discs (28) from the
splines on the DT output shaft.

27

28

Fig. 1981
16. Remove the piston (29) from the Easyshift unit (23) and replace the O-rings
23
(30).
30

29

Fig. 1982
17. If necessary, place the Easyshift hub (19) under a press, remove the circlip
(31) and drive out the bearing (32).
31

19

32

Fig. 1983

30-469
 Method of intervention
Refitting
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Heat the inner race of the bearing (32) and fit onto the Easyshift hub (19).
3. Fit the circlip (31)

31

19

32

Fig. 1984
4. Remove and replace the “Vespel” seals (33).

33

Fig. 1985
5. Check the condition of the O-rings (34) on the dual traction output shaft and
34
replace if necessary.

34

Fig. 1986
6. Fit the three discs on the splines of the DT output shaft and fasten in place
with the circlip (27).

27

28

Fig. 1987

30-470
Method of intervention
7. Apply Loctite 242 to thread of the screw (21) and tighten the screw to a
torque of 2 kgm.

242

23
22
21

Fig. 1988
8. Apply Loctite 554 to the outer surface of the oil seal (16) and fit the seal in
its seat, oriented correctly as shown in the figure.

55
4
16

Fig. 1989
9. Note
Ensure that the oil seal is installed the correct way around
16
(16).

Fig. 1990
10. Using the specific tool, fit the oil seal (16) in its seat.

16

Fig. 1991

30-471
 Method of intervention
11. Fit the friction shoes (13), the pressure plate (14) and the retainer block (15)
in the correct order shown in the figure.

15

13

14

Fig. 1992
12. Replace the O-ring (35) on the lever (6).
35

Fig. 1993
13. Fit the mechanical park brake (6) and the retainer plate (5), tightening the
screw (4) to a torque of 20.4±1 Nm. 5

Fig. 1994
14. Apply a layer of DOW CORNING 7091 sealant to the mating surface of the cover (10).
15. Replace the O-ring (36).

36

10

Fig. 1995
16. Fasten the cover (10), tightening the screws (9) to a torque of 40.4±2 Nm.

30-472
Method of intervention
17. Tighten the union (7) to a torque of 40±4 Nm.
Note
9
Replace the copper gaskets under the union (7). 8

10

Fig. 1996

Completion
l See para. 30.10.31 - Gearbox and HI-LO unit - page 30-293
l See para. 30.10.14 - Clutch housing - Separ... - page 30-221
l See para. 30.13.1 - Cab - page 30-520
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.13.9 - Engine cowl - page 30-532
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.18.1 - Rear wheels - page 30-602
l Fill the transmission with oil.

30.10.76 - Pump drive PTO - External gear without 60 l ECO pump

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.14.7 - Disassembling the comp... - page 30-547
Removal
1. Undo the screws (1) and remove the cover (2).

Fig. 1997
2. Use a soft mallet to drive out the hub (3) and the bearing (4).
Retrieve the fastener key (5).
3. Remove the gear (6) and retrieve the two spacers (7). 7 6 8
Remove the second bearing (8). 3 4

Fig. 1998

30-473
 Method of intervention
4. Drive the bearing (4) out from the hub (3) with the press.
4

Fig. 1999

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Apply a thin layer of DOW CORNING 7091 to the mating surface, then fit the cover (2) and tighten the screws (1) to a torque
of 20.4 Nm.
Completion
l See para. 30.14.7 - Disassembling the comp... - page 30-547
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602

30-474
Method of intervention
30.11 - E0 - Rear axle
30.11.1 - Wheel carriers
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
Removal
1. Undo the nut (1) and remove the plate (2).
2. Using suitable lifting equipment, lift the cab slightly on the side you are
working and hold in position.

Fig. 2000
3. Undo the nuts (3) and detach the hitch piston mounting plate (4) from the transmission casing.
4. Undo the screws (5) and remove the cab mount (6).
5. Undo the fastener screws and remove the plate (7).
6

3
5

4 7

Fig. 2001
6. Fit and tighten an eye-bolt (8) onto the wheel carrier (9), connect to a hoist and tauten the hitch cable slightly to take up the
slack.
7. Undo all the remaining fastener screws and nuts (10).
8. Using a screw (11) as a guide, separate the wheel carrier (9) from the
transmission casing. 10

Important 8

Take care not to let the wheel carrier overbalance when re- 9

moving from its seat.

11

Fig. 2002
9. Remove the internal axle shaft (12), marking its position for subsequent refitting (the right hand axle shaft is longer).

30-475
 Method of intervention
10. Remove the crown wheel (13) of the reduction gear unit with the two seal
plates (14). 13
12
14

14

Fig. 2003
11. Repeat these operations from the opposite side to remove the other wheel mount.
Refitting
1. If the Park Brake was not removed, fit the internal axle shaft (12).
13
Note
12
14
If instead the Park Brake assembly must be refitted, the in-
ternal axle shaft must be fit in the Park Brake before the final
tightening of the fastening screws, as this serves to centre
the brake discs.
Fit a new seal plate (14) on the external flange of the Park Brake, ensuring
that it is installed the correct way around.
14
Note
The holes for the fastening screws are not symmetric. Fig. 2004

Fit the crown wheel (13) of the reduction unit on the wheel carrier, ensuring
that it is installed the correct way around.
Fit a new seal plate (14) on the crown wheel, ensuring that it is installed the
correct way around.
2. Connect the eye-bolt to a hoist.
Fit the wheel carrier (9) on the outer flange of the Park Brake. 10
Apply a drop of Loctite 243 on the thread of the screws and nuts fastening
8
the wheel mount.
9
Tighten the screws and nuts (10) fastening the wheel carrier to a torque of
70 Nm.
Remove the eye-bolt (8) used to hitch the wheel carrier.
Important
Take care not to let the wheel carrier overbalance when in-
stalling in its seat.
Fig. 2005

3. Fit the plate (7) and tighten the fastener screws to a torque of 170 Nm.
4. Fit the cab mount (6) and tighten the screws (5) to a torque of 70 Nm.

30-476
Method of intervention
5. Fit the hitch piston mounting plate (4) and tighten the nuts (3) to a torque
of 70 Nm. 6

3
5

4 7

Fig. 2006
6. Lower the cab and return to its seat.
7. Fit the plate (2) and tighten the nut (1) to a torque of 176 Nm.

Fig. 2007
8. Repeat these operations from the opposite side to refit the other wheel mount.

Completion
l See para. 30.18.1 - Rear wheels - page 30-602

30.11.2 - Wheel mount disassembly

Wheel mount disassembly
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.11.1 - Wheel carriers - page 30-475
Removal
1. Fit the complete wheel mount (1) on the tool (A).

Fig. 2008

30-477
 Method of intervention
2. Remove the anti-loosening plate (2).
2
Undo the screw (3) and remove the spacer (4) and the spacer rings (5). 3
4

Fig. 2009
3. Remove the complete planetary gear carrier (6).

Fig. 2010
4. Using an extractor, force the axle shaft (7) to disengage the inner ring (8) of
8
the differential side bearing.

8 7

Fig. 2011
5. Use two eyebolts (9) and a chain to connect the wheel mount (1) to a crane,
and remove the wheel mount. 9

Fig. 2012

30-478
Method of intervention
6. Remove the outer ring (10) of the differential side bearing and the seal ring
(11) from the inner side of the wheel mount.
10

11

Fig. 2013
7. Remove the outer ring (12) of the wheel side bearing and the disc (13) from
the outer side of the wheel mount.
12

13

Fig. 2014
8. Remove the inner race (14) of the wheel side bearing (7) from the axle
shaft.
Remove the seal ring (15) from the axle shaft.
Note 15
Always replace the seal ring with a new component after 14

removing.

Fig. 2015
9. Only if necessary, remove the slider ring (16) of the seal ring from the wheel
mount.

16

Fig. 2016

30-479
 Method of intervention
Removal of the planetary gear carrier
1. Remove the retainer ring (17) and remove the planet gear pins (18).
17
Remove the planetary gear units (19) with the two anti-friction ring bearings
(20). 18
20

19

20

Fig. 2017
2. Remove the roller bearing cages (21) and the spacer (22).
21

22

21

Fig. 2018

Assembly of the planetary gear carrier assembly

1. Fit the planetary gear carrier assembly, performing the operations carried out upon removal in reverse order.
Note
Lubricate the roller bearing cages with oil.

Assembly of the wheel mount

1. Fit the axle shaft (7) on the tool (A).

12

Fig. 2019

30-480
Method of intervention
2. Fit a new seal ring (15) on the axle shaft (7).
Heat the inner ring (14) of the wheel side bearing to 110°C and install on
the axle shaft.
Fill the area between the seal ring and the wheel side bearing with grease.
15
14

Fig. 2020
3. Using a soft mallet, fit the disc (13) and the outer ring (12) of the wheel side
bearing in the wheel mount.
12

13

Fig. 2021
4. Using a soft mallet, fit the seal ring (11) and the outer ring (10) of the dif-
ferential side bearing in the wheel mount.
10

11

Fig. 2022
5. Use two eyebolts (9) and a chain to connect the wheel mount (1) to a crane,
and fit the wheel mount on the axle shaft. 9

Fig. 2023

30-481
 Method of intervention
6. Use a soft mallet to install the inner ring (8) of the differential side bearing
on the axle shaft (7). 8

Fig. 2024
7. Fit the complete planetary gear carrier (6). 3
Fit the spacer (4). 4
Tighten the screw (3) to a torque of 150 - 155 Nm.
Note 6

While tightening to torque, turn the wheel mount clockwise

and counter-clockwise for at least 5+5 turns to settle the
bearings.
Reduce the tightening torque of the screw to 20-25 Nm.
Note
Turn the wheel mount clockwise and counter-clockwise for Fig. 2025
at least 5+5 turns to settle the bearings.

Undo the screw (3) and remove the spacer (4).

8. Zero a depth gauge on the inner surface of the planetary gear carrier (6).

Fig. 2026
9. Measure the depth of surface G of the axle shaft (7) = 1.57 mm. 6

Fig. 2027

30-482
Method of intervention
10. Select appropriate calibrated rings (5) for a total thickness S equal to G ±
0.02 mm, to attain zero endfloat.

Fig. 2028
11. Fit the calibrated rings (5).
Fit the spacer (4). 3
4
Apply Loctite DRI-LOC 211 sealant on the thread of the fastening screw.
Tighten the screw (3) to a torque of 150 Nm ± 5 %.
5

Fig. 2029
12. Fit the anti-loosening plate (2) and, if tops of the plate do not enter their
respective seats on the planetary gear carrier when aligning the holes of
the plate with the screw head, continue to tighten the screws until correct 2
assembly is possible.

Fig. 2030

30-483
 Method of intervention
Completion
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.18.1 - Rear wheels - page 30-602

30.11.3 - Park Brake assembly (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.11.1 - Wheel carriers - page 30-475
Removal
1. Remove any components of the hydraulic system interfering with the following procedure.
2. Undo the plug and screw a cock (1) onto the union (2).
3. Connect a hand pump to the cock and pressurise to 20 bar.
4. Close the cock and (1) disconnect the hand pump.
1
Note
This procedure releases the force exerted on the Park
Brake fastener screws by the internal belleville spring wash-
ers, facilitating disassembly.
2

Fig. 2031
5. Apply the special tool (3) for lifting the Park Brake and connect to a hoist
with a chain.

Fig. 2032
6. Undo the Allen screws (4) fastening the Park Brake.
7. Remove the Park Brake (5) and the plate (6), retaining the inner brake disc.
Important
The inner brake disc is now free and could fall if not held in place.

8. Remove the O-ring (7) from the Park Brake housing.

7
6
5 4

Fig. 2033

30-484
Method of intervention
9. Remove the inner brake disc (8), the thrust plate (9) and the outer brake
disc (10). 8

10

Fig. 2034
10. Place the Park Brake on the work bench, then tap the three pins on the
brake piston (12) with a bush (11) and a soft mallet to push the piston 12
back into the position necessary for the subsequent step in the assembly
procedure.
Important
This operation is carried out if the Park Bake does not re-
quire disassembly. Otherwise, it will be carried out at the
end of the Park Brake reassembly procedure. 11

Fig. 2035
11. Repeat the procedures described previously from the opposite side to remove the other Park Brake.

Refitting
1. Fit the external brake disc (10), the thrust plate (9) and the internal brake
disc (8) on the Park Brake. 8

10

Fig. 2036
2. Connect the eye-bolt of the special tool (3) on the Park Brake to a hoist using a chain, while holding the internal brake disc in
place.
Important
The inner brake disc is now free and could fall if not held in place.

3. Fit a new plate (6) on the differential flange, ensuring that it is installed the correct way around.
Note
The holes for the fastening screws are not symmetric.

4. Fit the Park Brake (5), holding the internal brake disc (8) in place and ensuring that the discs (10 and 8) engage correctly with
the axle shaft (13).
5. Apply a drop of Loctite 243 on the thread of the fastening screws.
6. Tighten the screws (4) fastening the Park Brake to a torque of 40.4 Nm.

30-485
 Method of intervention
7. Fit a new O-ring (7) on the Park Brake housing.
13

7
6
5 4

Fig. 2037
8. Repeat the procedures described previously from the opposite side to refit the other Park Brake.
9. Remove the special tool (3) for lifting the Park Brake.

Fig. 2038
10. See para. 30.11.1 - Wheel carriers - page 30-475
Note
Try to rotate an axle shaft, the other should rotate freely in the opposite direction.

11. Connect a hand pump to the cock.

12. Open the cock (1) and release the pressure.
13. Close the cock and disconnect the hand pump.
14. Remove the cock (1) from the union (2) and fit and tighten the plug.
1

Fig. 2039
15. Refit any components of the hydraulic system removed previously.
16. See para. 30.18.1 - Rear wheels - page 30-602

30-486
Method of intervention
30.11.4 - Park Brake unit disassembly (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Removal
1. Connect a hand pump to the cock (1).
Open the cock (1) and release the pressure.
Close the cock and disconnect the hand pump.
1

Fig. 2040
2. Use two levers to remove the brake piston (2) releasing it from the play recovery devices and the anti-rotation pins.
3. Remove the O-ring (3) from the brake piston.
4. Remove the O-ring (4) from the Park Brake housing.

Fig. 2041
5. Turn the Park Brake unit over.
6. Fit the L brackets (7), tightening the screws (8) to prevent the Belleville washers (which are preloaded to approximately 70,000
N) from breaking the fastener screws (5) as they are decompressed.
7. Undo and remove the screws (5).
8. Gradually and uniformly loosen the screws (8) retaining the brackets (7), until the Belleville washers are completely decom-
pressed.
Note
Loosen screws (8) by approx. ¼ turn at a time, proceeding in a circle.

9. Completely undo and remove the screws (8) and the brackets (7).
6
5

Fig. 2042

30-487
 Method of intervention
10. Remove the flange (6) and the Belleville washer (9).

Fig. 2043
11. Turn the Park Brake unit over.
12. Use two rubber mallets to remove the piston (10) from the Park Brake housing.
13. Remove the O-ring (11) from the Park Brake piston.
14. Remove the O-ring (12) from the Park Brake housing.

12

10

11

Fig. 2044
15. Undo the play recovery devices (13) and remove.
16. If necessary, use locking pliers to remove the anti-rotation pins (14).

13
14

Fig. 2045

30-488
Method of intervention
Installation
1. Fit a new O-ring (12) on the Park Brake housing, smearing it with grease.
2. Fit a new O-ring (11) on the Park Brake piston, smearing it with grease.
3. Use two rubber mallets to fit the piston (10) in the Park Brake housing.
11

10

12

Fig. 2046
4. Fit the Belleville washer (9).
Note
Ensure that the Belleville washers are installed the correct way around; the concave side must face the outer
flange (6).

5. Apply a drop of Loctite 243 to the threads of the screws (5).

6. Fit the outer flange (6) on the Park Brake housing, and fit and snug the fastener screws (5).
7. Tighten the screws (5) gradually and uniformly to compress the Belleville washer (9).
8. Finish by tightening the screws (5) to a torque of 35.1 Nm.
5

Fig. 2047
9. Turn the Park Brake unit over.
10. If removed previously, fit new anti-rotation pins (14).
11. Apply a drop of Loctite 243 to the threads of the play recovery devices (13).
12. Fit the play recovery devices (13) and tighten to a torque of 20.4 Nm.

13
14

Fig. 2048
13. Fit a new O-ring (4) on the Park Brake housing (brake piston side), smearing it with grease.
14. Fit a new O-ring (3) on the brake piston (2), smearing it with grease.

30-489
 Method of intervention
15. Fit the brake piston (2) with a rubber mallet, and use a bush to push it fully
back.
2

Fig. 2049
16. Connect a hand pump to the cock (1) and pressurise to 20 bar.
17. Close the cock and (1) disconnect the hand pump.

Fig. 2050

30.11.5 - Rear differential (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
Removal
1. Disconnect the unions and/or remove any lines of the hydraulic system interfering with the following operations.
2. Undo and remove the plugs (1 and 2).
3. Note
Renew the copper washers on reassembly.
1
2

Fig. 2051

30-490
Method of intervention
4. Remove the spring pin (3) with a punch.
3

Fig. 2052
5. Push the rod (4) in the direction indicated, extract partially from the trans-
mission casing and remove the piston (5).

4
5

Fig. 2053
6. Remove the spring (6) and the spacer (7). 6
7

Fig. 2054
7. Remove the rod (4) completely from the transmission casing.
8. Remove the fork (8), the spring (9) and the spacer (10).

10
9

Fig. 2055
9. Secure the differential (11) to a suitable hoist.

30-491
 Method of intervention
10. Remove the cylinders (12).

12

12

11

Fig. 2056
11. Undo the screws (13), leaving one screw fastened for safety.

13

Fig. 2057
12. Using a suitable punch in soft material, separate the differential carrier flanges (14) from the transmission casing.
13. Undo the last screw (13) and remove the flange (14).
14. Note
Mark the assembly positions of the flanges (14) to prevent swapping them during reassembly.

15. Following the same procedure, remove the differential carrier flange on the
13
opposite side.

14

14

Fig. 2058
16. Remove the differential (11) from the transmission casing.

11

Fig. 2059

30-492
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Adjust the preload of the differential bearings
See para. 30.10.64 - Adjustment of the diff... - page 30-415
3. Tighten the screws (13) to a torque of 32 - 40 Nm.

13

Fig. 2060
4. Adjust the pinion - crown wheel backlash
See para. 30.10.64 - Adjustment of the diff... - page 30-415
Completion
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.18.1 - Rear wheels - page 30-602

30.11.6 - Rear differential (5110 C -> ZKDY440200TD10001)

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
Removal
1. Disconnect the unions and/or remove any lines of the hydraulic system interfering with the following operations.
2. Undo and remove the plugs (1 and 2).
3. Note
Renew the copper washers on reassembly.
1
2

Fig. 2061

30-493
 Method of intervention
4. Remove the spring pin (3) with a punch.
3

Fig. 2062
5. Push the rod (4) in the direction indicated, extract partially from the trans-
mission casing and remove the piston (5).

4
5

Fig. 2063
6. Remove the spring (6) and the spacer (7). 6
7

Fig. 2064
7. Remove the rod (4) completely from the transmission casing.
8. Remove the fork (8), the spring (9) and the spacer (10).

10
9

Fig. 2065
9. Secure the differential (11) to a suitable hoist.

30-494
Method of intervention
10. Remove the cylinders (12).

12

12

11

Fig. 2066
11. Undo the screws (13), leaving one screw fastened for safety.

13

Fig. 2067
12. Using a suitable punch in soft material, separate the differential carrier flanges (14) from the transmission casing.
13. Undo the last screw (13) and remove the flange (14).
14. Note
Mark the assembly positions of the flanges (14) to prevent swapping them during reassembly.

15. Following the same procedure, remove the differential carrier flange on the
13
opposite side.

14

14

Fig. 2068
16. Remove the differential (11) from the transmission casing.

11

Fig. 2069

30-495
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Adjust the preload of the differential bearings
See para. 30.10.65 - Adjustment of the diff... - page 30-424
3. Tighten the screws (13) to a torque of 32 - 40 Nm.

13

Fig. 2070
4. Adjust the pinion - crown wheel backlash
See para. 30.10.65 - Adjustment of the diff... - page 30-424
Completion
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.18.1 - Rear wheels - page 30-602

30.11.7 - Rear differential (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,

5120 C -> ZKDY560200TD10001)
Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
Removal
1. Disconnect the unions and/or remove any lines of the hydraulic system interfering with the following operations.
2. Undo and remove the plugs (1 and 2).
3. Note
Renew the copper washers on reassembly.
1
2

Fig. 2071

30-496
Method of intervention
4. Remove the spring pin (3) with a punch.
3

Fig. 2072
5. Push the rod (4) in the direction indicated, extract partially from the trans-
mission casing and remove the piston (5).

4
5

Fig. 2073
6. Remove the spring (6) and the spacer (7). 6
7

Fig. 2074
7. Remove the rod (4) completely from the transmission casing.
8. Remove the fork (8), the spring (9) and the spacer (10).

10
9

Fig. 2075
9. Secure the differential (11) to a suitable hoist.

30-497
 Method of intervention
10. Remove the cylinders (12).

12

12

11

Fig. 2076
11. Undo the screws (13), leaving one screw fastened for safety.

13

Fig. 2077
12. Using a suitable punch in soft material, separate the differential carrier flanges (14) from the transmission casing.
13. Undo the last screw (13) and remove the flange (14).
14. Note
Mark the assembly positions of the flanges (14) to prevent swapping them during reassembly.

15. Following the same procedure, remove the differential carrier flange on the
13
opposite side.

14

14

Fig. 2078
16. Remove the differential (11) from the transmission casing.

11

Fig. 2079

30-498
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Adjust the preload of the differential bearings
See para. 30.10.65 - Adjustment of the diff... - page 30-424
3. Tighten the screws (13) to a torque of 32 - 40 Nm.

13

Fig. 2080
4. Adjust the pinion - crown wheel backlash
See para. 30.10.65 - Adjustment of the diff... - page 30-424
Completion
l See para. 30.10.44 - PTO output shaft - 2 s... - page 30-332
l See para. 30.19.1 - Tow hook sled - page 30-605
l See para. 30.11.3 - Park Brake assembly (5... - page 30-484
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.17.1 - S.A.C. Automatic contr... - page 30-584
l See para. 30.18.1 - Rear wheels - page 30-602

30-499
 Method of intervention
30.11.8 - Removing rear differential

14 3

13

10
10

11 11

12
8

9 5
6 4

7
1
Fig. 2081

Disassemble
1. Remove the bearing (1) from the differential crown wheel side with an ex-
tractor tool.
1

Fig. 2082

30-500
Method of intervention
2. Remove the bearing (2) from the planetary gear carrier side with an extrac-
tor tool.
2

Fig. 2083
3. Remove the differential lock engage sleeve (3).
3

Fig. 2084
4. Undo the screws (4) and remove the differential crown wheel (5).
4 5

Fig. 2085
5. Remove the sun gear (6) and the relative thrust washer (7).
7

Fig. 2086

30-501
 Method of intervention
6. Remove the spring pins (8).
8

Fig. 2087
7. Remove the pin (9) and remove the sun gear (10) and the relative thrust
washer (11). 10

11

Fig. 2088
8. Repeat the same procedure to remove the other pin (9) and remove the
planet gear unit (10) and the relative thrust washer (11). 11
10

Fig. 2089
9. Withdraw pin (12).

12

Fig. 2090

30-502
Method of intervention
10. Remove the planet gear units (10) and the relative thrust washers (11).
10

11

11

Fig. 2091
11. Remove the sun gear (13) and the relative thrust washer (14).

13

14

Fig. 2092

Reassemble
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Lubricate the planet gear units, sun gears and the relative thrust washers with transmission oil.
3. Tighten the screws (4) fastening the crown wheel (5) to a torque of 112±5.5
Nm. 4 5

Note
Apply a drop of Loctite 243 to the threads of the screws (4).

Fig. 2093

30.11.9 - Disassembling the brake carrier (versions without Park Brake)

Removal
1. Tighten a suitable plug (A) into one of the oil passage holes and blow air into the other hole.
Note
Restrain the piston (1) to prevent it from falling out uncontrollably.

30-503
 Method of intervention
2. Remove the piston (1) from the brake carrier (2).
1

A 2

Fig. 2094
3. Remove and replace the O-rings (3).

Fig. 2095

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Fit the piston (1) on the brake carrier (2), ensuring that the anti-rotation pins
(4) engage correctly in the corresponding holes on the piston.
1
Note
Lubricate the O-rings and the piston to facilitate installation.
4 4

Fig. 2096

30.11.10 - Brake carrier (versions without Park Brake)

Preliminary operations
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.11.1 - Wheel carriers - page 30-475

30-504
Method of intervention
Removal
1. Detach the brake carrier (1) from the transmission housing (2).
Note
While the three threaded holes on the flange (arrow) appear
to be usable to force off the brake carrier, they are in fact
blind. Use a lever to detach the brake carrier (1).

Fig. 2097
2. Remove the brake carrier (1) and retrieve the brake disc (3).
Note
Hold the brake disc in place to prevent it from falling when
removing the brake carrier.

3
1

Fig. 2098

Refitting
1. Before reassembly, clean the mating surfaces between the brake carrier (1) and the transmission casing thoroughly and apply
DOW CORNING 7091 sealant.
2. Fit the brake disc (3) in its seat.
3. Fit the brake carrier (1) on the transmission casing.

Fig. 2099

Completion
l See para. 30.11.1 - Wheel carriers - page 30-475
l See para. 30.18.1 - Rear wheels - page 30-602

30-505
 Method of intervention
30.12 - F0 - Front axle
30.12.1 - Front axle
Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
Removal
1. Place a safety stand under the oil sump.
2. Working on the left hand side, undo the inner screw (1) of the brake line
guard.
1

Fig. 2100
3. Undo the front nut (2) and remove the left hand brake line guard (3).
4. Undo the four screws (4) and remove the cover (5) of the steering angle
sensor. 4
5
3

Fig. 2101
5. Disconnect the connector (6) of the steering angle sensor SBA, and undo the fastener screw (7) of the clamp.
6. Undo the union (8) of the left hand brake line (9).
7. Move the brake line and the sensor cable aside.
8
7

Fig. 2102
8. Repeat the sequence of operations described above on the right hand side to remove the guard and disconnect the right hand
brake line.
9. Place a container under the vehicle to collect steering system fluid.

30-506
Method of intervention
10. On both sides, undo the unions (10) of the steering cylinders and move the
hydraulic lines (11) aside.
10

10

11

Fig. 2103
11. Undo the union (12) and disconnect the front differential lock oil line (13).

12

13

Fig. 2104
12. Place a pneumatic hitch under the front axle, lift the vehicle and remove the front wheels.
13. Secure the front axle to a hoist with two straps.
14. Undo the rear nuts (14) fastening the front axle.

14

14

Fig. 2105
15. Undo the front fastener nuts (15) and remove the front axle (16).

15
15

16

Fig. 2106

30-507
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
Tighten the nuts (14 and 15) fastening the front axle to a torque of 270 Nm.
Tighten the brake line unions (8) to a torque of 30 Nm±10%.
Tighten the steering line unions (10) to a torque of 19 Nm±10%.
Tighten the differential lock line union (12) to a torque of 30 Nm±10%.
Completion
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.12.2 - Steering cylinders

Removal
1. Undo the screws (1) and remove the cover (2).
2. Recover spacers (3).

Fig. 2107
3. Undo the screws (4) and remove the cover (5).

Fig. 2108
4. Undo the unions (6) and disconnect the hydraulic steering lines (7)
Note
Plug the lines and the respective holes on the cylinders to
7
prevent contamination.

6
6

Fig. 2109
5. Remove the grease nipple (8).
6. Loosen the nut (9) and remove the grub screw (10).

30-508
Method of intervention
7. Remove the pin (11), pulling out from below.

10

11

Fig. 2110
8. Retrieve the protective gaskets (12), complete with spacers (13).
13

12

Fig. 2111
9. Remove the screw (14) and remove the pin (15), supporting the weight of
the cylinder adequately.
14

15

Fig. 2112
10. Retrieve the protective gaskets (16) and the relative spacers (17), and de-
17
tach the steering cylinder (18).

16
18

Fig. 2113

30-509
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace the copper gaskets removed previously from the unions.
3. Tighten the screw (14) fastening the pin to a torque of 20.4 Nm ±1 %.
4. Fit the pin (11), turning into the correct position so that it is secured in place by tightening the grub screw (10).
5. Lock the grub screw (10), tightening the nut (9) to a torque of 45±2 Nm.
6. Tighten the unions (6) to a torque of 40±4 Nm.

30.12.3 - Removing steering cylinders

Removal
1. Place the steering cylinder in the vice and undo the ring nut (1).

Fig. 2114
2. Use a plastic mallet to push the head (2) into the cylinder.

Fig. 2115
3. Remove the circlip (3) retaining the head.

Fig. 2116
4. Remove the shaft complete with piston (4), head (2) and fastener ring nut (1), and place in the vice.
5. Undo the self-locking nut (5), and use a suitable extractor tool to remove the piston (4) from the shaft.

30-510
Method of intervention
6. Remove the head (2) and the relative fastener ring nut (1).
5

Fig. 2117
7. Remove the circlip (6).
8. Turn the cylinder over and use a suitable mallet to drive the ball joint (7)
out of its seat.
6

Fig. 2118
9. Remove the circlip (8) using the same procedure.
10. Turn the shaft over and use a suitable mallet to drive the ball joint (9) out
of its seat.

Fig. 2119

30-511
 Method of intervention
Installation
1. Replace the O-rings (10), the seal ring on the shaft (11) and the dust seal
12
ring (12) on the head (2), ensuring that the rings (11 and 12) are rotated
into the correct positions.
10
11 2

10 12

Fig. 2120
2. Replace the seal (13) on the piston (4).

13
4

13

Fig. 2121
3. Assemble the shaft, installing the ring nut (1), the circlip (3) and the head (2) in the sequence given.
Note
Lubricate the lips of the rings (11 and 12) with oil before installing the head (2) on the shaft.

4. Fit the piston (4) on the shaft, and fasten with the self-locking nut (5), tight-
ening to a torque of 86 to 90 Nm. 5

Fig. 2122
5. Lubricate the O-ring (10) on the head and the seal ring on the piston (13) with oil, and fit the shaft in the cylinder.
6. Push the head into the cylinder and fit the circlip (3) to keep it within the
cylinder.

Fig. 2123

30-512
Method of intervention
7. Pull the shaft to pull the head (2) out from the cylinder, and tighten the ring 1
nut (1) to a torque of 40 Nm.
Note
Moisten the thread of the ring nut (2) with Loctite 242.
2

Fig. 2124
8. Using a suitable mallet, install the ball joints (7 and 9) in their respective
seats and fasten in place with the relative circlips (6 and 8). 6

Fig. 2125

30.12.4 - 4WD shaft ()

Removal
1. Undo the fastener screws (1) and nuts (2) and remove the pipe shield (3).

1 2
2

Fig. 2126
2. Undo the two rear screws (4).

Fig. 2127

30-513
 Method of intervention
3. Undo the front screws (5) and move the dual traction shaft guard (6) aside,
without disconnecting the lines.

5
6

Fig. 2128
4. Remove the stop pins and remove the dual traction shaft.

Fig. 2129

Refitting
1. Carry out the removal operations in reverse order.

30.12.5 - Separating front carrier from engine

Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
Separation
1. Place a safety stand under the oil sump.
2. Working on the left hand side, undo the inner screw (1) of the brake line
guard.
1

Fig. 2130
3. Undo the front nut (2) and remove the left hand brake line guard (3).

30-514
Method of intervention
4. Undo the four screws (4) and remove the cover (5) of the steering angle
sensor. 4
5
3

Fig. 2131
5. Disconnect the connector (6) of the steering angle sensor SBA, and undo the fastener screw (7) of the clamp.
6. Undo the union (8) of the left hand brake line (9).
7. Move the brake line and the sensor cable aside.
8
7

Fig. 2132
8. Repeat the sequence of operations described above on the right hand side to remove the guard and disconnect the right hand
brake line.
9. Place a container under the vehicle to collect steering system fluid.
10. On both sides, undo the unions (10) of the steering cylinders and move the
hydraulic lines (11) aside.
10

10

11

Fig. 2133
11. Undo the union (12) and disconnect the front differential lock oil line (13).

12

13

Fig. 2134

30-515
 Method of intervention
12. Loosen the clamp (14) and disconnect the air hose (15).
14

15

Fig. 2135
13. Undo the clamps (16) and disconnect the fuel lines (17).

17
17

16
16

Fig. 2136
14. Undo the clamp (18) and disconnect the line (19) connecting with the expansion tank.
15. Undo the clamp (20) and disconnect the intercooler outlet hose (21).
21 20

19 18

Fig. 2137
16. Undo the unions (22) and disconnect the transmission oil delivery and re-
turn lines (23) from the oil radiator.
22 23

22

23

Fig. 2138
17. Loosen the clamps (24) and disconnect the coolant delivery and return lines (25) from the radiator.

30-516
Method of intervention
18. Undo the clamp (26) and disconnect the intercooler inlet hose (27).
24

25
27

26

25

24

Fig. 2139
19. Disconnect the A/C system pressure switch connection (28).
20. Undo the screws (29) fastening the inlet and outlet unions.
21. Remove the lines (30).
28 29

30

30

29

Fig. 2140
22. Undo the screws (31) fastening the radiator assembly mounting bracket
(32).

31
32
31

Fig. 2141
23. Place two wooden wedges (33) between the front axle (34) and the front carrier (35) to prevent the carrier from wobbling.
24. Support the front of the carrier with a strap and a hoist.

35
33

34

Fig. 2142
25. Place a stand (36) under the oil sump, with a block of wood in between.

30-517
 Method of intervention
26. Undo the lower nuts (37) fastening the front carrier to the engine.

37 37

36

Fig. 2143
27. Undo the upper screws (38) fastening the front carrier to the engine.

38

38

Fig. 2144
28. Move the carrier forwards, complete with front axle and radiator assembly, to separate it from the engine.
29. Place a stand under the front part of the carrier, with a wooden block in between, and remove the carrier strap.

Connection
1. Follow the procedure for separation in reverse order.
2. Tighten the upper screws (38) fastening the front carrier to the engine to a torque of 173 Nm.
3. Tighten the lower nuts (37) fastening the front carrier to the engine to a torque of 185 Nm.
4. Tighten the transmission oil delivery and return lines (22) to the radiator to a torque of 73 Nm ± 10%.
5. Tighten the front differential lock line union (12) to a torque of 30 Nm± 10%.
6. Tighten the steering cylinder unions (10) to a torque of 19 Nm± 10%.
7. Tighten the brake line unions (18) to a torque of 30 Nm± 10%.
Completion
l See para. 30.12.4 - 4WD shaft () - page 30-513

30.12.6 - Front mount

Preliminary operations
l See para. 30.12.4 - 4WD shaft () - page 30-513
l See para. 30.12.5 - Separating front carri... - page 30-514
l See para. 30.9.8 - Air filter container - page 30-154
l See para. 30.9.9 - Radiator assembly - page 30-155

30-518
Method of intervention
Removal
1. Undo the rear nuts (1) fastening the front axle.

Fig. 2145
2. Undo the front fastener nuts (2) and remove the front axle carrier (3).
3

2
2

Fig. 2146

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the nuts (1 and 2) fastening the front axle carrier to a torque of 270 Nm.
Completion
l See para. 30.9.9 - Radiator assembly - page 30-155
l See para. 30.9.8 - Air filter container - page 30-154
l See para. 30.12.5 - Separating front carri... - page 30-514
l See para. 30.12.4 - 4WD shaft () - page 30-513

30-519
 Method of intervention
30.13 - G0 - Bodywork - Cab - Platform
30.13.1 - Cab
Preliminary operations
Place two stands under the wheel carriers, with wooden blocks in between, and remove the rear wheels.
l See para. 30.18.1 - Rear wheels - page 30-602
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.9.5 - Fuel tank - page 30-151
l See para. 30.9.6 - Exhaust pipe - page 30-153
Removal
1. Undo the screws (1) and detach the guards (2).
2. Undo the unions (3) and disconnect the A/C lines (4).
2
1

4
3

Fig. 2147
3. Undo the unions (5) and disconnect the steering oil lines (6).

Fig. 2148
4. Undo the nut (7) and move the brake fluid reservoir (8) aside.

8
7

Fig. 2149

30-520
Method of intervention
5. Undo the nut (9) and disconnect the cab ground cable (10).

9 10

Fig. 2150
6. Undo the unions (11) and disconnect the brake lines (12) from the SAFIM 12
valve (13).

11

13

Fig. 2151
7. Undo the union (14) and disconnect the steering oil return line (15).

14
15

Fig. 2152
8. Undo the bolt (16) and disconnect the gear selector Bowden cable (17).
9. Undo the bolt (18) and disconnect the reduction gear Bowden cable (19).

19
18 17
16

Fig. 2153

30-521
 Method of intervention
10. Undo the unions (20) and disconnect the park brake lines (21).

21

20

Fig. 2154
11. Undo the union (22) and disconnect the line (23) from the left hand park
brake.
23

22

Fig. 2155
12. Disconnect the cab power connectors (24).
24

Fig. 2156
13. Disconnect wiring connector (25).

25

Fig. 2157

30-522
Method of intervention
14. Undo the screws (26) and disconnect the three Bowden cables (27) for the
rear distributor.
27

26

Fig. 2158
15. Undo the clamps (28) and disconnect the cab heating lines (29).
29

28

Fig. 2159
16. Undo the three screws (30) and detach the trailer connector (31).
31
30

Fig. 2160
17. Open the clip (32) and disconnect the PTO 540-1000 rpm tie-rod (33).

33

32

Fig. 2161

30-523
 Method of intervention
18. Undo the union (34) and disconnect the line (35) from the right hand park
brake.

35

34

Fig. 2162
19. Remove the retainer ring (36) and disconnect the Ground speed PTO
Bowden cables (37).
37

36

Fig. 2163
20. Undo the union (38) and disconnect the steering oil delivery line (39).

39 38

Fig. 2164
21. Secure straps to the turn indicator mounts (40).

40

Fig. 2165

30-524
Method of intervention
22. Secure straps to the eye bolts (41) fastened to the respective reinforced
attachment points on the cab chassis.

41

Fig. 2166
23. Secure the cab to the lifting beam (42) with straps and a hoist.
24. Raise the hoist slightly to take up the slack in the straps.

42

Fig. 2167
25. Undo the cab mount nuts (43).

43 43

Fig. 2168
26. Lift the cab (44), remove it from the vehicle and set it down on a suitable
support.

44

Fig. 2169

30-525
 Method of intervention
Refitting
1. Tighten the cab mount nuts (43) to a torque of 185 Nm.
2. Tighten the connector (38) of the steering oil delivery line (39) to a torque of 76 Nm.
3. Tighten the connector (14) of the steering oil return line (15) to a torque of 90 Nm.
4. Tighten the connector (34) of the right hand park brake line (35) to a torque of 60 Nm.
5. Tighten the connector (22) of the left hand park brake line (23) to a torque of 60 Nm.
6. Tighten the unions (20) of the park brake lines (21) to a torque of 50 Nm.
7. Tighten the unions (11) of the brake lines (12) to the SAFIM valve to a torque of 50 Nm.
8. Tighten the nut (9) fastening the cab ground cable (10) to a torque of 70 Nm.
9. Tighten the unions (5) of the steering lines (6) to a torque of 60 Nm.
10. Tighten the unions (3) of the A/C system lines (4) to a torque of 35 Nm.
Completion
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.9.6 - Exhaust pipe - page 30-153
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.18.1 - Rear wheels - page 30-602
l Remove the two stands from underneath the wheel carriers
l See para. 30.11.1 - Wheel carriers - page 30-475

30.13.2 - Condenser
Removal
1. Discharge the A/C system.
2. Turn the lock lever (1) and move the condenser to the side.

Fig. 2170
3. Disconnect the general pressure switch connection (2).
4. Undo the screws (3) fastening the inlet and outlet unions.

Fig. 2171

30-526
Method of intervention
5. Undo the screws (4) fastening the sliding system and remove the condens-
er (5) with the dehydrator filter.
4

Fig. 2172

Refitting
1. Carry out the removal operations in reverse order.

30.13.3 - Disassembling the condenser

Removal
1. Undo the screw (1) fastening the outlet union.

Fig. 2173
2. Loosen the clamp (2) and remove the dehydrator filter (3).

Fig. 2174
3. Undo the fastener screws (4) on both sides and separate the condenser (5)
from the frame (6).

5 6

Fig. 2175

30-527
 Method of intervention
Installation
1. Carry out the disassembly operations in reverse order.

30.13.4 - Dehydrator filter

Removal
1. Discharge the A/C system.
2. Turn the lock lever (1) and move the condenser to the side.

Fig. 2176
3. Undo the screws (2) fastening the inlet and outlet unions.

Fig. 2177
4. Loosen the fastener clamp (3) and remove the dehydrator filter (4).

Fig. 2178

Refitting
1. Carry out the removal operations in reverse order.

30-528
Method of intervention
30.13.5 - A/C unit
Removal
1. Undo and remove the fastener screws (1) and remove the cover (2).

1 2

Fig. 2179
2. Disconnect the electrical connection (3).

Fig. 2180
3. Undo the clamps (4) and disconnect the cab heating lines (5).
4
5

Fig. 2181
4. Disconnect all the electrical connections (6) on the right hand side.

6
6

Fig. 2182

30-529
 Method of intervention
5. Undo the two screws (7) and disconnect the refrigerant fluid lines (8).

Fig. 2183
6. Undo the four fastener screws (9) and remove the A/C unit (10).

9 9
10

Fig. 2184

Refitting
1. Refit by following the procedure for removal in reverse order.

30.13.6 - Heater unit

Removal
1. Undo and remove the fastener screws (1) and remove the cover (2).

1 2

Fig. 2185
2. Disconnect the electrical connection (3).

Fig. 2186

30-530
Method of intervention
3. Undo the clamps (4) and disconnect the cab heating lines (5).
4
5

Fig. 2187
4. Undo the four fastener screws (6) and remove the heater unit (7).

6 6
7

Fig. 2188

Refitting
1. Refit by following the procedure for removal in reverse order.

30.13.7 - Cab access steps

Removal
1. Undo the four fastener screws (1) and remove the cab access steps (2).
1

Fig. 2189
2. If necessary, repeat the procedure on the opposite side.
Refitting
1. Carry out the removal operations in reverse order.
2. Tighten the fastener screw to a torque of 40.8 Nm.

30.13.8 - Expansion valve

Preliminary operations
l See para. 30.13.5 - A/C unit - page 30-528

30-531
 Method of intervention
Removal
1. Undo the screws (1) and remove the expansion valve (2).
1

Fig. 2190

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
Completion
l See para. 30.13.5 - A/C unit - page 30-528

30.13.9 - Engine cowl

Removal
1. Disconnect the brake/clutch fluid level sensor connector (1).
1

Fig. 2191
2. Disconnect the three connectors (2) of the cowl wiring loom (3).

Fig. 2192
3. Secure the cowl to a hoist with a strap.

30-532
Method of intervention
4. Undo the two bolts (4) fastening the engine cowl.

Fig. 2193
5. Disconnect the head (5) of the cylinder and remove the engine cowl (6).

6
5

Fig. 2194

Refitting
1. Refit by following the procedure for removal in reverse order.

30.13.10 - Hand brake bowden cable replacement

Removal
1. Inside the cab, on the left side, unscrew the PTO speed knob (1) and re-
move it. 1
Beware not to loose the inner spring.

Fig. 2195
2. Pull out the pin (2) and remove the PTO control grip (3) and, if present, the
3
PTO Synchro control grip too.

Fig. 2196

30-533
 Method of intervention
3. Lower fully down the hand brake lever, remove the screws (4) and the 4
cover (5).

4
Fig. 2197
4. Under the tractor, on the transmission left hand side, loosen the nut (6),
remove the pin (7) and by a small screwdriver remove the seeger ring (8).

8
6

Fig. 2198
5. Disconnect the bowden cable from the hand brake lever by removing first
the cotter pin (9), then the pin (10) and seeger ring (11).
Now the bowden cable is free and can be removed pulling it from the bot-
tom of the cab. 9
10

11

Fig. 2199
6. Transfer the fork (12) and the nut (6) on the new cable.

12

Fig. 2200

30-534
Method of intervention
Refitting
1. Mount the new bowden cable and connect it inside the cab to the hand brake lever with its pin.Then go underneath the cab and
connect the bowden cable to the reaction bracket with the seeger ring (8) but wait to connect the fork (12) to the brake lever.
Then proceed to the hand brake stroke adjustement as follows.
Hand brake stroke adjustement
1. Lift the hand brake lever counting three clicks and let the lever in this posi-
tion.
Go underneath the cab and push fully upwards the brake lever (13) tilll the
inner brake cam goes in contact with the brake reaction plate and keep it
in position. 8

12

13

Fig. 2201
2. Screw-in the bowden cable fork (12) till the pin-hole is lined up with the lever hole and fit the connecting pin.
3. Release the hand brake lever fully down and then pull it upwards again counting the number of clicks necessary to go to full
tension.
4. The adjustement is correct if the cable goes in tension after three free clicks. Otherwise repeat the fork adjustement screwing-
in half a turn per time till reaching the proper adjustement.
5. When completed the adjustement fit the pin definitively with its cotter pin and block the fork counter-nut (6).
6. Complete the reassembly by remounting the remaining parts inside the cab.

30-535
 Method of intervention
30.14 - H0 - Hydraulic system
30.14.1 - Rear ancillary utility distributor
Removal
1. Undo the unions (1 and 2) and disconnect the oil lines.
2. Disconnect the oil recovery lines (3).

2 1

Fig. 2202
3. Undo the three screws (4), then lift and remove the distributor (5), complete 4
with manifolds (6) and quick connector unions.

6 5

Fig. 2203
4. Remove the protective covers (7).
5. Undo the unions (8) and remove the manifolds (6), retrieving the O-rings.
7 6
8

Fig. 2204

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace the gaskets removed during disassembly.
3. Fasten the distributor (5) to the relative mount, tightening the screws (4) to a torque of 20.4±1 Nm.
4. Fasten the manifolds (6), tightening the unions (8) to a torque of 58±5.8 Nm.
5. Connect the oil delivery line and tighten the union (1) to a torque of 76±3.8 Nm.
6. Connect the oil return line and tighten the union (2) to a torque of 58±5.8 Nm.

30-536
Method of intervention
30.14.2 - Services solenoid valve assembly
Removal
1. Disconnect the electrical connection (1) from the solenoid valve block.

Fig. 2205
2. Disconnect the electrical connections (2) from the solenoid valve block.
Note
Mark the positions of the connectors to prevent accidentally swapping them during reconnection.

3. Release the wiring loom (3) from the clamps and move it aside.
4. Undo the union (4) and disconnect the line (5) from the solenoid valve.
5
2

Fig. 2206
5. Undo the screw (6), remove the oil line fastener and move the line (5) aside.

Fig. 2207

30-537
 Method of intervention
6. Loosen the unions (7 and 8) and disconnect the lines (9, 10 and 11).

11

9
7
8

10

Fig. 2208
7. Undo the unions (12) and disconnect the rear PTO control lines.
8. Undo the unions (13, 14 and 15) and disconnect the relative lines.
9. Undo and remove the union (16) with the relative copper gaskets.

12

13
16
14
15

Fig. 2209
10. Undo the screws (17) and detach the solenoid valve block (18).
11. Retrieve the spacers between the solenoid valve block and the transmis-
sion.
18

17

Fig. 2210

30-538
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace all the gaskets removed during disassembly.
3. Tighten the fastener screws (17) to a torque of 20.4±1 Nm.
4. Tighten the union (16) to a torque of 40±4 Nm.
5. Tighten the unions (13 and 14) to a torque of 28±1.4 Nm.
6. Tighten the union (15) to a torque of 110±5.5 Nm.
7. Connect the rear PTO control lines and tighten the unions (12) to a torque of 19±0.9Nm.
8. Tighten the unions (7) to a torque of 110±5.5 Nm.
9. Tighten the union (8) to a torque of 76±3.8 Nm.

30.14.3 - Disassembling the ancillary solenoid valve block

Removal
1. Undo the screws (1) and detach the solenoid valve block (2).
2

Fig. 2211
2. Separate the pressure holding block (3) from the accumulator block (4).

3
4

Fig. 2212
3. Loosen the valve (5) and remove.
5

Fig. 2213

30-539
 Method of intervention
4. Undo the plug (6) and remove the spring (7) and the valve (8).
7
Note 6

Mark the correct installation positions to prevent acciden-

tally swapping with other valves during reassembly. 8

Fig. 2214
5. Remove the plug (9) and remove the ball (10).

10

Fig. 2215
6. Undo the plug (11) and remove the valve (12) with the relative spring.
Note
12
Mark the correct installation positions to prevent acciden-
tally swapping with other valves during reassembly. 11

Fig. 2216
7. Undo the plug (13) and remove the valve (14) with the relative spring.
Note
13
Mark the correct installation positions to prevent acciden-
tally swapping with other valves during reassembly.

14

Fig. 2217

30-540
Method of intervention
8. Undo the nut (15) and remove the solenoid (16) from the solenoid valve.

16

15

Fig. 2218
9. Applying a wrench to the hexagonal part, remove the solenoid valve body (17).
10. Repeat the procedure for the remaining solenoid valves.

17

Fig. 2219

Installation
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace all seals removed during disassembly.
3. Replace the O-rings on the valve stems (12 and 8).
4. Tighten the solenoid valve body (17) to a torque of 15 to 20 Nm.
5. Fasten the solenoid, tightening the nut (15) to a torque of 5±0.5 Nm.
6. Tighten the plug (9) to a torque of 14±1.4 Nm.
7. Tighten the plug (13) to a torque of 40±4 Nm.
8. Tighten the plug (11) to a torque of 48±5 Nm.
9. Tighten the plug (6) to a torque of 58±5,8 Nm.
10. Tighten the valve (5) to a torque of 35 to 40 Nm.

30.14.4 - Shuttle solenoid valves assembly (5110 C -> ZKDY520200TD10001, 5120 C ->
ZKDY560200TD10001)
Preliminary operations
l See para. 30.13.7 - Cab access steps - page 30-531
l See para. 30.15.1 - Battery mount with wir... - page 30-569
Removal
1. Disconnect the electrical connections (1, 2 and 3).
1

2
3

Fig. 2220

30-541
 Method of intervention
2. Disconnect the electrical connections (4 and 5).
3. Loosen the unions (6 and 7) and disconnect the oil lines from the solenoid
7
valve block. 4

Fig. 2221
4. Undo the screws (8) and remove the shuttle solenoid valve unit (9).

Fig. 2222

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace the O-Rings on the mating surface between the valve block and the transmission casing.
3. Tighten the fastener screws (8) to a torque of 20.4±1 Nm.
4. Tighten the union (7) to a torque of 110±5.5 Nm.
Completion
l See para. 30.15.1 - Battery mount with wir... - page 30-569
l See para. 30.13.7 - Cab access steps - page 30-531

30.14.5 - Disassembling shuttle solenoid valve block (5110 C -> ZKDY520200TD10001,

5120 C -> ZKDY560200TD10001)
Removal
1. Place the solenoid valve block on a work bench.
2. Undo the accumulator (1).
1

Fig. 2223

30-542
Method of intervention
3. Undo the nut (2) and remove the solenoids (3 and 4) of the solenoid valve,
removing the relative O-Rings.

Fig. 2224
4. With the wrench fitted to the hexagonal part of the body (arrow), undo the solenoid valve body (5) from the solenoid valve
block.
5. Undo the nut (6) and remove the solenoid (7) of the solenoid valve, remov-
ing the relative O-Rings.

Fig. 2225
6. With the wrench fitted to the hexagonal part of the body (arrow), remove the
solenoid valve body (8).

Fig. 2226

30-543
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Replace all seals removed during disassembly.
3. Tighten the solenoid valve body (8) to a torque of 15 - 20 Nm.
4. Fasten the solenoid (7), tightening the nut (6) to a torque of 5±0.5 Nm.
5. Tighten the solenoid valve body (5) to a torque of 45 - 50 Nm.
6. Fasten the solenoids (3 and 4), tightening the nut (2) to a torque of 5 - 8 Nm.

30.14.6 - Power steering valve

Removal
1. Disconnect the solenoid valve connector (1) and the power steering connector (2).
2. Undo the nut (3) and remove the solenoid (4). 3

Fig. 2227
3. Undo the two unions (5) and disconnect the lines (6).

Fig. 2228
4. Undo the two unions (7) and disconnect the lines (8).
5. Undo and remove the two unions (9).

Fig. 2229

30-544
Method of intervention
6. Undo the upper (10) and lower (11) screws fastening the power steering
unit.

10

11

Fig. 2230
7. Remove power steering valve (12).

12

Fig. 2231

Refitting
1. Fit and tighten two stud bolts (13) to facilitate assembly.
2. With the help of another operator working from inside the cab, install the
power steering unit, ensuring that it is connected correctly with the steering 13
column (14).

14

Fig. 2232
3. Fasten the power steering unit with two nuts (15).

15

Fig. 2233
4. Fit the two lower screws (11), hand-tightening only.
5. Remove the two nuts and the stud bolts, and fit the two upper screws (10), hand-tightening only.

30-545
 Method of intervention
6. Tighten the lower (11) and upper (10) fastener screws to a torque of 38.6
Nm.

10

11

Fig. 2234
7. Fit the two unions (9) and tighten to a torque of 135 Nm.
8. Tighten the unions (7) of the lines (8) to a torque of 60 Nm.

Fig. 2235
9. Tighten the unions (5) of the lines (6) to a torque of 90 Nm.

Fig. 2236
10. Fit the solenoid (4) and tighten the nut (3) to a torque of 5±0.5 Nm.
11. Connect the power steering unit connector (2) and the solenoid valve con- 3
nector (1).
1

Fig. 2237

30-546
Method of intervention
30.14.7 - Disassembling the complete pump assembly
Removal
1. Loosen the collars (1, 2 and 3) and disconnect the oil pickup lines (4, 5 and
5
6) of the relative pumps.

6 3

2
1

Fig. 2238

60l ECO pump

1. Undo the screws (7) and disconnect the delivery line (8) from the pump.
2. Undo the screws (9) and remove the oil pickup line (4).
3. Undo the two fastener screws (10) and detach the 60 l ECO pump (11) from 8
7
its mount.

10

11

4
9

Fig. 2239
4. Undo the nuts (12) and detach the 60 l ECO pump mount (13).
5. Remove the 60l ECO pump control sleeve (14).
12

14
13

12

Fig. 2240

Power steering pump

1. Undo the union (15) and disconnect the oil delivery line (16).

30-547
 Method of intervention
2. Remove the fastener screw (17) and release the line (16).
17

16
15

Fig. 2241
3. Undo the fastener screws (18) and remove the oil pickup line (5).
4. Undo the fastener screws (19) and remove the oil delivery line (20).
5. Undo the two nuts (21) and remove the power steering pump (22) complete
with carrier plate. 5 21

Note
If necessary, the pump may be separated from the mount
18
following the same procedure described for the 60l ECO
pump.
20 22

19
Fig. 2242
6. Remove the power steering pump control sleeve (23).

23

Fig. 2243

30-548
Method of intervention
Ancillary pump
1. Undo the union (24) and disconnect the oil delivery line (25).
2. Undo the fastener screws and remove the oil delivery line (25) from the pump.
3. Undo the fastener screws (26) and remove the oil pickup line (6).
4. Undo the union and disconnect the oil delivery line (27) from the transfer pump.
5. Undo the screws (28) and remove the ancillary pump (29). 26 27
6

24

25

28
29

Fig. 2244

Transfer pump
1. Undo the screws (30) and disconnect the oil pickup line (31) from the transfer pump.
2. Undo the nuts (32) and remove the oil transfer pump (33).

32

33

30

31

Fig. 2245
3. Remove the ancillary and transfer pump control sleeve (34).

34

Fig. 2246
4. Undo the fastener screws (35) and remove the lateral plug (36).

35

36

Fig. 2247

30-549
 Method of intervention
5. Remove the transmission oil filter cartridge (37) from its housing.

37

Fig. 2248
6. On the opposite side, undo the three fastener screws (38) and remove the
oil pickup line (39). 38

39

Fig. 2249

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Replace all seals removed during disassembly.
3. In addition to fitting paper gaskets, apply a thin layer of Loctite 510 sealant or Loctite 518 sealant to the mating surfaces of
the pumps.
4. Tighten the oil pickup line fastener screws (38) to a torque of 20.4±1 Nm.
5. Tighten the air filter cover fastener screws (35) to a torque of 20.4±1 Nm.
Transfer pump
1. Fit the sleeve (34), with the shorter splined end facing towards the transfer pump.
2. Tighten the nuts (32) fastening the transfer pump to a torque of 40.4±2 Nm.
3. Tighten the screws (30) to a torque of 20.4±1 Nm.
4. Tighten the delivery line fastener union (27) to a torque of 73±7.3 Nm.
Ancillary pump
1. Tighten the screws (28) fastening the ancillary pump to a torque of 38+7 Nm.
Note
Moisten the threads of the pump fastener screws with Loctite 242.

2. Fasten the oil delivery line to the pump, tightening the screws to a torque of 7+2 Nm.
3. Fasten the oil pickup line to the pump, tightening the screws (26) to a torque of 7+2 Nm.
Power steering pump
1. Tighten the nuts (21) fastening the power steering pump to a torque of 40.4±2 Nm.
2. Fasten the oil delivery line to the pump, tightening the screws (19) to a torque of 7+2 Nm.
3. Fasten the oil pickup line to the pump, tightening the screws (18) to a torque of 7+2 Nm.

30-550
Method of intervention
60l ECO pump
1. Tighten the screws (10) fastening the 60l ECO pump to a torque of 38+7 Nm.
Note
Moisten the threads of the pump fastener screws with Loctite 242.

2. Fasten the oil delivery line to the pump, tightening the screws (7) to a torque of 7+2 Nm.
3. Fasten the oil pickup line to the pump, tightening the screws (9) to a torque of 7+2 Nm.

30.14.8 - Transmission oil radiator

Preliminary operations
l See para. 30.9.8 - Air filter container - page 30-154
l See para. 30.13.2 - Condenser - page 30-526
Removal
1. Undo the unions (1) and disconnect the transmission oil delivery and return
lines from the oil radiator.
1

Fig. 2250
2. Undo the two fastener screws (2), working on both sides.

2 2

2 2

Fig. 2251
3. Remove the transmission oil radiator (3) with the oil delivery and return
lines (4).
4

Fig. 2252
4. If necessary, remove the oil delivery and return lines.

30-551
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the screws (2) fastening the transmission oil radiator (3) to a torque of 20 Nm.
Completion
l See para. 30.9.8 - Air filter container - page 30-154
l See para. 30.13.2 - Condenser - page 30-526

30.14.9 - 60L ECO 8-way distributor solenoid valve

Removal
1. Disconnect the electrical connection (1) from the SAV solenoid valve.

Fig. 2253
2. Disconnect the electrical connection (2) from the ECO solenoid valve.

Fig. 2254
3. Undo the union (3) and disconnect the delivery line (4).
3 4

Fig. 2255

30-552
Method of intervention
4. Undo the rear union (5) and disconnect the line from the check valve (6).

6
5

Fig. 2256
5. Undo the two screws (7) and disconnect the inlet return line (8).

Fig. 2257
6. Undo the screws (9) and disconnect delivery line (10).
7. Undo the two screws (11) and remove the solenoid valve block (12).

12
11

10

Fig. 2258

30-553
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace all the gaskets removed during disassembly.
3. Tighten the fastener screws (11) to a torque of 20.4±1 Nm.
4. Connect the line (10) to the solenoid valve, tightening the screws (9) to a torque of 8.4±0.4 Nm.
5. Connect the line (8) to the solenoid valve, tightening the screws (7) to a torque of 8.4±0.4 Nm.
6. Connect the line to the check-valve (6), tightening the union (5) to a torque of 30±3 Nm.

30.14.10 - Disassembling the 60L ECO 8-way distributor solenoid valve

Removal
1. Undo the screws (1) and remove the pipe (2).

1
2

Fig. 2259
2. Undo the check valve (3) from the solenoid valve block.

Fig. 2260
3. Undo the nut (4) and remove the solenoid (5) from the ECO solenoid valve.

5 4

Fig. 2261

30-554
Method of intervention
4. Applying a wrench to the hexagonal part (arrow), remove the ECO valve
body (6) from the solenoid valve block.

Fig. 2262
5. Undo the nut (7) and remove the solenoid (8) from the SAV solenoid valve.

Fig. 2263
6. Applying a wrench to the hexagonal part (arrow), remove the SAV valve
body (9) from the solenoid valve block.
9

Fig. 2264
7. Unscrew and remove the valve (10).

10

Fig. 2265

30-555
 Method of intervention
Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Replace all seals removed during disassembly.
3. Tighten the valve (10) to a torque of 35 to 40 Nm.
4. Fit the SAV valve body (9) and tighten to a torque of 15 to 20 Nm.
5. Fasten the solenoid (8) of the solenoid valve, tightening the nut (7) to a torque of 4.5 to 5.5 Nm.
6. Fit the ECO valve body (6) and tighten to a torque of 15 to 20 Nm.
7. Fasten the solenoid (5) of the solenoid valve, tightening the nut (4) to a torque of 4.5 to 5.5 Nm.
8. Fasten the pipe (2), tightening the screws (1) to a torque of 8.4±0.4 Nm.

30.14.11 - 2-way distributor

Removal
1. Disconnect the electrical connections (1) from the solenoid valves.

Fig. 2266
2. Remove the quick connector union covers (2), without disconnecting them
from the oil recovery line (3), and move them aside without removing.

Fig. 2267
3. Place a suitable container under the distributor to collect any escaping oil,
and disconnect the lines by disconnecting the unions (4, 5 and 6).
4

6 5

Fig. 2268

30-556
Method of intervention
4. Undo the fastener screws (7) and remove the two-way distributor (8). 8

Fig. 2269

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Replace the copper gaskets removed during disassembly.
3. Tighten the fastener screws (7) to a torque of 20.4±1 Nm.
4. Tighten the union (4) to a torque of 73±7.3 Nm.
5. Tighten the union (6) to a torque of 76±3.8 Nm.

30.14.12 - Disassembling the 2-way distributor

Removal
1. Undo the nut (1) and remove the solenoids (2 and 3) of the dual solenoid
valve. 1

Fig. 2270
2. Applying a wrench to the hexagonal part (arrow), undo the solenoid valve
body (4).

Fig. 2271

30-557
 Method of intervention
3. Undo the nut (5) and remove the solenoid (6) from the solenoid valve.

Fig. 2272
4. Applying a wrench to the hexagonal part (arrow), undo the solenoid valve
body (7).

Fig. 2273
5. Undo the valve (8) and the union (9).
8

Fig. 2274
6. Retrieve the moving element (10) of the valve and the relative spring (11).
11
10

Fig. 2275

30-558
Method of intervention
7. Unscrew and remove the valve (12).
12

Fig. 2276

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Replace the O-rings removed previously, lubricating the new O-rings with oil before fitting.
3. Tighten the valve (12) to a torque of 35 to 40 Nm.
4. Tighten the valve (8) to a torque of 73±7.3 Nm.
5. Tighten the union (9) to a torque of 58±5.8 Nm.
6. Tighten the solenoid valve body (7) to a torque of 15 to 20 Nm.
7. Fasten the solenoid (6), tightening the nut (5) to a torque of 5 to 8 Nm.
8. Tighten the solenoid valve body (4) to a torque of 15 to 20 Nm.
9. Fasten the solenoids (2 and 3), tightening the nut (1) to a torque of 5 to 8 Nm.

30.14.13 - Pressure transducer / Temperature sender (intake air)

1. m DEUTZ AP1908 assembly product
WARNING
Ensure maximum cleanliness during all work. Before pro-
ceeding with removal, remove any paint residue or debris.
Thoroughly clean the area around the components to be
worked on. Dry any wet areas with an air jet. All fuel lines
and unions should be closed immediately after opening us-
ing new, clean plugs or caps. Remove plugs and caps only
immediately prior to assembly.
m 1 - Temperature sender
m 2 - Hex screw: 11 Nm
m 3 - Hex screw: 30 Nm © 51446-0

m 4 - Hex screw: 5 Nm Fig. 2277

m 5 - Pressure transducer
m 6 - Console
m 7 – O-ring
m 8 - Banjo bolt: 18 Nm
m 9 - Piece of flexible hose
m 242 - Assembly product
m Clean the mating surfaces.
NOTE
Use new seals.

NOTE
Positions 1 and 5: use assembly sealant. Use a new
O-ring.

30-559
 Method of intervention
30.14.14 - 4-rear way ancillary utility distributor
Removal
1. Disconnect the negative battery terminal clamp.
2. Detach the three point linkage (2) from the top link (1) to allow more area 11
to work in. The lower the three point linkage while supporting its weight.
22

Fig. 2278
3. Loosen the nuts (3) of the Bowden cables.
4. Undo the screws (4) and move back the Bowden cable mount (5).

Fig. 2279
5. Remove the pin (6) and remove the Bowden cable from its seat on the rear
distributor (7).
6
Note
Perform the same procedure on all the Bowden cables.

Note
Mark the positions of the Bowden cables before disconnect-
ing to ensure that they are refitted correctly.
Fig. 2280
6. Loosen the oil pipe connector (8) of the distributor (9) on the transmission
side, without disconnecting.
9

Fig. 2281

30-560
Method of intervention
7. Undo the connectors (10) of the oil delivery and return pipes from the dis- 10
tributor.

10

Fig. 2282
8. Undo the two fastener screws (11) of the distributor block.
11

11

Fig. 2283
9. Undo the third fastener screw of the distributor block, fitting the wrench in
the connector (12) from the transmission side.

12

Fig. 2284
10. Remove the complete rear distributor (13).

13

Fig. 2285

30-561
 Method of intervention
11. Check the condition of the oil seal ring (14). If necessary, replace with a
new component with the same characteristics.

14

Fig. 2286
12. Undo the nuts (15) and separate the distributor (16) from the manifolds 15
(17).

17
16

Fig. 2287

Refitting
1. Refit the distributor by following the procedure for removal in reverse order, and:
2. replace all the copper gaskets and check that the rubber seals are still in good condition.
3. Once the assembly is refitted, the travel of the Bowden cables relative to the control levers in cab must be adjusted as follows.
4. Loosen or tighten the Bowden cable with the adjusters (18).

18

Fig. 2288
5. The cable is adjusted correctly when the control lever (19) is near the mid-
line of the device (20) in the locked position. 19

20

= =

Fig. 2289

30-562
Method of intervention
6. Once adjusted correctly, tighten the lock nut (3) of the Bowden cable.

Fig. 2290

30.14.15 - 6-rear way ancillary utility distributor

Removal
1. Disconnect the negative battery terminal clamp.
2. Detach the three point linkage (2) from the top link (1) to allow more area 11
to work in. The lower the three point linkage while supporting its weight.
22

Fig. 2291
3. Loosen the nuts (3) of the Bowden cables.
4. Undo the screws (4) and move back the Bowden cable mount (5).
3

Fig. 2292
5. Remove the pin (6) and remove the Bowden cable from its seat on the rear
distributor (7).
6
Note
Perform the same procedure on all the Bowden cables.

Note
Mark the positions of the Bowden cables before disconnect-
ing to ensure that they are refitted correctly.
Fig. 2293

30-563
 Method of intervention
6. Disconnect the oil recovery pipe (8) from the distributor couplings.

Fig. 2294
7. Undo the screw (9) of the mounting bracket of the lift oil delivery pipes.

Fig. 2295
8. Undo the connections (10) of the lift oil delivery pipes.

10

Fig. 2296
9. Move the lift oil delivery pipes (11) out of the work area.
11

Fig. 2297

30-564
Method of intervention
10. Loosen the distributor oil pipe (12) on the transmission side, without discon-
necting. 12

Fig. 2298
11. Undo the two connectors (13) of the oil pipes from the seat on the distribu-
tor.

13

Fig. 2299
12. Undo the three fastener screws (14).
14

14

Fig. 2300
13. Remove the complete rear distributor (15).

15

Fig. 2301

30-565
 Method of intervention
14. Check the condition of the oil seal ring (16). If necessary, replace with a
new component with the same characteristics.

16

Fig. 2302
15. Remove the connectors (17) push-fit into the distributor couplers. Perform
17
on both sides
Note
Perform on both sides

Fig. 2303
16. Undo the nuts (18) and separate the distributor (19) from the manifolds
(20). 18

19 20

Fig. 2304

30-566
Method of intervention
Refitting
1. Refit the distributor by following the procedure for removal in reverse order, and:
2. replace all the copper gaskets and check that the rubber seals are still in good condition.
3. Once the assembly is refitted, the travel of the Bowden cables relative to the control levers in cab must be adjusted as follows.
4. Loosen or tighten the Bowden cable with the adjusters (21).

21

Fig. 2305
5. The cable is adjusted correctly when the control lever (22) is near the mid-
line of the device (23) in the locked position.

=
=

Fig. 2306
6. Once adjusted correctly, tighten the lock nuts (3) of the Bowden cable.

Fig. 2307

30.14.16 - Replacing positioning for automatic release

Object
This document define the proper procedure to replace the automatic spool n. 367
with the new type 372 by the kit p/n 0.026.0247.4 which is composed by a single
spool preassembled with its detent mechanism.

1 2 2 4 5

Fig. 2308

30-567
 Method of intervention
Procedure to remove the spool type 367
1. After disconnecting the Bowden cables from the spools, check each spool
end for possible presence of paint in the area indicated in figure and if
present, remove it to prevent possible damages to the inner sealing O-ring
when removing the spools from their seats.

Fig. 2309
2. Unscrew the spools one by one positioning a 30mm spanner as shown
below.

Fig. 2310
3. Remove the spools 367 from the distributor body ensuring that the O-ring 4
doesn’t remains in the distributor seat.

Fig. 2311

Assembly sequence of spool kit type 372

1. Check and clean if necessary the spool seating holes of distributor body as well as the new spool kits before assembly.
2. Check the steel washer 3 and O-ring 4 proper positioning (see picture 1) on each spool kit before assembly in order to prevent
any damage.
3. Tighten the spools one by one with a suitable torque wrench (CH.30) apply-
ing a torque of 25Nm(±10%) as shown below.

Fig. 2312

30-568
Method of intervention
30.15 - L0 - Electrical system
30.15.1 - Battery mount with wiring loom
Removal
1. Disconnect the transmission oil filter clogging sensor pressure switch con-
nector (1).

Fig. 2313
2. Disconnect the Ground speed PTO engaged confirmation switch connector
(2).

Fig. 2314
3. Disconnect the SAV solenoid valve connector (3) and disconnect the SAC
position sensor connector (4).

Fig. 2315
4. Disconnect the ECO solenoid valve connector (5).

Fig. 2316

30-569
 Method of intervention
5. Disconnect the SAC draft sensor connector (6).

Fig. 2317
6. Disconnect the up and down solenoid valve connectors (7).

7
7

Fig. 2318
7. Disconnect the connectors (8) of the three solenoid valves of the two-way 8
distributor.

8 8

Fig. 2319
8. Disconnect the connectors (9) of the dual traction, PTO, differential lock
and HI-LO solenoid valves. 9

Fig. 2320

30-570
Method of intervention
9. Disconnect the ancillary pressure switch connector (10) and the wheel 11
speed sensor connector (11).

10

Fig. 2321
10. Disconnect the gear lever position start consent signal connector (12).
12

Fig. 2322
11. Disconnect the pressurised oil filter clogging sensor pressure switch con-
nector (13).

13

Fig. 2323
12. Disconnect the stop and go brakes pressure switch connector (14).

14

Fig. 2324

30-571
 Method of intervention
13. Disconnect the hydraulic reverse shuttle solenoid valve connectors (15).

15

15

Fig. 2325
14. Disconnect the hydraulic reverse shuttle pressure switch connector (16)
and the transmission oil temperature sensor connector (17). 16

17

Fig. 2326
15. Disconnect the connector (18) from the speed sensor.

18

Fig. 2327
16. Undo the nut (19) and disconnect the cab ground cable (20).

19 20

Fig. 2328

30-572
Method of intervention
17. Undo the two screws (21) fastening the battery master switch mounting
bracket (22).
22

21

Fig. 2329
18. Undo the transverse fastener screw (23) and retrieve the spacer (24).
24

23

Fig. 2330
19. Secure the battery mount (25) to a hoist with a strap.
20. Undo the four fastener screws (26) and remove the battery mount (25) with
complete wiring loom. 26

26

25

Fig. 2331

30-573
 Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the screws (26) fastening the battery mount (25) to a torque of 67 Nm.
3. Tighten the lateral fastener screws (23) to a torque of 350 Nm.
4. Connect the ground cable (20) and tighten the nut (19) to a torque of 70 Nm.

30-574
Method of intervention
30.16 - M0 - Front PTO
30.16.1 - Disassembling front PTO
25 26 27 14 16 20 19 17

28

18

29

30

31

Fig. 2332

Removal
1. Undo the lower plug (1) and drain the oil.
2. Replace the copper washer and tighten the plug (1) to a torque of 73±7 Nm.

Fig. 2333
3. Place the front PTO on the servicing tool.
4. Undo the union (2) and the fastener screw (3) and remove the oil line (4).

30-575
 Method of intervention
5. Undo the fastener screws and remove the oil line (5).
3
4

Fig. 2334
6. Undo the fastener nut (6) and remove the solenoid (7) from the solenoid
valve. 6

Fig. 2335
7. Unscrew and remove the solenoid valve (8).

Fig. 2336
8. Undo the fastener screws (9) and remove the solenoid valve block (10).

10

Fig. 2337

30-576
Method of intervention
9. Undo the screws (11) and remove the upper cover (12).

11

12

Fig. 2338
10. Undo the screw (13) engaging with the PTO clutch (14).
11. Undo the screw (15) engaging with the oil pump (16).

16 14

13
15

Fig. 2339
12. Pulling from the U-joint (17), remove the PTO input shaft (18) complete with
oil seal (19) and bearing (20). 19

17

18
20

Fig. 2340
13. Place the shaft in a press, remove the circlip (21), the ball bearing (20) and
the oil seal (19), and replace with new components.
20

21 20

19

Fig. 2341

30-577
 Method of intervention
14. Screw a slide hammer extractor into the relative threaded seat and remove
the lateral union tubes (22).

22

Fig. 2342
15. Undo the fastener nuts (23) and remove from the front cover (24) using a
mallet in soft material.
23

24

Fig. 2343
16. Remove the outer bearing (25) together with the gear (26).

26

25

Fig. 2344
17. Remove the front PTO clutch (14) and the oil pump (16) from the front PTO
14 16
casing.

Fig. 2345

30-578
Method of intervention
18. Remove the inner bearing (27) from its seat.

27

Fig. 2346
19. Remove the flange shaft (28) (the gear will slide off and remain in the casing) and the inner race of the bearing (29).
20. Remove the outer race of the roller bearing (29).

29
28

Fig. 2347
21. Retrieve the gear (30)
30

Fig. 2348
22. Remove the (complete) inner roller bearing (31).

31

Fig. 2349

30-579
 Method of intervention
23. Remove the oil seal (32) from the front cover (24).

32

24

Fig. 2350

Reassemble
1. Assemble following the procedure for disassembly in reverse order, noting the following additional instructions for the steps
indicated.
2. Install the inner races of the bearings (31 and 29) with the protrusion (ar-
row) facing towards the gear (see drawing).

31 29

Fig. 2351
3. Tighten the screws (15 and 13) to a torque of 70±3.5 Nm.
Note
Replace the copper washers under the screws (15 and 13).

13
15

Fig. 2352
4. Fit the union tubes (22), with the threaded hole facing outwards.

22

Fig. 2353

30-580
Method of intervention
5. Replace the O-rings (33) behind the block (10).

10

33

Fig. 2354
6. Fit the block (10) and tighten the fastener screws (9) to a torque of 8.4±2
Nm.

10

Fig. 2355
7. Fit the solenoid valve (8) in the block (10) and tighten to a torque of 17.5±2.5
Nm.
Note
Replace the O-rings on the solenoid valve (8).
8

Fig. 2356
8. Fasten the solenoid (7) to the solenoid valve, tightening the nut (6) to a
torque of 5±0.5 Nm. 6

Fig. 2357

30-581
 Method of intervention
Detail of assembly of oil seal on front cover
1. Fit the oil seal (32) in the correct position as shown in the figure.

32

Fig. 2358
2. Install the oil seal (32) on the front cover (24), using the specific tool and
a suitable mallet to drive the seal into its seat until the protrusion is flush
with the cover.

32

24

Fig. 2359
3. Fit the oil seal (19) in the correct position as shown in the figure.
4. Heat the inner race of the bearing (20) to 80°C, then install in its seat on the front PTO input shaft.
5. Fit circlip (21)

21
20
19

Fig. 2360
6. Fit the front PTO input shaft, engaging the splined end with the oil pump and with the PTO clutch.
7. Install the oil seal (19) in its seat on the front PTO casing, using the specific
tool and a suitable mallet. 19

Fig. 2361
8. Apply DOW CORNING sealant to the contact surface between the front cover (24) and the front PTO casing.

30-582
Method of intervention
9. Tighten the nuts (23) to a torque of 21.9 ±1.1 Nm.
23

24

Fig. 2362
10. Apply DOW CORNING sealant to the contact surface between the upper cover (12) and the front PTO casing.
11. Tighten the screws (11) to a torque of 40.4±2 Nm.
12. Replace the O-rings and copper washers.
13. Replace the paper gasket (33).

33

12

11

Fig. 2363
14. Replace the seals (34) under the screws fastening the line (5), and tighten
the screws to a torque of 20.4±1 Nm.
34

Fig. 2364
15. Tighten the union (2) to a torque of 30±1.5 Nm.

30-583
 Method of intervention
30.17 - R0 - Rear lift
30.17.1 - S.A.C. Automatic control station
Preliminary operations
l See para. 30.14.11 - 2-way distributor - page 30-556
l See para. 30.14.1 - Rear ancillary utility... - page 30-536
Removal
1. Undo the union (1) and remove the rear ancillary distributor delivery line (2).
2

Fig. 2365
2. Undo the union (3) and disconnect the return line (4).
3. Undo the screw (5) and move the trailer braking line bracket (6) aside.

6
5

4
3

Fig. 2366
4. Undo the unions (7) and remove the hitch oil delivery line (8).
5. Undo the unions (9) on the hitch cover (10) and on the supplementary cyl-
11
inders, and disconnect the oil delivery lines (11).

10
7 9

Fig. 2367

30-584
Method of intervention
6. Undo the nut (12) and move the trailer braking line bracket (13) aside.

13 12

Fig. 2368
7. Undo the unions (14) and remove the PTO lubrication line (15).

14 15

14

Fig. 2369
8. Undo the nuts (16) and remove the flange (17) of the 3-point linkage.

16

17

Fig. 2370
9. Undo the two screws (18) and move the ground speed PTO control mount-
ing bracket (19) aside.

18

19

Fig. 2371
10. Undo the screw (20), remove the pin (21) and disconnect the tie-rod (22) from the hitch arm (23).
11. Remove the split pin (24).
Important
Always renew the cotter pin on reassembly.

30-585
 Method of intervention
12. Remove the pin (25), retrieve the spacer (26) and disconnect the supple-
mentary cylinder (27) from the hitch arm (23). 24
23
26

21

25

22
27 20

Fig. 2372
13. Undo the rear fastener nut (28).

28

Fig. 2373
14. Undo the fastener screws (29) and nuts (30) and remove the hitch assem-
bly (31).

29
29
30

31

30

Fig. 2374

30-586
Method of intervention
Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Fit the hitch assembly (31), and tighten the fastener nuts (30 and 28) to a torque of 76 Nm and the screws (29) to a torque of
70 Nm.
3. Refit the Ground speed PTO control mounting bracket (19) in its seat and tighten the two screws (18) to a torque of 40.4 Nm.
4. Refit the flange (17) of the 3-point linkage and tighten the nuts (16) to a torque of 112 Nm.
5. Fit the PTO lubrication line (15), tighten the union (14) on the hitch to a torque of 73 Nm, and tighten the union (14) on the
PTO cover to a torque of 40 Nm.
6. Refit the trailer braking line bracket (13) in its seat and tighten the nut (12) to a torque of 73 Nm.
7. Connect the oil delivery lines (11), tighten the union (9) on the hitch cover to a torque of 58 Nm and tighten the unions (10) on
the supplementary cylinders to a torque of 48 Nm.
8. Refit the hitch oil delivery line (8), tighten the union (7) on the hitch to a torque of 110 Nm and tighten the union (7) on the valve
body to a torque of 73 Nm.
9. Refit the trailer braking line bracket (6) in its seat and tighten the screw (5) to a torque of 19.5 Nm.
10. Connect the return line (4) and tighten the union (3) to a torque of 76 Nm.
11. Fit the rear ancillary distributor delivery line (2) and tighten the union (1) to a torque of 76 Nm.
Completion
l See para. 30.14.1 - Rear ancillary utility... - page 30-536
l See para. 30.14.11 - 2-way distributor - page 30-556

30.17.2 - Disassembling the hitch assembly (SAC)

Removal
1. Undo the screws (1) and remove the SAC position sensor (2).

Fig. 2375
2. Undo the screws (3) and remove the SAC position sensor mounting bracket
(4).

Fig. 2376
3. If necessary, undo the screws (5) and remove the rubber sensor buffer (6).

30-587
 Method of intervention
4. Remove the circlip (7).
7

Fig. 2377
5. Remove the hitch arm (8).

Fig. 2378
6. Repeat the procedure on the opposite side.
7. Remove the spacers (9), then use a screwdriver to prise out the oil seals
(10) (this will damage the seals irreparably).

10

Fig. 2379
8. Undo the union (11) of the supplementary cylinder oil delivery line (12).
12

11

Fig. 2380

30-588
Method of intervention
9. Undo the fastener screws (13) and remove the upper cover (14) and the
lines (12).

12

14

13

12

Fig. 2381
10. Loosen the check nut (15) and undo the stop screw (16) for the lever (17).

15
17

16

Fig. 2382
11. Undo the fastener screws (18) and remove the front cover (19).

18

19

Fig. 2383
12. Remove the hitch cylinder (20).

20

Fig. 2384
13. Remove the piston (21) and retrieve the O-ring (22).

30-589
 Method of intervention
14. Use a screwdriver to prise out the seal ring (23).
21

22

23

Fig. 2385
15. Undo the screws (24) and remove the pressure relief valve block (25).

25

24

Fig. 2386
16. Retrieve the two O-rings (26) and, if necessary, replace the pressure relief
valve (25).

26

25

Fig. 2387
17. Remove the shaft and retrieve the lever (27) with link (28).
18. Remove the pin (29) and separate the link (28) from the lever (27).
29

28

27

Fig. 2388

30-590
Method of intervention
Installation
1. To install the hitch assembly (SAC), follow the procedure for removal in reverse order, noting the following additional instruc-
tions for the steps indicated:
2. Check the state of the bushes.
3. If any signs of wear are found, replace as described in the procedure:
See para. 30.17.3 - Bushes - page 30-592
4. Assemble the lever (27) and the link (28) and install the pin (29).
29

28

27

Fig. 2389
5. Install the shaft, ensuring that it connects correctly with the lever.
6. Apply a drop of Loctite 242 to the thread (30) of the lever stop screw.

30

Fig. 2390
7. Tighten the screw (16) fully into its seat on the shaft (31), then loosen by ½
31
turn and tighten the check nut (15).

15

16

Fig. 2391
8. Use the special tool (32) to install the seals (10) in their seats.

32
10

Fig. 2392

30-591
 Method of intervention
9. Use the special tool (33) to install the seals (10) in the hitch casing.

33

Fig. 2393

30.17.3 - Bushes
Removal
1. Position the hitch cover under a press and, using a suitable tool, remove
bushes (1).

Fig. 2394

Refitting
1. Install new bushes (1) making sure that they are inserted flush with the
bores in the hitch cover.

Fig. 2395
2. Note
Install bushes (1) with the split oriented towards the top of 1

the hitch housing.

Fig. 2396

30-592
Method of intervention
30.17.4 - Auxiliary hitch cylinders
Removal
1. Lower the rear hitch completely, disconnect the cable from the negative battery terminal and engage the parking brake.
2. Undo the union (1) of the oil delivery line (2).

Fig. 2397
3. Remove the split pin (3).
Important
Fit new split pins on reassembly.

4. Remove the pin (4), retrieve the spacer (5) and disconnect the supplemen-
tary cylinder (6) from the hitch arm (7). 3
7
5

Fig. 2398
5. Remove the retainer ring (8).
6. Detach the cylinder (9) from the pin (10) and remove.

10

Fig. 2399

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Connect the oil delivery line (2) and tighten the union (1) on the supplementary cylinder to a torque of 48 Nm.

30-593
 Method of intervention
30.17.5 - Disassembling the rear hitch control distributor
Removal
1. Disconnect the up and down solenoid valve connectors (1).

Fig. 2400
2. Undo the union (2) and remove the line (3).

Fig. 2401
3. Undo the three fastener screws (4).

Fig. 2402
4. Remove the solenoid valve block (5) and the carrier plate (6).

Fig. 2403
5. Undo the screws (7) and separate the solenoid valves (8) from the body (9).
6. Retrieve the O-rings (10).

30-594
Method of intervention
7. Undo the plugs (11) if necessary.
10

8
7

11

Fig. 2404

Installation
1. Assemble by following the procedure for removal in reverse order and noting the following additional instructions for the steps
indicated:
2. Replace the old O-rings with the O-rings provided in the specific spare parts kit.
3. Refit the carrier plate (5) and the solenoid valve block (4), and tighten the three fastener screws (3) to a torque of 20.4 Nm
4. Reconnect the line (2) and tighten the union (1) to a torque of 73 Nm.

30.17.6 - Mechanical draft sensor

Removal
1. Disconnect wiring connector (1).

Fig. 2405
2. Undo the check nut (2) and remove the draft sensor (3).
2

Fig. 2406

30-595
 Method of intervention
3. Undo the bush (4) and remove together with the sensor pin (5).

Fig. 2407

Refitting
1. Fit the sensor pin (5) in the bush (4).
2. Apply a drop of Loctite 242 to the thread (6) of the bush (4), then tighten the
4
bush to a torque of 150 Nm. 6
5

Fig. 2408
3. Ensure that the sensor pin is turned into the correct position, with the refer-
ence notch (7) facing down and the hole (8) facing up.

Fig. 2409
4. Fit the draft sensor (3) and tighten the check nut (7).
2

Fig. 2410

30-596
Method of intervention
5. Connect the connector (1).

Fig. 2411

30.17.7 - 3-point linkage

Removal
1. Undo the screw (1), remove the pin (2) and disconnect the tie-rod (3) from
the hitch arm (4).
4

3
1

Fig. 2412
2. Remove the split pin (5) and remove the pin (6) and the washer (7).
Important
6
Replace the split pin with a new component after every re-
moval.
5

Fig. 2413
3. Remove the split pin (8) and remove the ring (9).
4. Remove the complete 3-point linkage (10).

10

Fig. 2414

30-597
 Method of intervention
Refitting
1. Refit by following the procedure for removal in reverse order.

30.17.8 - Rear lift draft rod replacement

Removal
1. Set the rear lift (1) to its lower position and the rear hitch (2) to its highest
position to clear the access to the working zone. 2

Fig. 2415
2. Unscrew the nuts (3) and remove the cable guard (4), the sensor guard (5) 3 4
and disconnect the draft sensor plug (6).

5
Fig. 2416
3. Remove the sensor (7) by loosening the counter-nut (7) fastening the sen-
sor.
8
Pull the inner bush (9) fully backward.
Note
Unscrew the counter-nut (8) only slightly and let it in position
to facilitate the adjustment when remounting the sensor.
7 9

Fig. 2417
4. Dismount the right hand side stabilizer (10) by removing the cotter pins (11)
fastening the pin (12).
11 12

10

Fig. 2418

30-598
Method of intervention
5. Dismount the bracket (13) by removing its three fixing nuts.

13

Fig. 2419
6. Remove completely the left hand side three point hitch rod (14) by remov-
ing the upper and bottom pin (15, 16).
15
DANGER
Beware to hold in position the left hand side low arm while 16
removing the pins to prevent it dropping down.

14

Fig. 2420
7. Remove the left hand arm (17) by removing the rod roll pin (18) and the
ring (19).
19

18
17

Fig. 2421
8. Then remove the guard (20), the vibration damper (21) and the washer
(22).
22
20

21

Fig. 2422

30-599
 Method of intervention
9. On the right side pull out the draft rod (23) and remove the guard, the vibra-
tion damper and the washer like on the other side.

23

Fig. 2423
10. On a suitable workbench remove the rod roll pin (24) and the ring (25).

24

25

Fig. 2424

Refitting
1. Fit the ring on the new draft rod and refit following the disassembly steps in reverse order paying caution to the following
procedures.
2. Clamp the nuts fastening the bracket (13) to the torque of 224 Nm.
3. Be carefull to push the bush (9) inside its seat keeping the reference mark
(26) on the upper side of the vertical axis, till it touches the draft rod.

26

Fig. 2425
4. After the sensor refit, do not fasten the nut (7) and connect the All Round
Tester to check the measured effort value.
To visualize the sensor reading on the All Rount Tester, as showed below
The target value is 50% and can be modified changing the sensor position.
When the 50% value is reached fasten the nut (7).

Fig. 2426

30-600
Method of intervention
5. Grease the rod on both sides using the grease gun.

Fig. 2427
6. Check the correct movement of the electronic rear lift.

30-601
 Method of intervention
30.18 - S0 - Wheels
30.18.1 - Rear wheels
Removal
1. Place suitable lifting equipment under the rear gearbox housing and lift the
tractor to take the weight off the tyre of the wheel to be removed, so there
is no bulge in the tyre wall.
mPlace a stand (A) under the rear axle on the side of the wheel to be
removed.
Lower the lift and check that the stand (A) is securely in place.
A

Fig. 2428
2. Undo the fastener screws/nuts (1) and remove the wheel (2).
2

Fig. 2429

Refitting
Refit by following the procedure for removal in reverse order.
Refer to the following tables for the correct tightening torques.
Wheel-hub fastener screws: tightening torques
Table 189
SCREW TYPE CLASS TREATMENT NOMINAL TIGHTENING INSTRUMENT TOLER-
TORQUE ANCE
M 14x1.5 8.8 Geomet 79 Nm (8.1 kgm) ±15%
M 16x1.5 8.8 Electrolytic zinc plating 172 Nm (17.5 kgm) ±15%
M 16x1.5 10.9 Geomet 178 Nm (18.2 kgm) ±15%
M 18x1.5 10.9 Geomet 258 Nm (26.3 kgm) ±15%
M 20x1.5 10.9 Geomet 358 Nm (36.5 kgm) ±15%
Wheel-hub fastener nuts: tightening torques
Table 190
SCREW TYPE CLASS TREATMENT NOMINAL TIGHTENING INSTRUMENT TOLER-
TORQUE ANCE
M 14x1.5 8 Geomet 79 Nm (8.1 kgm) ±15%
M 18x1.5 10 Electrolytic zinc plating 368 Nm (37.5 kgm) ±15%
M 18x1.5 10 Geomet 258 Nm (26.3 kgm) ±15%
M 20x1.5 10 Electrolytic zinc plating 515 Nm (52.5 kgm) ±15%
M 20x1.5 10 Geomet 358 Nm (36.5 kgm) ±15%
M 22x1.5 10 Geomet 485 Nm (49.5 kgm) ±15%
M 22x1.5 (Nord-Lock) 10 - 470 Nm (47.9 kgm) ±15%

30-602
Method of intervention
30.18.2 - Front Wheels
Removal
1. Place two wooden wedges (1) between the front axle (2) and the front car-
rier (3) to prevent the carrier from wobbling.

3
1

Fig. 2430
2. Use a suitable lift to lift the front of the tractor and take the weight off the tyre
of the wheel to be removed, so there is no bulge in the tyre wall.

Fig. 2431
3. Undo the fastener screws/nuts (4) and remove the wheel (5).
5

Fig. 2432
4. Place a stand (A) under the front axle and lower the jack until the axle is resting on the stand.
5. Check that the stand is placed in the correct position.

Fig. 2433
6. Repeat the same procedure for the other wheel.

30-603
 Method of intervention
Refitting
Refit by following the procedure for removal in reverse order.
Refer to the following tables for the correct tightening torques.
Wheel-hub fastener screws: tightening torques
Table 191
SCREW TYPE CLASS TREATMENT NOMINAL TIGHTENING INSTRUMENT TOLER-
TORQUE ANCE
M 14x1.5 8.8 Geomet 79 Nm (8.1 kgm) ±15%
M 16x1.5 8.8 Electrolytic zinc plating 172 Nm (17.5 kgm) ±15%
M 16x1.5 10.9 Geomet 178 Nm (18.2 kgm) ±15%
M 18x1.5 10.9 Geomet 258 Nm (26.3 kgm) ±15%
M 20x1.5 10.9 Geomet 358 Nm (36.5 kgm) ±15%
Wheel-hub fastener nuts: tightening torques
Table 192
SCREW TYPE CLASS TREATMENT NOMINAL TIGHTENING INSTRUMENT TOLER-
TORQUE ANCE
M 14x1.5 8 Geomet 79 Nm (8.1 kgm) ±15%
M 18x1.5 10 Electrolytic zinc plating 368 Nm (37.5 kgm) ±15%
M 18x1.5 10 Geomet 258 Nm (26.3 kgm) ±15%
M 20x1.5 10 Electrolytic zinc plating 515 Nm (52.5 kgm) ±15%
M 20x1.5 10 Geomet 358 Nm (36.5 kgm) ±15%
M 22x1.5 10 Geomet 485 Nm (49.5 kgm) ±15%
M 22x1.5 (Nord-Lock) 10 - 470 Nm (47.9 kgm) ±15%

30-604
Method of intervention
30.19 - V0 - Ballast - towing hitches
30.19.1 - Tow hook sled
Removal
1. Loosen all the screws (1), removing all but two.
2. Secure the tow hook (2) with straps and tauten the cables slightly to take up the slack.
3. Undo the remaining screws (1) and remove the complete sled.

Fig. 2434

Refitting
1. Refit following the procedure for removal in reverse order, noting the following additional instructions for the steps indicated:
2. Tighten the screws fastening the tow hook sled to a torque of 173±17 Nm.

30-605
 Method of intervention
30.20 - V1 - AFTERMARKET KITS
30.20.1 - Head and pin kit assembly procedure for automatic hitch
This procedure fits for the following spare parts kit:
l 0.900.2093.9
l 0.900.2681.4
l 0.900.2681.5
l 0.900.2681.6
Installation procedure
1. Remove the complete mechanism (1) and the towing pin (2).
1

Fig. 2435
2. Insert the new pin (3) into the coupling, after having greased its head.

Fig. 2436
3. Grease the complete mechanism (see the picture).

Fig. 2437

30-606
Method of intervention
4. Install the new complete mechanism (1) on the coupling. Insert the two
screws (M10x30) (4) without tighten them.
4

Fig. 2438
5. Rotate the opening lever till the top position has reached

Fig. 2439
6. Tighten the two screws (4) to the torque of N=45 ÷ 55 Nm

Fig. 2440
7. Rotate the opening lever till the down position. Open and close the coupling
some times.

Fig. 2441

30-607
 Method of intervention
8. Check that the opening lever is down in order to ensure a sure locking of
the coupling pin. The security device has to be completely re-entered in its
position
OK !

Fig. 2442

30-608
40 - Wiring diagrams

40-1
 Wiring diagrams
40.1 - Introduction
40.1.1 - Introduction
For easier consultation, this unit has been divided into the following chapters:
l Introduction
m Contains a brief description of the terminology used, the procedures to follow for troubleshooting and repairs, and the

instruments required for fault diagnosis.

l Components list
m Contains the components of the electrical systems, organised by type.
m Indicates the system code, the component code and description, the technical data required for functional testing and

a description of the pin-outs of the ECUs.

l Systems
m Contains the wiring diagrams of the tractor’s systems.

l Wiring harnesses
m Contains the layouts, the wiring diagrams and the positions of connectors on the tractor.

Introduction
This section of the workshop manual is intended as a practical guide to fault diagnosis of the tractor’s electrical and electronic
systems. The following pages provide the technician with all the necessary information regarding the tractor’s systems and compo-
nents. Due to the possible time difference between the introduction of technical modifications (in line with our policy of continuous
product improvement) and the corresponding amendment of our printed documentation, the data contained in this document are
subject to modification and as such are not binding.
Definition of components and symbols
To prevent any misunderstanding or ambiguity, definitions for some of the key terms used in this unit are listed below.
Table 193
TERM DESCRIPTION
Connector Element used to connect two components (e.g. wiring-switch, wiring-wiring)
Temperature sensor Electrical component that converts the temperature of a medium (air, water, oil, etc.) into a voltage
or resistance
Pressure sensor Electrical component that converts the pressure of a medium (air, water, etc.) into a voltage or
resistance
Position sensor Electrical component that converts an angular or linear position into a voltage
Pressure switch Switch that changes state (opens or closes a contact) according to the operating pressure in the
circuit in which it is installed
Thermostat Switch that changes state (opens or closes a contact) according to the temperature of the medium
(air, water, etc.) in which it is immersed.
Switch Mechanical component that opens or closes one or more electrical contacts.
Solenoid valve Valve operated by applying electrical current to a coil (or solenoid)
Chapter “Components” shows the wiring diagrams for certain switches and buttons. The following symbols are used for ease of
interpretation:
Contact between pins CLOSED (stable switch position)

Contact between pins CLOSED (unstable switch position)

Indicator LED

Indicator light

40-2
Wiring diagrams
Diode

General rules
The inspection, maintenance, fault diagnosis and repair operations are essential to ensure that the tractor continues to operate cor-
rectly over time and to prevent malfunctions and breakdowns. This paragraph describes repair procedures and aims to help improve
the quality of repairs.
Modification of the tractor’s electrical/electronic circuits
The manufacturer prohibits any modification or alteration of the electrical wiring for the connection of any non-approved electrical
appliances or components. In particular, if the electrical system or a component is altered without the Manufacturer’s authorisation,
the Manufacturer will accept no liability for any damage to the vehicle and the vehicle warranty will be invalidated.
Main wiring faults
Bad contact between connectors
l The main causes of poor contact between connectors are incorrect insertion of the male into the female connector, deforma-
tion of one or both connectors, and corrosion or oxidisation of the pin contact surfaces.
Defective pin soldering or crimping
l The pins of the male and female connectors make good contact in the crimped or soldered area, but the wires are subjected
to excessive strain, leading to breakage of the insulation and a poor connection or breakage of the wire.
Disconnecting wiring
l If connectors are disconnected by pulling on the cables, or if components are removed with the wires still connected, or if the
wiring is subject to impact by a heavy object this could damage the soldering or crimping of wires on the pins and some wires
may break.
Penetration of water inside connectors
l The connectors are designed to prevent penetration of liquids (water, oil etc.); however, when cleaning the tractor with pres-
sure washers or steam washers water could penetrate or condense in the connectors. As the connectors are designed to
prevent liquid penetration, any water that does get in will be unable to drain out, and thus may cause short circuits across the
pins. It is therefore good practice to dry the connectors with a low pressure jet of compressed air after washing the tractor.
Oil or dirt on connectors
l If the connectors or pin contact surfaces show signs of oil or grease contamination, this will prevent the passage of current
(oil and grease are electrical insulators) creating a poor contact. Clean the connectors thoroughly using a dry cloth or a low
pressure jet of compressed air and use specific products (deoxidising sprays, etc.) to degrease the contacts.
Important
Take care not to bend the pins when cleaning them. Use dry oil-free compressed air.

Removal, refitting and drying of connectors and wiring

When disconnecting wiring, pull on the connectors rather than on the wires themselves. For connectors that are held in position with
screws or levers, fully loosen the screws, then pull on the connector. For connectors that are clipped together, fully depress the clip
then pull the connector apart. After disconnecting connectors, apply water proof covers to prevent contamination of the contacts with
dirt or moisture.
Connecting the connectors. Check the condition of the connectors:
l Make sure the pin contact surfaces are free of water, dirt or oil.
l Check that the connectors are not deformed and that the pins are not corroded or oxidised.
l Check that the connector casings are not damaged or split.
l If a connector is contaminated with oil or grease, or if moisture has penetrated the casing, clean it thoroughly.
l If a connector is damaged, deformed or broken, replace it with a new one.
When connecting connectors, make sure they are properly aligned before applying force. For connectors with clips, insert the two
halves until they clip together.
Cleaning and drying wiring

40-3
 Wiring diagrams
l When wiring is dirty or contaminated with oil or grease, clean it with a dry cloth, or, if necessary, with water or steam. If the
wiring must be cleaned with water, avoid directing the water or steam jet on the connectors; if water penetrates the connector,
clean it thoroughly.
l Check that the connector is not short circuited due to the presence of water by testing for continuity across the pins.
l After checking that the connector is good condition, degrease the contacts using a deoxidising product.
Renewal of damaged electrical components.
l When replacing electrical components (fuses, relays, etc.), use only original parts supplied by the manufacturer.
l When replacing fuses, check that the new fuse conforms to DIN 72581 or ISO 8820 standards, and in particular:
m fuse F1 (100A) DIN 72581/2
m bayonet fuse (F2, F3, etc.) DIN 72581/3C
m fuse F51 (100A) and F52 (200A) ISO 8820.

l The fitting of replacement fuses that do not comply with these standards will invalidate the warranty with immediate effect and
release the manufacturer from all liability.
l When replacing relays, make sure that the new relay conforms to the standards marked on the original relay.
Diagnostic instruments
For the correct diagnosis of any faults in the tractor’s electrical system, the following instruments are required:
l Digital multimeter with the following minimum characteristics:
m AC VOLT 0-600
m DC VOLT 0-600
m OHM 0-32M
m AC AMP 0-10
m DC AMP 0-10

l All Round Tester or computer with “PCTESTER” software installed

l SDF Analyzer
Wire colour codes
Table 194
COLOUR CODES
A Light blue
B White
S Orange
G Yellow
H Grey
L Blue
M Brown
N Black
R Red
S Pink
V Green
Z Purple

40.1.2 - Basic electronics for mechanics (1/2)

What is electronics?
The name of this branch of electrical science is derived from the word “ELECTRON”, the name given to a small electrically charged
particle.
The movement of electrons produces electrical current, which we know more about for its effects - heat, light, magnetism, elec-
trolysis, etc. - than for its actual nature.
While electrical engineering is concerned with these external effects of electrical current, electronics deals with way materials react
to the gain or loss of electrons.
Electrons in fact move from (-) to (+), but according to a convention that was established before the emergence of modern atomic
theory, electric current flows in the opposite direction from (+) to (-).
Using electronics it is possible to program complex logical processes, which could not be achieved in other ways.
The various applications of electronics on our tractors can be divided into two groups:
l Invisible electronics, which operate without requiring any intervention of the driver, (voltage regulation, rectification of the cur-
rent produced by the alternator, timing, etc.);

40-4
Wiring diagrams
l Visible electronics, ranging from the visible and audible information to made available to the driver via the vehicle’s instru-
ments and signalling systems, to the control systems that serve to optimise work processes (Performance Monitor, SBA
System, I-Monitor, etc.).
Logical development of the electronics
As mentioned previously, electronics is generally viewed as a branch of electrical science, even though in certain aspects they are
quite independent.
Whereas electrical engineering generally deals with large amounts of current, electronics is more concerned with very low levels of
current.
Electronic applications are based on the movement of electrons and thus exploit the different degrees to which different materials
conduct electrical current:
l Conductors,
l Insulators,
l Semiconductors
We therefore need to know what happens “electrically” inside the material.
All matter is composed of tiny particles called atoms.
The atom can be likened to a planetary system which has at its core a nucleus, comprised of protons and neutrons, around which
rotate the electrons in different orbits, or shells.

Fig. 2443
Under certain conditions, electrons can move from one atom to another.
If the number of electrons in an atom is the same as the number of protons, the atom is neutral (it has no charge).
If the number of electrons exceeds the number of protons, the atom is negatively charged, while if it loses electrons it will become
positively charged.

40-5
 Wiring diagrams
Atomic structure of matter
The atom is the smallest particle of a simple element that can combine with other
atoms to form molecules.

Fig. 2444

The composition of the nucleus and the number of electrons present in an atom
determine which element it belongs to.

Fig. 2445

The structure of an atom can be compared to that of the solar system:

1. Electron (Planet)
2. Nucleus (Sun)

Fig. 2446

Electrical charges of the same sign (1) repel each other while charges of opposite
signs (2) attract.

Fig. 2447

40-6
Wiring diagrams
40.1.3 - Basic electronics for mechanics (2/2)
Conductors, Insulators and Semiconductors
The behaviour exhibited by different materials in response to electricity derives from their atomic structure:
1. In conductors (generally metals), electrons are able to move freely from one atom to another;
2. In insulators (generally metalloids) electron movement is restricted to varying degrees, depending on the type of material.
Their atoms are not able to acquire electrons.
3. Semiconductors (germanium, silicon, selenium, etc.), are materials which in their pure state may act as insulators, but with
the addition of precisely calibrated amounts certain impurities, they can become conductors. Their electrical properties thus
lie somewhere in the range between insulators and conductors. If these materials in their pure state are subjected to a techni-
cal process known as “doping” (the addition of impurities with a certain number of atoms with free electrical charges), they
become positively or negatively charged, depending on the specific process.
Electrical voltage
We have talked about “external causes” that can provoke the movement of electrons in atoms.
One of these external causes is “voltage” or “potential difference”, which exerts a “force” on electrical charges, causing them to start
moving.
This force is known as electromotive force; the force supplied by electrical sources (battery, dynamo, alternator).
The concept of voltage or potential difference is illustrated by the example shown
here.
l The levels in A and B are equal if the valve is open.

Fig. 2448

The concept of voltage or potential difference is illustrated by the example shown

here.
l For water to flow from A to B, there must a difference in level “h” when the
valve closed.
l The difference between the height of water in A and that in B creates a dif-
ference in pressure.

Fig. 2449

When the valve is opened, water flows from A to B until the point where the two
pressures are equalised.
The same happens with electrical current:
l to obtain current flow, there has to be potential difference at one of the
conductor (caused by the presence of electrical charge).

Fig. 2450

40-7
 Wiring diagrams
Resistance
The water model can also be used to explain the concept of electrical resistance. If water encounters obstacles when flowing through
a pipe the the flow rate will slow or the direction of flow will change .
The same applies to electrical current; obstacles of an electrical nature reduce the flow of electrons. Every material offers some de-
gree resistance to the flow of electrons; the level of this resistance will depend on its atomic structure and its dimensions. Obstacles
in a water course will slow down or change the direction of the water flow.
Electrical resistance can be compared to a restriction in the conductor or scaling
on the inside of a water pipe.

Fig. 2451

The electrical resistance of a material can be defined as the opposition it presents to the flow of electrons and varies according to the
nature of the material and its dimensions.
Electrical continuity
Staying with the water analogy, let’s examine how to obtain a continuous flow of water in a circuit. 424For the flow to be continuous,
the water must be returned to basin 1.
In this hydraulic circuit, the function of the pump (2) is to return the water to basin
or tank (1).

Fig. 2452

Similarly, for current to flow continuously in an electrical circuit, the electrons must return from the positively charged terminal to the
negatively charged terminal, in order to maintain a potential difference between the two terminals. This is the job of the electrical
power source.
Electrical power supply
An electrical power source can be defined as a system capable of separating and initiating the motion of a number of electrons.
A battery, for example, has two metal terminals, one positive and one negative.
Inside the battery, a chemical process causes free electrons to flow to the negative terminal to create a negative charge and a corre-
sponding positive charge to build at the positive terminal.
This process will continue inside the battery until the actions which caused it are balanced by the forces of attraction between the
electrons and the positive charges.
If the electrons could flow to the positive terminal, the initial neutral status could be restored, but as there is internal connection betwe-
en the two terminals, this can only be achieved if there is an external connection between B and A.
We can therefore state that a difference in potential, or voltage, has been created between the two terminals A and B.
If we now connect an external load between B and A, the electrons concentrated at terminal A (+) will starting moving towards terminal
B, thereby pushing along the free electrons present in the connecting conductor.
An electrical current is thus created, (which by convention is deemed as flowing from A to B), and this current will continue to flow as
long as there remains a difference in potential between the two terminals.

40-8
Wiring diagrams
Schematic representation of a electrical power source
A = Positive terminal
B = Negative terminal
G = Generator

Fig. 2453

Electromotive force (e.m.f.)

Taking a simple electrical circuit , let’s see what happens to the voltage at the terminals of the power source when the circuit is closed
(in this example, the power source is a battery, but the same result would be obtained with a different source of power, such as an
alternator).
Simple circuit with switch “I “open: no current flow.
The same situation occurs if we replace the battery with an alternator in rotation.
A voltage (e.g. 12V) is present at the terminals of the power source, which can be
measured with a voltmeter. This no-load voltage is known as the electromotive
force.
R = resistance of a load.

Fig. 2454

Simple circuit with switch “I” closed. The battery powers the resistance R. A volt-
age drop occurs between the terminals of the power source, caused by the circula-
tion of current in the source itself, which has its own internal resistance.
Vd = r × A
r = internal resistance of the power source in series with the other elements of the
circuit
A = current flowing through the circuit

Fig. 2455

The following relationship is therefore true for every power source:

Available voltage = Electromotive force - Internal resistance x Current
V=E-(r×I)
Direct Current (DC) and Alternating Current (AC)
Electrical current can be either direct or variable: with direct current, the electrons always flow only one direction; with variable cur-
rent, the direction and intensity of electron flow varies over time in accordance with the laws of trigonometry.
If this change in direction is regular over time, the current is described as “alternating”. Alternating current changes cyclically from
positive values to zero and from zero to negative values and so on.
On a tractor, the battery supplies direct current voltage, and therefore direct current flows through the connected circuits.
The alternator produces alternating current, which, as we shall see, must be converted into direct current by a bridge rectifier before
it can be used.
The graph below illustrates the behaviour of a sinusoidal alternating current. The voltage increases from zero volts up to the maxi-
mum positive value and then decreases to zero volts . The polarity is then inverted and the the voltage rises to the maximum negative

40-9
 Wiring diagrams
value before returning once again to zero. This complete sequence is referred to as one “cycle”.
If a cycle is performed once every second, then the frequency of the alternating current is said to be 1 Hertz. In domestic electrical
supplies, the frequency of the supply is 50 Hz.
Frequency is thus the number of complete cycles performed in one second.
A period is defined as the time required for an alternating sine wave to complete one cycle, i.e. from zero to a positive peak to zero
to a negative peak and back to zero.
This time period is expressed in seconds and is denoted by the letter T.
The alternating current wave form illustrated in the graph is called sinusoidal.
T = 1 period

A = Amplitude

B = Positive voltage

C = Negative voltage

Fig. 2456

The number of cycles per second is the FREQUENCY and is expressed in Hertz and denoted with the letter “f”.
f=1÷T
T=1÷f
An AC current with a frequency of 50 Hertz therefore has a period of 1 ÷ 50 = 0.02 seconds.
Electrical values: Current and Voltage
CURRENT Symbol A
Value: Amount of electrical charge that passes through a conductor in a given unit of time.
Units: amperes.
Instrument: ammeter.
Connection to circuit: In series.
Basic electrical circuit incorporating a voltmeter and an ammeter.
Resistance is present in the conductors (R), in the loads (Ri1) and in the power
source (Ri2).
The inclusion of an ammeter (unlike a voltmeter) requires a modification to the
circuit, in that the circuit must be opened at some point by cutting a conductor and
the instrument must be then connected between the open ends of the conductor.

Fig. 2457

The inclusion of an ammeter (unlike a voltmeter) requires a modification to the

circuit, in that the circuit must be opened at some point by cutting a conductor and
the instrument must be then connected between the open ends of the conductor.

Fig. 2458

40-10
Wiring diagrams
VOLTAGE Symbol V
Voltage: Difference in potential; (emf); force that causes electrons to flow
Units: Volts
Measuring instrument: Voltmeter.
Connection to circuit: in parallel.
Resistance
In an electrical circuit, voltage and current are both dependent on RESISTANCE, i.e. the opposition to the flow of electrons in a
material.
We have already mentioned how the motion of electrons occurs as a result of forces produced by the collision of these minute par-
ticles.
This phenomenon generates heat and is this reason why materials heat up when current passes through them.
The greater the current (the greater the number of electrons in motion) the more heat is produced.
As the temperature increases, the movement of the electrons also increases, and the electrons find it more difficult to move under
the influence of the voltage.
In some materials, this resistance is minimal; these materials are good conductors of current (conductors: copper, aluminium, silver,
etc.). In others, the resistance is so high that it is difficult for electrons to move (insulators: mica, porcelain, glass, paper, etc.)
In addition to the nature of the material, resistance is also affected by its dimensions:
l LENGTH: the greater the length of the conductor the greater the number of collisions between atoms and free electrons.
l CROSS-SECTIONAL AREA; the greater the cross-sectional area, the greater the number of free electrons. Resistance is
inversely proportional to cross-sectional area.
l TEMPERATURE, the motion of atoms and consequently the probability of collision with free atoms increases proportionally
with the temperature, thus increasing also the resistance.
The electrical circuits on the tractor are generally comprised of wire conductors with a cross-sectional area that is negligible in com-
parison with their length.

Fig. 2459 - Load connection cables

1. Single colour.
2. Spiral striping with max. pitch 50 mm
3. Horizontal striping.
4. With narrow-spaced coloured rings.
5. With wide spaced rings.
6. With rings in groups of 2 of same or different colours, depending on use.
7. With coloured rings in groups of 3
RESISTANCE Symbol R ( Omega )
Resistance: Opposition to the flow of electrons.

40-11
 Wiring diagrams
Units: Ohm (Omega ).
Measuring instrument: Ohmmeter (tester), or voltmeter and ammeter when in presence of voltage.
The resistance of different materials - Resistivity
It has been determined experimentally that the resistance of a wire conductor is given by:
R = p × ( l ÷ S ) = ohms
in which:
p = (Greek letter pronounced “rho”) is a proportional coefficient that varies according to the nature of the material and is known as
“resistivity” or “specific resistance”.
l = length, expressed in metres
S = sectional area, expressed in mm²
This formula can also be written:
p=(R×S)÷l
so we can state that the unit of measurement of resistivity (p) represents a resistance of 1 ohm of a conductor of the material in que-
stion, with a length 1 metre, and sectional area of 1 mm², at a temperature of 0°C.
While for conductors resistivity is measured in ohms per mm²/m, for insulators it is almost always expressed in mega ohms/mm,
which is the resistance in millions of ohms of a cube with a side length of 1 m.
Variation of resistance with temperature (temperature coefficient)
For most metals, resistivity increases with the temperature (positive temperature coefficient); this is why when talking about resistivity
there must always be a reference to temperature.
There are exceptions to this rule, such as, for example, chromium and carbon, in which resistivity decreases with the temperature
(negative temperature coefficient) and some alloys in which resistivity does not vary, which have temperature coefficient of 0.
This increase or decrease in the resistance per degree of temperature and per ohm of resistance is termed the “temperature coeffi-
cient” , and is denoted with the Greek letter a (alpha).
If the initial resistance is R0, at a temperature t0 (ambient temperature), and the temperature difference is t = t1 - t0, the variation in
resistance will be:
R×t×a
and the final resistance is:
Rt = R0 + R0 × t × a
Rt = R0 (1 + a × t0)
This formula is of great practical importance as it allows us to calculate the final temperature of a coil or resistor using the resistance
variation method.
The temperature coefficient is used (positive or negative) to characterise thermistors (PTC = Positive Temperature Coefficient and
NTC = Negative Temperature Coefficient)
The interdependence of electrical values
In an electrical circuit, the relationship between current, voltage and resistance is given by the formula:
V=IxR
Volts = ohms x amps
If any of these values is unknown, it can be calculated, providing the other two values are known, simply by applying one of the
following formulae:
R=V÷I
I=V÷R
V=IxR
Power
The power developed or dissipated is given by the formula:
Power = Voltage x Current
Watt (W) = Volts x Amps
In mechanical engineering, power is still commonly expressed in terms of horsepower: hp
The relationship between horsepower and Watts is given in the following equation:

40-12
Wiring diagrams
1 hp = 736 W = 0.736 kW
1 kW = 1.36 hp
Dissipated power, in electrical terms, is power transformed into heat and is given by:
Power = Voltage x Current = Resistance x Current x Current
given that:
W=V×I
V=R×I
then:
W = R × I × I = R × I²
Multiples and submultiples of electrical values
Table 195
Multiples and submultiples of units of measurement
Prefix Multiply by Divide by
Name Symbol
mega- M 1,000,000 -
kilo- k 1000 -
hecto- h 100 -
deca- da 10 -
deci- D - 10
centi- S - 100
milli- M - 1.000
micro- µ - 1,000,000
nano- N - 1,000,000,000
pico- P - 1,000,000,000,000

40.1.4 - Electrical and electronic components (1/2)

Electrical and electronic components
Electronic components are used in circuits to modulate (vary, modify), control and regulate electrical values or to protect other devi-
ces.
In particular, electronic semiconductor components exploit the various reactions of electrons to heat, magnetism, and light in order
to generate small electrical signals. These electrical signals, when suitably modified, can be used by signalling devices or to control
other components.
Components can be classified on the basis of the functions they perform; components used to control or amplify power signals are
deemed ACTIVE; components which neither control nor amplify power are deemed PASSIVE.
Resistors*
Components of various design comprised of a conductor with a known resistivity that when included in a circuit causes a voltage
drop.
They are therefore used to change voltage and current; they come in different shapes and sizes, depending on their type, ohmic
resistance value, tolerance and heat dispersion characteristics.
Table 196
TYPES OF RESISTORS
FIXED VARIABLE THERMALLY SENSITIVE RE- LIGHT SENSITIVE RESIS-
SISTORS TORS
wirewound wirewound Thermistors: LDR
film film NTC -
- Linear or non-linear variation PTC -
All resistors are defined by their dimensions and characteristics: ohmic value, and maximum operating temperature.
* N.B. To avoid confusion, in this manual the term RESISTANCE is used for the value expressed in ohms which represents the op-
position to the flow of electrical current.
The term RESISTOR is used for the component used to introduce “resistance” into an electrical circuit.
Resistors are of two types: fixed or variable.
(the term “resistance” is also often used for the component).

40-13
 Wiring diagrams
Fixed resistors
How to determine the ohmic value of a resistor
In wirewound resistors, the value is printed with decimal point (or comma) and the
omega symbol.
If the value of the resistor is 10.5 ohms, the marking will be: 10.5 ohms
sometimes the letter R is used in place of the decimal separator (point or comma):
10 R5
On resistors with values measured in thousand of ohms, the printed value will
include the letter “k”, which stands for thousand (1000): 10.5 kohms (10,500 ohms)

Fig. 2460

Potentiometers (Variable resistors)

This a resistor with a sliding contact that varies the resistance as it is moved along
the resistor.
The symbols used in schematics for a variable resistor or potentiometer are shown
in the figure on the right:

Fig. 2461

Use of a variable resistor as a voltage divider

Divides the voltage into two or three parts in a specific ratio.
V1 = Applied voltage,
P = Potentiometer,
U = Load,
V2 = Required voltage (obtained by moving the sliding contact) < V1

Fig. 2462

Use of a variable resistor as an electrical resistance of absolute value

All the current flows through the sliding contact.
This means that the sliding contact must be held securely in place, otherwise the
voltage V2 will change.

Fig. 2463

40-14
Wiring diagrams
Preventing arcing between the resistor and sliding contact.
The figure shows a way to prevent the arcing between the resistor and the sliding
contact that may occur in the case of poor contact.
This connection allows some of the current to flow through the full length of the
resistor. The voltage drop between the sliding contact and the resistor is less than
V1, thus reducing the possibility of arcing.
The resistor of the rheostat can be sized so that the resistance can be varied in
both a linear and a non-linear way.

Fig. 2464

Voltage divider
Voltage dividers with fixed resistors or potentiometers are used whenever circuits require electrical power below the standard volta-
ges available on the tractor (12 Volts with engine off and 14.5 Volts with engine running).
Voltage dividers are found in the voltage regulator of the alternator and in the electronic control units.
Thermistors (Thermally Sensitive Resistors)
These are semiconductor resistors in which the resistance decreases as the temperature rises, ranging from just a few ohms at 0 °C
to tens of thousands of ohms at 100 °C; they are used to detect changes in temperature.
They may be either self-heating, if the heat is produced by the current flowing through them, or externally heated, if sensitive to the
temperature of the environment or the component on which they are mounted.
There are two types: PTC (Positive Temperature Coefficient) and NTC (Negative Temperature Coefficient)
With PTC thermistors, resistance increases with the temperature, while with the NTC type, resistance decreases as the temperature
rises.
NTC types are available with resistance values ranging from just a few ohms to several hundred kohms.
Operating characteristics of NTC thermistors

Fig. 2465

Operating characteristics of PTC thermistors

Note the linearity of the variation.

Fig. 2466

Thermistors are used in cab heating and climate control systems.

40-15
 Wiring diagrams
Capacitor
This component consists of a pair of conductors, generally in the form of flat plates, separated by an insulator (dielectric). Its function
to store electrical charge from a power supply.
This charge can then be given as and when required.
Symbol

Fig. 2467

Capacitor in a circuit with a generator.

Fig. 2468

The amount of electrical charge that a capacitor can store is referred to as its “capacitance” (C), and is measured in farads (F). In
practice, however, the farad is too large for general use so the following units are used instead:
mF = millifarad = 1/1,000 F
µF = microfarad = 1/1,000,000 F
nF = nanofarad = 1/1,000,000,000 F
On closing the switch, the electrons start moving but their flow is impeded by the dielectric. Electrons will therefore accumulate in the
plate connected to the negative terminal (-) of the generator, causing negative charge to build up. In the meantime the positive plate
loses electrons, thereby becoming positively charged. A potential difference is thus created across the plates of the capacitor, and
this increases until it equals the potential difference of the generator.
The capacitance of the capacitor is therefore proportional to the applied voltage and to the surface area of the plates and is inversely
proportional to the distance “d” between the plates. It also depends on the type of dielectric used.
The process described above is known as charging the capacitor, and is complete when the capacitor is fully charged. If a resistor
or a load of another type is connected to the capacitor, the latter discharges as electrons flow in opposite direction and the potential
difference between the plates decreases to zero.
Diodes
A diode can be defined simply as a junction between two semiconductors, one made of P-type material and the other made of N-type
material.

40-16
Wiring diagrams
A diode is a junction between two semiconductors, one made of P type material
and the other made of N type material.

Fig. 2469

The contact between the two semiconductors in different situations of electrical charge forms a barrier to electrical current flow at
the junction.
This barrier prevents the current from flowing through the diode.

Fig. 2470

Rectification, isolation, (switch), discharge and protection.

Fig. 2471

The diode symbol and the designations of its terminals.

Fig. 2472

The situation at the junction between the two semiconductors changes when a voltage is applied across the anode and cathode; the
diode is polarised, as shown in the figure.
When a voltage is applied to the diode, it polarises in the two ways indicated.

40-17
 Wiring diagrams
(A) = Direct polarisation (forward biasing)
( - ) = Cathode
( + ) = Anode

Fig. 2473

(B) = Reverse polarisation (reverse biasing)

( - ) = Cathode
( + ) = Anode

Fig. 2474

With forward biasing (positive connected to the anode and negative to the cathode) the resistance to current flow is significantly
reduced and the diode allows current to flow, providing that the applied voltage exceeds the threshold value, i.e. the voltage required
to initiate the process by which the barrier is reduced.
If the polarity of the diode is reversed, there is no electron flow except for the very weak current that crosses the junction. If the rever-
se voltage applied to the diode exceeds a certain value (thousand of Volts) the reverse current flowing through the diode will increase
rapidly to the point where the junction is damaged.
The function of the diode is therefore to allow current flow in one direction only, from the anode (+) to the cathode ( - ).
It this way it acts as an electrical one-way valve.
Forward biased diode allows current flow.
The lamp illuminates,

Fig. 2475

40-18
Wiring diagrams
Reverse biased diode blocks current flow.
The lamp does not illuminate.

Fig. 2476

The main function of the diode is to act as an electrical one-way valve.

Fig. 2477

Zener diode
We have already mentioned how diodes do not tolerate reverse voltage, as when this reaches a certain level, the reverse current flow
will increase significantly to the point where the diode itself is damaged.
The Zener diode is specifically designed to allow a certain amount of reverse current flow without damage to the junction.
It is also possible to make this reverse current flow occurs at a certain reverse voltage, known as “zener voltage”.
A zener diode can therefore be defined as semiconductor with a special PN junction with controlled reverse bias properties.
If forward biased, the Zener diode behaves just like a normal diode, while if reverse biased, it prevents current flow until the voltage
reaches the critical level, which is defined as the “Zener point”.
At this point the current increases rapidly.

40-19
 Wiring diagrams

Fig. 2478
The behaviour of the Zener diode can thus be compared to that of a pressure relief valve in a hydraulic circuit.
a) current and water flow
b) no current or water flow,
c) the water flows when it overcomes the opposing force of the valve spring. Likewise, the current flows when the voltage reaches
the zener point.
LED (light emitting diode)
A LED is a special diode with two terminals; it allows current flow in one direction only and emits light when low-voltage current pas-
ses through it.
The polarity of the terminals is very important, and the cathode is marked to facilitate identification.
The light emitted is monochromatic; the colours red, yellow, green and orange are available.
Operating characteristics of a LED and its symbol.

Fig. 2479

40-20
Wiring diagrams
LED
1. Light beam emitted
2. Diode
3. Transparent plastic cap
4. PIN terminals

Fig. 2480

LEDs are often used for signal lamps as their power consumption is very low, they require only low levels of reverse current and they
are impact resistant.
A typical application is as an indicator lamp, which, unlike a conventional bulb, can be flashed on and off repeatedly without failing.
They are also used to display segmented symbols and alphanumeric digits.
40.1.5 - Electrical and electronic components (2/2)
Transistors
A transistor is semiconductor which has three junctions.
It can be distinguished from a diode by its three leads, whereas a diode only has two.

Fig. 2481 - Schematic diagram and symbol of the transistor.

As you can see from the schematic, there two possible configurations: PNP (with a N semiconductor in the centre) or NPN (with a P
semiconductor in the centre). The central part is known as the “base”.
The lateral parts are doped with impurities and are termed the “collector” and the “emitter”. On the symbol, note that the emitter is
marked with an arrow, which indicates the direction of current flow between the base and the emitter.
Inside the transistor, there are two opposing barriers to current flow: if voltage is applied at one end of the semiconductor (E-C), one if
the barriers is eliminated while the other is strengthened and consequently no current flows; the same result is obtained if the polarity
of the applied voltage is reversed.

40-21
 Wiring diagrams
When voltage is applied across terminals (E) and (C), no current flows through
the transistor.

Fig. 2482

If a weak voltage is applied simultaneously to the base terminal, the transistor becomes a conductor and current flows between the
emitter and collector.
When voltage is also applied to the base terminal, the transistor allows current
flow.

Fig. 2483

When the voltage applied to the base terminal is modified, the current flow between the emitter and collector will also vary proportio-
nally. From this behaviour are derived the two main characteristics of the transistor:
1. Current does not flow through the transistor if the circuit between the emitter and collector is interrupted, i.e. no voltage ap-
plied.
2. The current flowing through the transistor is directly proportional to current that flows through the emitter-base circuit, within
the operating limits of the transistor. This means that the base current (the current that flows between the emitter and base) is
proportional to the collector current (the current flow between the emitter and the collector) and therefore the latter increases.
Given these two characteristics, a transistor can function as a switch (by removing the voltage at the base) or as an amplifier.
With a transistor, a weak current flowing from the emitter E to the base B (PNP transistor) or from the base to the emitter (NPN
transistor), can be used to control a strong current flow from the emitter to the collector (PNP) or from the collector to emitter (NPN).
This is the most useful characteristic of the transistor, which can be summarised in the equation:
a = ( Ic ) ÷ ( Ib )
This parameter, however, varies according to the collector current and voltage, as well as the temperature of the transistor.
The difference between NPN-type and PNP-type transistors lies solely in the direction of the current flow. The operating limits of
transistors are:
l the maximum collector current,
l maximum voltage from collector to emitter.

40-22
Wiring diagrams

Fig. 2484 - Operation schematic

Schematic showing operation of a PNP transistor and an NPN transistor when voltage is applied at the base.
The current Ic can flow from E to C only if it flows from E to B (1) or from B to E (2). Ic is amplified relative to Ib.

Fig. 2485
Typical connection of a transistor. The resistor R limits the current and protects the transistor.

40-23
 Wiring diagrams

Fig. 2486
Typical connection of a transistor. The resistor R limits the current and protects the transistor.

Fig. 2487
The transistor as a current amplifier
Use of a transistor as a switch or relay
Thanks to their amplifying properties, transistors can be used in place of relays (electromagnetic switches) as they can perform the
same function, but with the advantage that they use static components rather than moving parts.
The figure shows two electrical circuits, one controlled by a relay and the other by a transistor.
In the relay circuit, when the switch is closed in the relay control circuit, the contacts close the main circuit (drawn with the thick black
line); i.e. a relatively small current (0.2 A) can be used to control a much larger working current (8A).
The transistor circuit works in exactly the same way. When the switch in the control circuit is closed, the current flows from the positive
pole of the battery through the emitter; the base terminal of the transistor is polarised and the transistor allows current flow (EC) thus
allowing current to flow in the main circuit.

40-24
Wiring diagrams

Fig. 2488
Circuit diagrams show use of an electromagnetic relay (B) and use of a transistor as a relay (A). U = Load in main circuit.

40-25
 Wiring diagrams
40.2 - Components
40.2.1 - A - Starting and charging (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001)
Table 197
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A001 Alternator “D+” 40-192 40-583
40-338
A002 +30 Battery 40-192 40-654
40-338
A003 Battery negative 40-167 40-652
40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
A005 Alternator “B+” 40-192 40-657
40-338 40-654
A006 +30 Battery 40-167 40-654
40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545

40.2.2 - A - Starting and charging (5110 C -> ZKDY440200TD10001)

Table 198
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A001 Alternator “D+” 40-192 40-583
40-338
A002 +30 Battery 40-192 40-654
40-338

40-26
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A003 Battery negative 40-167 40-652
40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
A005 Alternator “B+” 40-192 40-657
40-338 40-654
A006 +30 Battery 40-167 40-654
40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545

40-27
 Wiring diagrams
40.2.3 - A - Starting and charging (5100 C -> ZKDY480200TD10001)
Table 199
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A001 Alternator “D+” 40-200 40-583
40-354
A002 +30 Battery 40-200 40-654
40-354
A003 Battery negative 40-179 40-652
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
A005 Alternator “B+” 40-200 40-657
40-354 40-654
A006 +30 Battery 40-179 40-654
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576

40.2.4 - A - Starting and charging (5110 C -> ZKDY520200TD10001)

Table 200
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A001 Alternator “D+” 40-200 40-583
40-354
A002 +30 Battery 40-200 40-654
40-354

40-28
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A003 Battery negative 40-179 40-652
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
A005 Alternator “B+” 40-200 40-657
40-354 40-654
A006 +30 Battery 40-179 40-654
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576

40-29
 Wiring diagrams
40.2.5 - A - Starting and charging (5120 C -> ZKDY560200TD10001)
Table 201
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
A001 Alternator “D+” 40-200 40-583
40-354
A002 +30 Battery 40-200 40-654
40-354
A003 Battery negative 40-179 40-652
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
A005 Alternator “B+” 40-200 40-654
40-354
A006 +30 Battery 40-179 40-654
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576

40-30
Wiring diagrams
40.2.6 - B - Fuses (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2489
l B001 - Power fuse (150A)
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l B004 - Pre-heating power feed fuse (150A)
l Ba001 - Cluster fuse, +30 (3A)
l Ba002 - Corner light fuse, +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse, +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse, +30 (15A)
l Ba009 – Cab Socket fuse, +30 (15 A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse, +15 (15A)
l Bb002 - Low beam headlights fuse, +15 (5A)
l Bb003 – Brake switch fuse, +15 (15 A)
l Bb004 - Stoll fuse, +15 (7.5A)
l Bb005 - Seat Socket fuse, +15 (15A)
l Bb006 - Engine fuse, +15 (7.5A)
l Bb007 – Ancillary fuse, +15 (7.5 A)
l Bb008 - Cluster fuse, +15 (3A)
l Bb009 - ISO 11786 line fuse, +15 (10A)

40-31
 Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2489
l Bb010 - Rear hitch fuse, +15 (3A)
l Bb011 - AC system fuse, +15 (7.5A)
l Bb012 – Body SV fuse, +15 (7.5 A)
l Bb013 – Relay/SW fuse, +15 (7.5 A)
l Bb014 - Radio/amplifier fuse, +15 (5A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bb019 – Front windscreen wiper motor/horn fuse, +15 (15 A)
l Bb020 - Rear screen wiper motor fuse, +15 (15A)
l Bc001 - Not used
l Bc002 - Fan fuse, +30 (30A)
l Bc003 - Not used
l Bc004 - HLHP control unit fuse, +30 (20A)
l Bc005 - Not used
l Bc006 - Hazard lights fuse, +30 (20A)
l Bc007 - Not used
l Bc008 - Power socket fuse, +30 (20A)
l Bc009 - Not used
l Bd001 - Power fuse, +15 (3A)
l Bd002 - Power fuse, +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)

40-32
Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2489
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)

40-33
 Wiring diagrams
Table 202
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
B001 Power fuse (150A) 40-167 40-586
40-192 40-654
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
B002 Outlet power fuse 40-167 40-596
ISO 11783 (60A) 40-192
40-208
40-510
B003 Outlet power fuse 40-167 40-596
ISO 11783 (25A)
B004 Pre-heat power fuse 40-192 40-657
(150 A)
Ba001 Line fuse ISO 11783 40-338 40-586
+30 (15A) 40-521
40-531
40-540
Ba002 Low beam head- 40-276 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-246 40-586
(15A) 40-276
40-369
Ba004 Front suspension 40-167 40-586
fuse +30 (7.5A) 40-192
40-214
40-246
40-276
40-338
40-369
40-377
40-399
40-437
40-459
40-531
40-545
Ba005 High beam head- 40-246 40-586
lights fuse +30 (15A) 40-276
Ba006 Radio fuse +30 (5A) 40-459 40-586
Ba008 Cluster fuse +30 40-276 40-586
(3A)
Ba009 Wolp fuse +30 (10A) 40-459 40-586
Ba010 Power fuse +30 40-276 40-586
(15A)
Bb001 Turn indicator lights 40-531 40-586
fuse +15 (15A)

40-34
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb002 Radio/amplifier fuse 40-246 40-586
+15 (5A) 40-276
Bb003 Stoll fuse +15 (7.5A) 40-521 40-586
Bb004 Russia Kit/25A fuse 40-459 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-459 40-586
Bb006 Brake lights fuse +15 40-167 40-586
(15A) 40-192
40-208
40-338
Bb007 Climate control fuse 40-214 40-586
+15 (20A) 40-399
40-437
Bb008 Shuttle lever fuse 40-192 40-586
+15 (3A) 40-338
40-510
40-521
40-531
40-540
Bb009 Rear hitch fuse +15 40-488 40-586
(3A)
Bb010 Cigarette lighter fuse 40-167 40-586
+15 (15A) 40-437
40-488
40-545
Table 203
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb011 Power fuse +15 (3A) 40-377 40-586
Bb012 Lights Gen fuse +15 40-399 40-586
(5A)
Bb013 Wolp fuse +15 (3A) 40-276 40-586
40-276
40-459
Bb014 Trailer braking fuse 40-369 40-586
+15 (7.5A)
Bb017 Engine fuse +15 40-338 40-586
(7.5A) 40-531
Bb019 IC/WOD/MM1 fuse 40-326 40-586
+15 (3A)
Bb020 Line fuse ISO 11786 40-326 40-586
+15 (10A)
Bc002 Power outlet fuse 40-377 40-586
+30 (20A)
Bc004 HLHP control unit 40-208 40-586
fuse, +30 (20A) 40-214
40-338
40-399
40-437
40-488
40-521
40-540
40-545
Bc006 Sidelights fuse 40-246 40-586
(7.5A)
Bc008 Not used 40-459 40-586

40-35
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bd001 Front cab roof work- 40-167 40-586
ing lights fuse +30 40-192
(25A) 40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-540
40-545
Bd002 Low beam head- 40-167 40-586
lights fuse, +15 (5A) 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
Bd003 Rear cab roof work- 40-246 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-167 40-586
fuse +30 (20A) 40-214
40-246
40-276
40-369
40-377
40-399
40-437
40-459
40-545
Bd005 Steering fuse +30 40-377 40-586
(25A)
Bd006 Electric Pump fuse 40-192 40-586
+30 (20A) 40-246
40-276
40-326
40-338
40-377
40-459
40-531
40-545

40-36
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bg001 Front windscreen 40-276 40-586
wiper motor fuse +15
(15A)
Bg002 Rear windscreen 40-276 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-276 40-586
(10A)

40.2.7 - B - Fuses (5110 C -> ZKDY440200TD10001)

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2492
l B001 - Power fuse (150A)
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l B004 - Pre-heating power feed fuse (150A)
l Ba001 - Cluster fuse, +30 (3A)
l Ba002 - Corner light fuse, +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse, +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)

40-37
 Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2492
l Ba008 - Rotating beacon fuse, +30 (15A)
l Ba009 – Cab Socket fuse, +30 (15 A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse, +15 (15A)
l Bb002 - Low beam headlights fuse, +15 (5A)
l Bb003 – Brake switch fuse, +15 (15 A)
l Bb004 - Stoll fuse, +15 (7.5A)
l Bb005 - Seat Socket fuse, +15 (15A)
l Bb006 - Engine fuse, +15 (7.5A)
l Bb007 – Ancillary fuse, +15 (7.5 A)
l Bb008 - Cluster fuse, +15 (3A)
l Bb009 - ISO 11786 line fuse, +15 (10A)
l Bb010 - Rear hitch fuse, +15 (3A)
l Bb011 - AC system fuse, +15 (7.5A)
l Bb012 – Body SV fuse, +15 (7.5 A)
l Bb013 – Relay/SW fuse, +15 (7.5 A)
l Bb014 - Radio/amplifier fuse, +15 (5A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bb019 – Front windscreen wiper motor/horn fuse, +15 (15 A)
l Bb020 - Rear screen wiper motor fuse, +15 (15A)
l Bc001 - Not used
l Bc002 - Fan fuse, +30 (30A)
l Bc003 - Not used

40-38
Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2492
l Bc004 - HLHP control unit fuse, +30 (20A)
l Bc005 - Not used
l Bc006 - Hazard lights fuse, +30 (20A)
l Bc007 - Not used
l Bc008 - Power socket fuse, +30 (20A)
l Bc009 - Not used
l Bd001 - Power fuse, +15 (3A)
l Bd002 - Power fuse, +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)

40-39
 Wiring diagrams
Table 204
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
B001 Power fuse (150A) 40-167 40-586
40-192 40-654
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
B002 Outlet power fuse 40-167 40-596
ISO 11783 (60A) 40-192
40-208
40-510
B003 Outlet power fuse 40-167 40-596
ISO 11783 (25A)
B004 Pre-heat power fuse 40-192 40-657
(150 A)
Ba001 Line fuse ISO 11783 40-338 40-586
+30 (15A) 40-521
40-531
40-540
Ba002 Low beam head- 40-276 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-246 40-586
(15A) 40-276
40-369
Ba004 Front suspension 40-167 40-586
fuse +30 (7.5A) 40-192
40-224
40-246
40-276
40-338
40-369
40-377
40-399
40-437
40-459
40-531
40-545
Ba005 High beam head- 40-246 40-586
lights fuse +30 (15A) 40-276
Ba006 Radio fuse +30 (5A) 40-459 40-586
Ba008 Cluster fuse +30 40-276 40-586
(3A)
Ba009 Wolp fuse +30 (10A) 40-459 40-586
Ba010 Power fuse +30 40-276 40-586
(15A)
Bb001 Turn indicator lights 40-531 40-586
fuse +15 (15A)

40-40
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb002 Radio/amplifier fuse 40-246 40-586
+15 (5A) 40-276
Bb003 Stoll fuse +15 (7.5A) 40-521 40-586
Bb004 Russia Kit/25A fuse 40-459 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-459 40-586
Bb006 Brake lights fuse +15 40-167 40-586
(15A) 40-192
40-208
40-338
Bb007 Climate control fuse 40-224 40-586
+15 (20A) 40-399
40-437
Bb008 Shuttle lever fuse 40-192 40-586
+15 (3A) 40-338
40-510
40-521
40-531
40-540
Bb009 Rear hitch fuse +15 40-488 40-586
(3A)
Bb010 Cigarette lighter fuse 40-167 40-586
+15 (15A) 40-437
40-488
40-545
Table 205
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb011 Power fuse +15 (3A) 40-377 40-586
Bb012 Lights Gen fuse +15 40-399 40-586
(5A)
Bb013 Wolp fuse +15 (3A) 40-276 40-586
40-276
40-459
Bb014 Trailer braking fuse 40-369 40-586
+15 (7.5A)
Bb017 Engine fuse +15 40-338 40-586
(7.5A) 40-531
Bb019 IC/WOD/MM1 fuse 40-326 40-586
+15 (3A)
Bb020 Line fuse ISO 11786 40-326 40-586
+15 (10A)
Bc002 Power outlet fuse 40-377 40-586
+30 (20A)
Bc004 HLHP control unit 40-208 40-586
fuse, +30 (20A) 40-224
40-338
40-399
40-437
40-488
40-521
40-540
40-545
Bc006 Sidelights fuse 40-246 40-586
(7.5A)
Bc008 Not used 40-459 40-586

40-41
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bd001 Front cab roof work- 40-167 40-586
ing lights fuse +30 40-192
(25A) 40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-540
40-545
Bd002 Low beam head- 40-167 40-586
lights fuse, +15 (5A) 40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
Bd003 Rear cab roof work- 40-246 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-167 40-586
fuse +30 (20A) 40-224
40-246
40-276
40-369
40-377
40-399
40-437
40-459
40-545
Bd005 Steering fuse +30 40-377 40-586
(25A)
Bd006 Electric Pump fuse 40-192 40-586
+30 (20A) 40-246
40-276
40-326
40-338
40-377
40-459
40-531
40-545

40-42
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bg001 Front windscreen 40-276 40-586
wiper motor fuse +15
(15A)
Bg002 Rear windscreen 40-276 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-276 40-586
(10A)

40.2.8 - B - Fuses (5100 C -> ZKDY480200TD10001)

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2495
l B001 - Power fuse (150A)
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l B004 - Pre-heating power feed fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba006 - High beam headlights fuse +30 (15A)

40-43
 Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2495
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat Socket fuse +15 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb008 - Cluster fuse +15 (3A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear lift fuse +15 (3A)
l Bb011 - AC system fuse +15 (7.5A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bb019 – Windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear windscreen wiper motor fuse +15 (15A)
l Bc001 - Not used
l Bc002 - Fan fuse +30 (30A)
l Bc003 - Not used

40-44
Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2495
l Bc004 - HLHP control unit fuse +30 (20A)
l Bc005 - Not used
l Bc006 - Hazard lights fuse +30 (20A)
l Bc007 - Not used
l Bc008 - Power socket fuse +30 (20A)
l Bc009 - Not used
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)

40-45
 Wiring diagrams
Table 206
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
B001 Power fuse (150A) 40-179 40-586
40-200 40-654
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
B002 Outlet power fuse 40-179 40-606
ISO 11783 (60A) 40-200
40-552
40-515
B003 Outlet power fuse 40-179 40-606
ISO 11783 (25A)
B004 Pre-heat power fuse 40-200 40-657
(150 A)
Ba001 Line fuse ISO 11783 40-354 40-586
+30 (15A) 40-558
40-567
40-540
Ba002 Low beam head- 40-301 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-261 40-586
(15A) 40-301
40-369
Ba004 Front suspension 40-179 40-586
fuse +30 (7.5A) 40-200
40-235
40-261
40-301
40-354
40-369
40-388
40-411
40-448
40-474
40-567
40-576
Ba005 High beam head- 40-261 40-586
lights fuse +30 (15A) 40-301
Ba006 Radio fuse +30 (5A) 40-474 40-586
Ba008 Cluster fuse +30 40-301 40-586
(3A)
Ba009 Wolp fuse +30 (10A) 40-474 40-586
Ba010 Power fuse +30 40-301 40-586
(15A)
Bb001 Turn indicator lights 40-567 40-586
fuse +15 (15A)

40-46
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb002 Radio/amplifier fuse 40-261 40-586
+15 (5A) 40-301
Bb003 Stoll fuse +15 (7.5A) 40-558 40-586
Bb004 Russia Kit/25A fuse 40-474 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-474 40-586
Bb006 Brake lights fuse +15 40-179 40-586
(15A) 40-200
40-552
40-354
Bb007 Climate control fuse 40-235 40-586
+15 (20A) 40-411
40-448
Bb008 Shuttle lever fuse 40-200 40-586
+15 (3A) 40-354
40-515
40-558
40-567
40-540
Bb009 Rear lift fuse +15 40-499 40-586
(3A)
Bb010 Cigarette lighter fuse 40-179 40-586
+15 (15A) 40-448
40-499
40-576
Table 207
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb011 Power fuse +15 (3A) 40-388 40-586
Bb012 Lights Gen fuse +15 40-411 40-586
(5A)
Bb013 Wolp fuse +15 (3A) 40-301 40-586
40-301
40-474
Bb014 Trailer braking fuse 40-369 40-586
+15 (7.5A)
Bb017 Engine fuse +15 40-354 40-586
(7.5A) 40-567
Bb019 IC/WOD/MM1 fuse 40-326 40-586
+15 (3A)
Bb020 Line fuse ISO 11786 40-326 40-586
+15 (10A)
Bc002 Power outlet fuse 40-388 40-586
+30 (20A)
Bc004 HLHP control unit 40-552 40-586
fuse +30 (20A) 40-235
40-354
40-411
40-448
40-499
40-558
40-540
40-576
Bc006 Sidelights fuse 40-261 40-586
(7.5A)
Bc008 Not used 40-474 40-586

40-47
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bd001 Front cab roof work- 40-179 40-586
ing lights fuse +30 40-200
(25A) 40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-540
40-576
Bd002 Low beam head- 40-179 40-586
lights fuse +15 (5A) 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
Bd003 Rear cab roof work- 40-261 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-179 40-586
fuse +30 (20A) 40-235
40-261
40-301
40-369
40-388
40-411
40-448
40-474
40-576
Bd005 Steering fuse +30 40-388 40-586
(25A)
Bd006 Electric Pump fuse 40-200 40-586
+30 (20A) 40-261
40-301
40-326
40-354
40-388
40-474
40-567
40-576

40-48
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bg001 Windscreen wiper 40-301 40-586
motor fuse +15
(15A)
Bg002 Rear windscreen 40-301 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-301 40-586
(10A)

40.2.9 - B - Fuses (5110 C -> ZKDY520200TD10001)

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2498
l B001 - Power fuse (150A)
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l B004 - Pre-heating power feed fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba006 - High beam headlights fuse +30 (15A)

40-49
 Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2498
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat Socket fuse +15 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb008 - Cluster fuse +15 (3A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear lift fuse +15 (3A)
l Bb011 - AC system fuse +15 (7.5A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bc001 - Not used
l Bc002 - Fan fuse +30 (30A)
l Bc003 - Not used

40-50
Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2498
l Bc004 - HLHP control unit fuse +30 (20A)
l Bc005 - Not used
l Bc006 - Hazard lights fuse +30 (20A)
l Bc007 - Not used
l Bc008 - Power socket fuse +30 (20A)
l Bc009 - Not used
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)

40-51
 Wiring diagrams
Table 208
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
B001 Power fuse (150A) 40-179 40-586
40-200 40-654
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
B002 Outlet power fuse 40-179 40-606
ISO 11783 (60A) 40-200
40-552
40-515
B003 Outlet power fuse 40-179 40-606
ISO 11783 (25A)
B004 Pre-heat power fuse 40-200 40-657
(150 A)
Ba001 Line fuse ISO 11783 40-354 40-586
+30 (15A) 40-558
40-567
40-540
Ba002 Low beam head- 40-301 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-261 40-586
(15A) 40-301
40-369
Ba004 Front suspension 40-179 40-586
fuse +30 (7.5A) 40-200
40-235
40-261
40-301
40-354
40-369
40-388
40-424
40-448
40-474
40-567
40-576
Ba005 High beam head- 40-261 40-586
lights fuse +30 (15A) 40-301
Ba006 Radio fuse +30 (5A) 40-474 40-586
Ba008 Cluster fuse +30 40-301 40-586
(3A)
Ba009 Wolp fuse +30 (10A) 40-474 40-586
Ba010 Power fuse +30 40-301 40-586
(15A)
Bb001 Turn indicator lights 40-567 40-586
fuse +15 (15A)

40-52
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb002 Radio/amplifier fuse 40-261 40-586
+15 (5A) 40-301
Bb003 Stoll fuse +15 (7.5A) 40-558 40-586
Bb004 Russia Kit/25A fuse 40-474 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-474 40-586
Bb006 Brake lights fuse +15 40-179 40-586
(15A) 40-200
40-552
40-354
Bb007 Climate control fuse 40-235 40-586
+15 (20A) 40-424
40-448
Bb008 Shuttle lever fuse 40-200 40-586
+15 (3A) 40-354
40-515
40-558
40-567
40-540
Bb009 Rear lift fuse +15 40-499 40-586
(3A)
Bb010 Cigarette lighter fuse 40-179 40-586
+15 (15A) 40-448
40-499
40-576
Table 209
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb011 Power fuse +15 (3A) 40-388 40-586
Bb012 Lights Gen fuse +15 40-424 40-586
(5A)
Bb013 Wolp fuse +15 (3A) 40-301 40-586
40-301
40-474
Bb014 Trailer braking fuse 40-369 40-586
+15 (7.5A)
Bb017 Engine fuse +15 40-354 40-586
(7.5A) 40-567
Bb019 IC/WOD/MM1 fuse 40-326 40-586
+15 (3A)
Bb020 Line fuse ISO 11786 40-326 40-586
+15 (10A)
Bc002 Power outlet fuse 40-388 40-586
+30 (20A)
Bc004 HLHP control unit 40-552 40-586
fuse +30 (20A) 40-235
40-354
40-424
40-448
40-499
40-558
40-540
40-576
Bc006 Sidelights fuse 40-261 40-586
(7.5A)
Bc008 Not used 40-474 40-586

40-53
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bd001 Front cab roof work- 40-179 40-586
ing lights fuse +30 40-200
(25A) 40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-540
40-576
Bd002 Low beam head- 40-179 40-586
lights fuse +15 (5A) 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
Bd003 Rear cab roof work- 40-261 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-179 40-586
fuse +30 (20A) 40-235
40-261
40-301
40-369
40-388
40-424
40-448
40-474
40-576
Bd005 Steering fuse +30 40-388 40-586
(25A)
Bd006 Electric Pump fuse 40-200 40-586
+30 (20A) 40-261
40-301
40-326
40-354
40-388
40-474
40-567
40-576

40-54
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bg001 Front windscreen 40-301 40-586
wiper motor fuse +15
(15A)
Bg002 Rear windscreen 40-301 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-301 40-586
(10A)

40.2.10 - B - Fuses (5120 C -> ZKDY560200TD10001)

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2501
l B001 - Power fuse (150A)
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l B004 - Pre-heating power feed fuse (150A)
l Ba001 - Cluster fuse, +30 (3A)
l Ba002 - Corner light fuse, +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse, +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)

40-55
 Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2501
l Ba008 - Rotating beacon fuse, +30 (15A)
l Ba009 – Cab Socket fuse, +30 (15 A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse, +15 (15A)
l Bb002 - Low beam headlights fuse, +15 (5A)
l Bb003 – Brake switch fuse, +15 (15 A)
l Bb004 - Stoll fuse, +15 (7.5A)
l Bb005 - Seat Socket fuse, +15 (15A)
l Bb006 - Engine fuse, +15 (7.5A)
l Bb007 – Ancillary fuse, +15 (7.5 A)
l Bb008 - Cluster fuse, +15 (3A)
l Bb009 - ISO 11786 line fuse, +15 (10A)
l Bb010 - Rear hitch fuse, +15 (3A)
l Bb011 - AC system fuse, +15 (7.5A)
l Bb012 – Body SV fuse, +15 (7.5 A)
l Bb013 – Relay/SW fuse, +15 (7.5 A)
l Bb014 - Radio/amplifier fuse, +15 (5A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bb019 – Front windscreen wiper motor/horn fuse, +15 (15 A)
l Bb020 - Rear screen wiper motor fuse, +15 (15A)
l Bc001 - Not used
l Bc002 - Fan fuse, +30 (30A)
l Bc003 - Not used

40-56
Wiring diagrams

Bd001 Bd005

Bg001

Bg002

Bg003

Bg004
Bd002 Bd006

Bd003 Bd007

Bd004 Bd008

Bc004 Bc007
Bc002

Bc003
Bc001

Bc005 Bc008

Bc006 Bc009
Bb012

Bb015
Bb011

Bb013

Bb014

Bb016

Bb018
Bb017

Bb020
Bb019
Bb002

Bb005
Bb001

Bb003

Bb004

Bb006

Bb008
Bb007

Bb010
Bb009
Ba007

Ba009
Ba006

Ba008

Ba010
Ba002

Ba004
Ba001

Ba003

Ba005

Fig. 2501
l Bc004 - HLHP control unit fuse, +30 (20A)
l Bc005 - Not used
l Bc006 - Hazard lights fuse, +30 (20A)
l Bc007 - Not used
l Bc008 - Power socket fuse, +30 (20A)
l Bc009 - Not used
l Bd001 - Power fuse, +15 (3A)
l Bd002 - Power fuse, +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)

40-57
 Wiring diagrams
Table 210
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
B001 Power fuse (150A) 40-179 40-586
40-200 40-654
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
B002 Outlet power fuse 40-179 40-606
ISO 11783 (60A) 40-200
40-552
40-515
B003 Outlet power fuse 40-179 40-606
ISO 11783 (25A)
B004 Pre-heat power fuse 40-200
(150 A)
Ba001 Line fuse ISO 11783 40-354 40-586
+30 (15A) 40-558
40-567
40-540
Ba002 Low beam head- 40-301 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-261 40-586
(15A) 40-301
40-369
Ba004 Front suspension 40-179 40-586
fuse +30 (7.5A) 40-200
40-235
40-261
40-301
40-354
40-369
40-388
40-424
40-448
40-474
40-567
40-576
Ba005 High beam head- 40-261 40-586
lights fuse +30 (15A) 40-301
Ba006 Radio fuse +30 (5A) 40-474 40-586
Ba008 Cluster fuse +30 40-301 40-586
(3A)
Ba009 Wolp fuse +30 (10A) 40-474 40-586
Ba010 Power fuse +30 40-301 40-586
(15A)
Bb001 Turn indicator lights 40-567 40-586
fuse +15 (15A)

40-58
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb002 Radio/amplifier fuse 40-261 40-586
+15 (5A) 40-301
Bb003 Stoll fuse +15 (7.5A) 40-558 40-586
Bb004 Russia Kit/25A fuse 40-474 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-474 40-586
Bb006 Brake lights fuse +15 40-179 40-586
(15A) 40-200
40-552
40-354
Bb007 Climate control fuse 40-235 40-586
+15 (20A) 40-424
40-448
Bb008 Shuttle lever fuse 40-200 40-586
+15 (3A) 40-354
40-515
40-558
40-567
40-540
Bb009 Rear hitch fuse +15 40-499 40-586
(3A)
Bb010 Cigarette lighter fuse 40-179 40-586
+15 (15A) 40-448
40-499
40-576
Table 211
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bb011 Power fuse +15 (3A) 40-388 40-586
Bb012 Lights Gen fuse +15 40-424 40-586
(5A)
Bb013 Wolp fuse +15 (3A) 40-301 40-586
40-301
40-474
Bb014 Trailer braking fuse 40-369 40-586
+15 (7.5A)
Bb017 Engine fuse +15 40-354 40-586
(7.5A) 40-567
Bb019 IC/WOD/MM1 fuse 40-326 40-586
+15 (3A)
Bb020 Line fuse ISO 11786 40-326 40-586
+15 (10A)
Bc002 Power outlet fuse 40-388 40-586
+30 (20A)
Bc004 HLHP control unit 40-552 40-586
fuse, +30 (20A) 40-235
40-354
40-424
40-448
40-499
40-558
40-540
40-576
Bc006 Sidelights fuse 40-261 40-586
(7.5A)
Bc008 Not used 40-474 40-586

40-59
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bd001 Front cab roof work- 40-179 40-586
ing lights fuse +30 40-200
(25A) 40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-540
40-576
Bd002 Low beam head- 40-179 40-586
lights fuse, +15 (5A) 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
Bd003 Rear cab roof work- 40-261 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-179 40-586
fuse +30 (20A) 40-235
40-261
40-301
40-369
40-388
40-424
40-448
40-474
40-576
Bd005 Steering fuse +30 40-388 40-586
(25A)
Bd006 Electric Pump fuse 40-200 40-586
+30 (20A) 40-261
40-301
40-326
40-354
40-388
40-474
40-567
40-576

40-60
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
Bg001 Front windscreen 40-301 40-586
wiper motor fuse +15
(15A)
Bg002 Rear windscreen 40-301 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-301 40-586
(10A)

40.2.11 - C - Grounds (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)

Table 212
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C002 Earthing point 40-167 40-596
40-208
40-246
40-276
40-338
40-437
40-459
40-521
40-531
C003 Earthing point 40-521 40-586
C004 Earthing point 40-167 40-586
40-192
40-192
40-246
40-488
40-510
40-521
40-531
40-540
C005 Earthing point 40-208 40-586
40-214
40-338
40-437
40-488
40-521
40-540
40-545
C006 Earthing point 40-167 40-586
40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545

40-61
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C007 Earthing point 40-246 40-586
40-326
40-338
40-437
40-521
C009 Earthing point 40-214 40-586
40-246
40-276
40-338
40-399
40-459
40-531
C011 Battery earth 40-167 40-652
40-192
40-208
40-214
40-276
40-326
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
C016 Earthing point 40-377 40-612
C017 Earthing point 40-276 40-612
40-326
40-369
40-377
40-459

40-62
Wiring diagrams
40.2.12 - C - Grounds (5110 C -> ZKDY440200TD10001)
Table 213
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C002 Earthing point 40-167 40-596
40-208
40-246
40-276
40-338
40-437
40-459
40-521
40-531
C003 Earthing point 40-521 40-586
C004 Earthing point 40-167 40-586
40-192
40-192
40-246
40-488
40-510
40-521
40-531
40-540
C005 Earthing point 40-208 40-586
40-224
40-338
40-437
40-488
40-521
40-540
40-545
C006 Earthing point 40-167 40-586
40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
C007 Earthing point 40-246 40-586
40-326
40-338
40-437
40-521
C009 Earthing point 40-224 40-586
40-246
40-276
40-338
40-399
40-459
40-531

40-63
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C011 Battery earth 40-167 40-652
40-192
40-208
40-224
40-276
40-326
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
C016 Earthing point 40-377 40-612
C017 Earthing point 40-276 40-612
40-326
40-369
40-377
40-459

40.2.13 - C - Grounds (5100 C -> ZKDY480200TD10001)

Table 214
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C002 Earthing point 40-179 40-606
40-552
40-261
40-301
40-354
40-448
40-474
40-558
40-567
C003 Earthing point 40-558 40-586
C004 Earthing point 40-179 40-586
40-200
40-200
40-261
40-499
40-515
40-558
40-567
40-540
C005 Earthing point 40-552 40-586
40-235
40-354
40-448
40-499
40-558
40-540
40-576

40-64
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C006 Earthing point 40-179 40-586
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
C007 Earthing point 40-261 40-586
40-326
40-354
40-448
40-558
C009 Earthing point 40-235 40-586
40-261
40-301
40-354
40-411
40-474
40-567
C011 Battery earth 40-179 40-652
40-200
40-552
40-235
40-301
40-326
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
C016 Earthing point 40-388 40-612
C017 Earthing point 40-301 40-612
40-326
40-369
40-388
40-474

40-65
 Wiring diagrams
40.2.14 - C - Grounds (5110 C -> ZKDY520200TD10001)
Table 215
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C002 Grounding point 40-179 40-606
40-552
40-261
40-301
40-354
40-448
40-474
40-558
40-567
C003 Grounding point 40-558 40-586
C004 Grounding point 40-179 40-586
40-200
40-200
40-261
40-499
40-515
40-558
40-567
40-540
C005 Grounding point 40-552 40-586
40-235
40-354
40-448
40-499
40-558
40-540
40-576
C006 Grounding point 40-179 40-586
40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
C007 Grounding point 40-261 40-586
40-326
40-354
40-448
40-558
C009 Grounding point 40-235 40-586
40-261
40-301
40-354
40-424
40-474
40-567

40-66
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
C011 Battery earth 40-179 40-652
40-200
40-552
40-235
40-301
40-326
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
C016 Grounding point 40-388 40-612
C017 Grounding point 40-301 40-612
40-326
40-369
40-388
40-474

40.2.15 - D - Intermediate connections (5090 C -> ZKDY360200TD10001)

Table 216
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D001 Wiring connector to 40-276 40-586
cab wiring loom 40-326
40-369
40-377
40-459
D001 Wiring connector for 40-276 40-612
roof wiring loom 40-326
40-369
40-377
40-459
D002 Wiring connector to 40-377 40-586
cab wiring loom
D002 Wiring connector for 40-377 40-612
roof wiring loom
D011 Wiring connector to 40-488 40-586
cab wiring loom
D011 Wiring connector to 40-488 40-658
ISO 11786 wiring
loom
Table 217
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector to 40-167 40-586
cab wiring loom 40-214
40-399
40-437
40-488
40-545

40-67
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector for 40-167 40-620
console wiring loom 40-214
40-399
40-437
40-488
40-545
D023 Wiring connector for 40-338 40-583
front wiring loom 40-377
40-437
D023 Wiring connector for 40-338 40-596
rear wiring loom 40-377
40-437
D024 Wiring connector for 40-192 40-583
front wiring loom 40-338
40-377
D024 Wiring connector for 40-192 40-596
rear wiring loom 40-338
40-377
D025 Wiring connector to 40-167 40-586
cab wiring loom 40-192
40-214
40-246
40-276
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-545
D025 Wiring connector for 40-167 40-596
rear wiring loom 40-192
40-214
40-246
40-276
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-545
D026 Wiring connector to 40-399 40-586
cab wiring loom
D026 Wiring connector for 40-399 40-596
rear wiring loom
D028 Wiring connector 40-246 40-623
for front light wiring 40-276
loom-horn 40-338
40-459
D028 Wiring connector for 40-246 40-596
rear wiring loom 40-276
40-338
40-459

40-68
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D029 Wiring connector for 40-214 40-596
rear wiring loom
D029 Wiring connector 40-214 40-641
for SBA/ASM wiring
loom
D030 Wiring connector for 40-276 40-612
roof wiring loom
D030 Wiring connector for 40-276 40-637
flashing beacon wir-
ing loom
D031 Wiring connector for 40-276 40-612
roof wiring loom/Ro-
tating beacon 2
D031 Wiring connector for 40-276 40-637
flashing beacon wir-
ing loom

Table 218
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D032 Wiring connector for 40-437 40-583
front wiring loom
D032 Wiring connector for 40-437 40-640
PTO solenoid valve
wiring loom
D033 Wiring connector for 40-326 40-612
roof wiring loom
D033 Wiring connector for 40-326 40-611
windscreen wiper 40-611
wiring loom
D040 Wiring connector 40-338 40-647
for hydraulic trailer 40-531
braking solenoid
valve wiring loom
D040 Wiring connector for 40-338 40-596
rear wiring loom 40-531
D041 Wiring connector for 40-531 40-596
rear wiring loom
D041 Wiring connector for 40-531 40-644
Air braking pressure
switch wiring loom
D042 Wiring connector 40-192 40-654
40-338
D042 Wiring connector 40-192 40-654
40-338

40-69
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D043 Wiring connector for 40-167 40-654
battery wiring loom 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
D043 Wiring connector to 40-167 40-586
cab wiring loom 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
D044 Wiring connector for 40-167 40-596
engine wiring loom 40-192
40-208
D045 Wiring connector for 40-246 40-586
trailer wiring loom 40-521

40-70
Wiring diagrams
Table 219
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D058 Wiring connection 40-276 40-635
to work lights wiring
loom
D058 Wiring connector for 40-276 40-612
roof wiring loom
Table 220
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D059 Wiring connection 40-276 40-635
to work lights wiring
loom
D059 Wiring connector for 40-276 40-612
roof wiring loom
D060 Wiring connection 40-276 40-635
to work lights wiring
loom
D060 Wiring connector for 40-276 40-612
roof wiring loom
D061 Wiring connection 40-276 40-635
to work lights wiring
loom
D061 Wiring connector for 40-276 40-612
roof wiring loom
D063 Wiring connection 40-276 40-612
to work lights wiring
loom
D066 Wiring connector for 40-167 40-596
rear wiring loom
D066 Wiring connector for 40-167 40-650
electric pump wiring
loom
Table 221
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D069 Wiring connector to 40-246 40-586
cab wiring loom 40-586
D069 Wiring connector 40-246 40-638
for lower front work 40-276
lights wiring loom
D070 Wiring connector to 40-246 40-586
cab wiring loom 40-276
D070 Wiring connector 40-246 40-638
for lower front work 40-276
lights wiring loom
D076 Wiring connector for 40-214 40-596
rear wiring loom
D076 Wiring connector for 40-214 40-645
SDD wiring loom
D078 Wiring connector for 40-399 40-596
rear wiring loom
D078 Wiring connector for 40-399 40-648
wiring loom 7/8
D079 Wiring connector for 40-399 40-596
rear wiring loom

40-71
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D079 Wiring connector for 40-399
wiring loom 100/110
HP
D080 Wiring connector for 40-399 40-596
rear wiring loom
D080 Wiring connector for 40-399
wiring loom 100/110
HP
D081 Wiring connector for 40-459 40-596
rear wiring loom
D081 Wiring connector for 40-459
STOLL wiring loom
D082 Wiring connector to 40-459
STOLL wiring loom
D082 Wiring connector for 40-459
STOLL wiring loom

40.2.16 - D - Intermediate connections (5100 C -> ZKDY400200TD10001)

Table 222
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D001 Wiring connector to 40-276 40-586
cab wiring loom 40-326
40-369
40-377
40-459
D001 Wiring connector for 40-276 40-612
roof wiring loom 40-326
40-369
40-377
40-459
D002 Wiring connector to 40-377 40-586
cab wiring loom
D002 Wiring connector for 40-377 40-612
roof wiring loom
D011 Wiring connector to 40-488 40-586
cab wiring loom
D011 Wiring connector to 40-488 40-658
ISO 11786 wiring
loom
Table 223
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector to 40-167 40-586
cab wiring loom 40-214
40-399
40-437
40-488
40-545
D015 Wiring connector for 40-167 40-620
console wiring loom 40-214
40-399
40-437
40-488
40-545
D023 Wiring connector for 40-338 40-583
front wiring loom 40-377
40-437

40-72
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D023 Wiring connector for 40-338 40-596
rear wiring loom 40-377
40-437
D024 Wiring connector for 40-192 40-583
front wiring loom 40-338
40-377
D024 Wiring connector for 40-192 40-596
rear wiring loom 40-338
40-377
D025 Wiring connector to 40-167 40-586
cab wiring loom 40-192
40-214
40-246
40-276
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-545
D025 Wiring connector for 40-167 40-596
rear wiring loom 40-192
40-214
40-246
40-276
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-545
D026 Wiring connector to 40-399 40-586
cab wiring loom
D026 Wiring connector for 40-399 40-596
rear wiring loom
D028 Wiring connector 40-246 40-625
for front light wiring 40-276
loom-horn 40-338
40-459
D028 Wiring connector for 40-246 40-596
rear wiring loom 40-276
40-338
40-459
D029 Wiring connector for 40-214 40-596
rear wiring loom
D029 Wiring connector 40-214 40-641
for SBA/ASM wiring
loom
D030 Wiring connector for 40-276 40-612
roof wiring loom

40-73
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D030 Wiring connector for 40-276 40-637
flashing beacon wir-
ing loom
D031 Wiring connector for 40-276 40-612
roof wiring loom/Ro-
tating beacon 2
D031 Wiring connector for 40-276 40-637
flashing beacon wir-
ing loom
Table 224
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D032 Wiring connector for 40-437 40-583
front wiring loom
D032 Wiring connector for 40-437 40-640
PTO solenoid valve
wiring loom
D033 Wiring connector for 40-326 40-612
roof wiring loom
D033 Wiring connector for 40-326 40-611
windscreen wiper 40-611
wiring loom
D040 Wiring connector 40-338 40-647
for hydraulic trailer 40-531
braking solenoid
valve wiring loom
D040 Wiring connector for 40-338 40-596
rear wiring loom 40-531
D041 Wiring connector for 40-531 40-596
rear wiring loom
D041 Wiring connector for 40-531 40-644
Air braking pressure
switch wiring loom
D042 Wiring connector 40-192 40-654
40-338
D042 Wiring connector 40-192 40-654
40-338
D043 Wiring connector for 40-167 40-654
battery wiring loom 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545

40-74
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D043 Wiring connector to 40-167 40-586
cab wiring loom 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
D044 Wiring connector for 40-167 40-596
engine wiring loom 40-192
40-208
D045 Wiring connector for 40-246 40-586
trailer wiring loom 40-521

Table 225
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D058 Wiring connection 40-276 40-635
to work lights wiring
loom
D058 Wiring connector for 40-276 40-612
roof wiring loom
Table 226
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D059 Wiring connection 40-276 40-635
to work lights wiring
loom
D059 Wiring connector for 40-276 40-612
roof wiring loom
D060 Wiring connection 40-276 40-635
to work lights wiring
loom
D060 Wiring connector for 40-276 40-612
roof wiring loom
D061 Wiring connection 40-276 40-635
to work lights wiring
loom
D061 Wiring connector for 40-276 40-612
roof wiring loom
D063 Wiring connection 40-276 40-612
to work lights wiring
loom
D066 Wiring connector for 40-167 40-596
rear wiring loom

40-75
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D066 Wiring connector for 40-167 40-650
electric pump wiring
loom
Table 227
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D069 Wiring connector to 40-246 40-586
cab wiring loom 40-586
D069 Wiring connector 40-246 40-638
for lower front work 40-276
lights wiring loom
D070 Wiring connector to 40-246 40-586
cab wiring loom 40-276
D070 Wiring connector 40-246 40-638
for lower front work 40-276
lights wiring loom
D076 Wiring connector for 40-214 40-596
rear wiring loom
D076 Wiring connector for 40-214 40-645
SDD wiring loom
D078 Wiring connector for 40-399 40-596
rear wiring loom
D078 Wiring connector for 40-399 40-648
wiring loom 7/8
D079 Wiring connector for 40-399 40-596
rear wiring loom
D079 Wiring connector for 40-399
wiring loom 100/110
HP
D080 Wiring connector for 40-399 40-596
rear wiring loom
D080 Wiring connector for 40-399
wiring loom 100/110
HP
D081 Wiring connector for 40-459 40-596
rear wiring loom
D081 Wiring connector for 40-459
STOLL wiring loom
D082 Wiring connector to 40-459
STOLL wiring loom
D082 Wiring connector for 40-459
STOLL wiring loom

40.2.17 - D - Intermediate connections (5110 C -> ZKDY440200TD10001)

Table 228
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D001 Wiring connector to 40-276 40-586
cab wiring loom 40-326
40-369
40-377
40-459
D001 Wiring connector for 40-276 40-612
roof wiring loom 40-326
40-369
40-377
40-459

40-76
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D002 Wiring connector to 40-377 40-586
cab wiring loom
D002 Wiring connector for 40-377 40-612
roof wiring loom
D011 Wiring connector to 40-488 40-586
cab wiring loom
D011 Wiring connector to 40-488 40-658
ISO 11786 wiring
loom
Table 229
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector to 40-167 40-586
cab wiring loom 40-214
40-399
40-437
40-488
40-545
D015 Wiring connector for 40-167 40-620
console wiring loom 40-214
40-399
40-437
40-488
40-545
D023 Wiring connector for 40-338 40-583
front wiring loom 40-377
40-437
D023 Wiring connector for 40-338 40-596
rear wiring loom 40-377
40-437
D024 Wiring connector for 40-192 40-583
front wiring loom 40-338
40-377
D024 Wiring connector for 40-192 40-596
rear wiring loom 40-338
40-377
D025 Wiring connector to 40-167 40-586
cab wiring loom 40-192
40-214
40-246
40-276
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-545

40-77
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D025 Wiring connector for 40-167 40-596
rear wiring loom 40-192
40-214
40-246
40-276
40-338
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-545
D026 Wiring connector to 40-399 40-586
cab wiring loom
D026 Wiring connector for 40-399 40-596
rear wiring loom
D028 Wiring connector 40-246 40-627
for front light wiring 40-276
loom-horn 40-338
40-459
D028 Wiring connector for 40-246 40-596
rear wiring loom 40-276
40-338
40-459
D029 Wiring connector for 40-214 40-596
rear wiring loom
D029 Wiring connector 40-214 40-641
for SBA/ASM wiring
loom
D030 Wiring connector for 40-276 40-612
roof wiring loom
D030 Wiring connector for 40-276 40-637
flashing beacon wir-
ing loom
D031 Wiring connector for 40-276 40-612
roof wiring loom/Ro-
tating beacon 2
D031 Wiring connector for 40-276 40-637
flashing beacon wir-
ing loom

40-78
Wiring diagrams
Table 230
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D032 Wiring connector for 40-437 40-583
front wiring loom
D032 Wiring connector for 40-437 40-640
PTO solenoid valve
wiring loom
D033 Wiring connector for 40-326 40-612
roof wiring loom
D033 Wiring connector for 40-326 40-611
windscreen wiper 40-611
wiring loom
D040 Wiring connector 40-338 40-647
for hydraulic trailer 40-531
braking solenoid
valve wiring loom
D040 Wiring connector for 40-338 40-596
rear wiring loom 40-531
D041 Wiring connector for 40-531 40-596
rear wiring loom
D041 Wiring connector for 40-531 40-644
Air braking pressure
switch wiring loom
D042 Wiring connector 40-192 40-654
40-338
D042 Wiring connector 40-192 40-654
40-338
D043 Wiring connector for 40-167 40-654
battery wiring loom 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545

40-79
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D043 Wiring connector to 40-167 40-586
cab wiring loom 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
D044 Wiring connector for 40-167 40-596
engine wiring loom 40-192
40-208
D045 Wiring connector for 40-246 40-586
trailer wiring loom 40-521
Table 231
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D058 Wiring connection 40-276 40-635
to work lights wiring
loom
D058 Wiring connector for 40-276 40-612
roof wiring loom
Table 232
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D059 Wiring connection 40-276 40-635
to work lights wiring
loom
D059 Wiring connector for 40-276 40-612
roof wiring loom
D060 Wiring connection 40-276 40-635
to work lights wiring
loom
D060 Wiring connector for 40-276 40-612
roof wiring loom
D061 Wiring connection 40-276 40-635
to work lights wiring
loom
D061 Wiring connector for 40-276 40-612
roof wiring loom
D063 Wiring connection 40-276 40-612
to work lights wiring
loom
D066 Wiring connector for 40-167 40-596
rear wiring loom

40-80
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D066 Wiring connector for 40-167 40-650
electric pump wiring
loom
Table 233
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D069 Wiring connector to 40-246 40-586
cab wiring loom 40-586
D069 Wiring connector 40-246 40-638
for lower front work 40-276
lights wiring loom
D070 Wiring connector to 40-246 40-586
cab wiring loom 40-276
D070 Wiring connector 40-246 40-638
for lower front work 40-276
lights wiring loom
D076 Wiring connector for 40-214 40-596
rear wiring loom
D076 Wiring connector for 40-214 40-645
SDD wiring loom
D078 Wiring connector for 40-399 40-596
rear wiring loom
D078 Wiring connector for 40-399 40-648
wiring loom 7/8
D079 Wiring connector for 40-399 40-596
rear wiring loom
D079 Wiring connector for 40-399
wiring loom 100/110
HP
D080 Wiring connector for 40-399 40-596
rear wiring loom
D080 Wiring connector for 40-399
wiring loom 100/110
HP
D081 Wiring connector for 40-459 40-596
rear wiring loom
D081 Wiring connector for 40-459
STOLL wiring loom
D082 Wiring connector to 40-459
STOLL wiring loom
D082 Wiring connector for 40-459
STOLL wiring loom

40.2.18 - D - Intermediate connections (5100 C -> ZKDY480200TD10001)

Table 234
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D001 Wiring connector to 40-301 40-586
cab wiring loom 40-326
40-369
40-388
40-474
D001 Wiring connector for 40-301 40-612
roof wiring loom 40-326
40-369
40-388
40-474

40-81
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D002 Wiring connector to 40-388 40-586
cab wiring loom
D002 Wiring connector for 40-388 40-612
roof wiring loom
D011 Wiring connector to 40-499 40-586
cab wiring loom
D011 Wiring connector to 40-499 40-658
ISO 11786 wiring
loom
Table 235
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector to 40-179 40-586
cab wiring loom 40-235
40-411
40-448
40-499
40-576
D015 Wiring connector for 40-179 40-620
console wiring loom 40-235
40-411
40-448
40-499
40-576
D023 Wiring connector for 40-354 40-583
front wiring loom 40-388
40-448
D023 Wiring connector for 40-354 40-606
rear wiring loom 40-388
40-448
D024 Wiring connector for 40-200 40-583
front wiring loom 40-354
40-388
D024 Wiring connector for 40-200 40-606
rear wiring loom 40-354
40-388
D025 Wiring connector to 40-179 40-586
cab wiring loom 40-200
40-235
40-261
40-301
40-354
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-531
40-576

40-82
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D025 Wiring connector for 40-179 40-606
rear wiring loom 40-200
40-235
40-261
40-301
40-354
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-531
40-576
D026 Wiring connector to 40-411 40-586
cab wiring loom
D026 Wiring connector for 40-411 40-606
rear wiring loom
D028 Wiring connector 40-261 40-629
for front light wiring 40-301
loom-horn 40-354
40-474
D028 Wiring connector for 40-261 40-606
rear wiring loom 40-301
40-354
40-474
D029 Wiring connector for 40-235 40-606
rear wiring loom
D029 Wiring connector 40-235 40-641
for SBA/ASM wiring
loom
D030 Wiring connector for 40-301 40-612
roof wiring loom
D030 Wiring connector for 40-301 40-637
flashing beacon wir-
ing loom
D031 Wiring connector for 40-301 40-612
roof wiring loom/Ro-
tating beacon 2
D031 Wiring connector for 40-301 40-637
flashing beacon wir-
ing loom

40-83
 Wiring diagrams
Table 236
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D032 Wiring connector for 40-448 40-583
front wiring loom
D032 Wiring connector for 40-448 40-640
PTO solenoid valve
wiring loom
D033 Wiring connector for 40-326 40-612
roof wiring loom
D033 Wiring connector for 40-326 40-611
windscreen wiper 40-611
wiring loom
D040 Wiring connector 40-354 40-647
for hydraulic trailer 40-531
braking solenoid
valve wiring loom
D040 Wiring connector for 40-354 40-606
rear wiring loom 40-531
D041 Wiring connector for 40-531 40-606
rear wiring loom
D041 Wiring connector for 40-531 40-644
Air braking pressure
switch wiring loom
D042 Wiring connector 40-200 40-654
40-354
D042 Wiring connector 40-200 40-654
40-354
D043 Wiring connector for 40-179 40-654
battery wiring loom 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-531
40-540
40-576

40-84
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D043 Wiring connector to 40-179 40-586
cab wiring loom 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-531
40-540
40-576
D044 Wiring connector for 40-179 40-606
engine wiring loom 40-200
40-552
D045 Wiring connector for 40-261 40-586
trailer wiring loom 40-558
Table 237
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D058 Wiring connection 40-301 40-635
to work lights wiring
loom
D058 Wiring connector for 40-301 40-612
roof wiring loom
Table 238
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D059 Wiring connection 40-301 40-635
to work lights wiring
loom
D059 Wiring connector for 40-301 40-612
roof wiring loom
D060 Wiring connection 40-301 40-635
to work lights wiring
loom
D060 Wiring connector for 40-301 40-612
roof wiring loom
D061 Wiring connection 40-301 40-635
to work lights wiring
loom
D061 Wiring connector for 40-301 40-612
roof wiring loom
D063 Wiring connection 40-301 40-612
to work lights wiring
loom
D066 Wiring connector for 40-179 40-606
rear wiring loom

40-85
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D066 Wiring connector for 40-179 40-650
electric pump wiring
loom
Table 239
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D069 Wiring connector to 40-261 40-586
cab wiring loom 40-586
D069 Wiring connector 40-261 40-638
for lower front work 40-301
lights wiring loom
D070 Wiring connector to 40-261 40-586
cab wiring loom 40-301
D070 Wiring connector 40-261 40-638
for lower front work 40-301
lights wiring loom
D076 Wiring connector for 40-235 40-606
rear wiring loom
D076 Wiring connector for 40-235 40-645
SDD wiring loom
D078 Wiring connector for 40-411 40-606
rear wiring loom
D078 Wiring connector for 40-411 40-648
wiring loom 7/8
D079 Wiring connector for 40-411 40-606
rear wiring loom
D079 Wiring connector for 40-411
wiring loom 100/110
HP
D080 Wiring connector for 40-411 40-606
rear wiring loom
D080 Wiring connector for 40-411
wiring loom 100/110
HP
D081 Wiring connector for 40-474 40-606
rear wiring loom
D081 Wiring connector for 40-474 40-642
STOLL wiring loom
D082 Wiring connector to 40-474 40-642
STOLL wiring loom
D082 Wiring connector for 40-474 40-642
STOLL wiring loom

40.2.19 - D - Intermediate connections (5110 C -> ZKDY520200TD10001)

Table 240
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D001 Wiring connector to 40-301 40-586
cab wiring loom 40-326
40-369
40-388
40-474
D001 Wiring connector for 40-301 40-612
roof wiring loom 40-326
40-369
40-388
40-474

40-86
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D002 Wiring connector to 40-388 40-586
cab wiring loom
D002 Wiring connector for 40-388 40-612
roof wiring loom
D011 Wiring connector to 40-499 40-586
cab wiring loom
D011 Wiring connector to 40-499 40-658
ISO 11786 wiring
loom
Table 241
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector to 40-179 40-586
cab wiring loom 40-235
40-424
40-448
40-499
40-576
D015 Wiring connector for 40-179 40-620
console wiring loom 40-235
40-424
40-448
40-499
40-576
D023 Wiring connector for 40-354 40-583
front wiring loom 40-388
40-448
D023 Wiring connector for 40-354 40-606
rear wiring loom 40-388
40-448
D024 Wiring connector for 40-200 40-583
front wiring loom 40-354
40-388
D024 Wiring connector for 40-200 40-606
rear wiring loom 40-354
40-388
D025 Wiring connector to 40-179 40-586
cab wiring loom 40-200
40-235
40-261
40-301
40-354
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-576

40-87
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D025 Wiring connector for 40-179 40-606
rear wiring loom 40-200
40-235
40-261
40-301
40-354
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-576
D026 Wiring connector to 40-424 40-586
cab wiring loom
D026 Wiring connector for 40-424 40-606
rear wiring loom
D028 Wiring connector 40-261 40-631
for front light wiring 40-301
loom-horn 40-354
40-474
D028 Wiring connector for 40-261 40-606
rear wiring loom 40-301
40-354
40-474
D029 Wiring connector for 40-235 40-606
rear wiring loom
D029 Wiring connector 40-235 40-641
for SBA/ASM wiring
loom
D030 Wiring connector for 40-301 40-612
roof wiring loom
D030 Wiring connector for 40-301 40-637
flashing beacon wir-
ing loom
D031 Wiring connector for 40-301 40-612
roof wiring loom/Ro-
tating beacon 2
D031 Wiring connector for 40-301 40-637
flashing beacon wir-
ing loom

40-88
Wiring diagrams
Table 242
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D032 Wiring connector for 40-448 40-583
front wiring loom
D032 Wiring connector for 40-448 40-640
PTO solenoid valve
wiring loom
D033 Wiring connector for 40-326 40-612
roof wiring loom
D033 Wiring connector for 40-326 40-611
windscreen wiper 40-611
wiring loom
D040 Wiring connector 40-354 40-647
for hydraulic trailer 40-567
braking solenoid
valve wiring loom
D040 Wiring connector for 40-354 40-606
rear wiring loom 40-567
D041 Wiring connector for 40-567 40-606
rear wiring loom
D041 Wiring connector for 40-567 40-644
Air braking pressure
switch wiring loom
D042 Wiring connector 40-200 40-654
40-354
D042 Wiring connector 40-200 40-654
40-354
D043 Wiring connector for 40-179 40-654
battery wiring loom 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576

40-89
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D043 Wiring connector to 40-179 40-586
cab wiring loom 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
D044 Wiring connector for 40-179 40-606
engine wiring loom 40-200
40-552
D045 Wiring connector for 40-261 40-586
trailer wiring loom 40-558
Table 243
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D058 Wiring connection 40-301 40-635
to work lights wiring
loom
D058 Wiring connector for 40-301 40-612
roof wiring loom
Table 244
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D059 Wiring connection 40-301 40-635
to work lights wiring
loom
D059 Wiring connector for 40-301 40-612
roof wiring loom
D060 Wiring connection 40-301 40-635
to work lights wiring
loom
D060 Wiring connector for 40-301 40-612
roof wiring loom
D061 Wiring connection 40-301 40-635
to work lights wiring
loom
D061 Wiring connector for 40-301 40-612
roof wiring loom
D063 Wiring connection 40-301 40-612
to work lights wiring
loom
D066 Wiring connector for 40-179 40-606
rear wiring loom

40-90
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D066 Wiring connector for 40-179 40-650
electric pump wiring
loom
Table 245
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D069 Wiring connector to 40-261 40-586
cab wiring loom 40-586
D069 Wiring connector 40-261 40-638
for lower front work 40-301
lights wiring loom
D070 Wiring connector to 40-261 40-586
cab wiring loom 40-301
D070 Wiring connector 40-261 40-638
for lower front work 40-301
lights wiring loom
D076 Wiring connector for 40-235 40-606
rear wiring loom
D076 Wiring connector for 40-235 40-645
SDD wiring loom
D078 Wiring connector for 40-424 40-606
rear wiring loom
D078 Wiring connector for 40-424 40-648
wiring loom 7/8
D079 Wiring connector for 40-424 40-606
rear wiring loom
D079 Wiring connector for 40-424 40-644
wiring loom 100/110
HP
D080 Wiring connector for 40-424 40-606
rear wiring loom
D080 Wiring connector for 40-424 40-644
wiring loom 100/110
HP
D081 Wiring connector for 40-474 40-606
rear wiring loom
D081 Wiring connector for 40-474 40-642
STOLL wiring loom
D082 Wiring connector to 40-474 40-642
STOLL wiring loom
D082 Wiring connector for 40-474 40-642
STOLL wiring loom

40.2.20 - D - Intermediate connections (5120 C -> ZKDY560200TD10001)

Table 246
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D001 Wiring connector to 40-301 40-586
cab wiring loom 40-326
40-369
40-388
40-474
D001 Wiring connector for 40-301 40-612
roof wiring loom 40-326
40-369
40-388
40-474

40-91
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D002 Wiring connector to 40-388 40-586
cab wiring loom
D002 Wiring connector for 40-388 40-612
roof wiring loom
D011 Wiring connector to 40-499 40-586
cab wiring loom
D011 Wiring connector to 40-499 40-658
ISO 11786 wiring
loom
Table 247
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D015 Wiring connector to 40-179 40-586
cab wiring loom 40-235
40-424
40-448
40-499
40-576
D015 Wiring connector for 40-179 40-620
console wiring loom 40-235
40-424
40-448
40-499
40-576
D023 Wiring connector for 40-354 40-583
front wiring loom 40-388
40-448
D023 Wiring connector for 40-354 40-606
rear wiring loom 40-388
40-448
D024 Wiring connector for 40-200 40-583
front wiring loom 40-354
40-388
D024 Wiring connector for 40-200 40-606
rear wiring loom 40-354
40-388
D025 Wiring connector to 40-179 40-586
cab wiring loom 40-200
40-235
40-261
40-301
40-354
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-576

40-92
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D025 Wiring connector for 40-179 40-606
rear wiring loom 40-200
40-235
40-261
40-301
40-354
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-576
D026 Wiring connector to 40-424 40-586
cab wiring loom
D026 Wiring connector for 40-424 40-606
rear wiring loom
D028 Wiring connector 40-261 40-633
for front light wiring 40-301
loom-horn 40-354
40-474
D028 Wiring connector for 40-261 40-606
rear wiring loom 40-301
40-354
40-474
D029 Wiring connector for 40-235 40-606
rear wiring loom
D029 Wiring connector 40-235 40-641
for SBA/ASM wiring
loom
D030 Wiring connector for 40-301 40-612
roof wiring loom
D030 Wiring connector for 40-301 40-637
flashing beacon wir-
ing loom
D031 Wiring connector for 40-301 40-612
roof wiring loom/Ro-
tating beacon 2
D031 Wiring connector for 40-301 40-637
flashing beacon wir-
ing loom

40-93
 Wiring diagrams
Table 248
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D032 Wiring connector for 40-448 40-583
front wiring loom
D032 Wiring connector for 40-448 40-640
PTO solenoid valve
wiring loom
D033 Wiring connector for 40-326 40-612
roof wiring loom
D033 Wiring connector for 40-326 40-611
windscreen wiper 40-611
wiring loom
D040 Wiring connector 40-354 40-647
for hydraulic trailer 40-567
braking solenoid
valve wiring loom
D040 Wiring connector for 40-354 40-606
rear wiring loom 40-567
D041 Wiring connector for 40-567 40-606
rear wiring loom
D041 Wiring connector for 40-567 40-644
Air braking pressure
switch wiring loom
D042 Wiring connector 40-200 40-654
40-354
D042 Wiring connector 40-200 40-654
40-354
D043 Wiring connector for 40-179 40-654
battery wiring loom 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576

40-94
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D043 Wiring connector to 40-179 40-586
cab wiring loom 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
D044 Wiring connector for 40-179 40-606
engine wiring loom 40-200
40-552
D045 Wiring connector for 40-261 40-586
trailer wiring loom 40-558
Table 249
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D058 Wiring connection 40-301 40-635
to work lights wiring
loom
D058 Wiring connector for 40-301 40-612
roof wiring loom
Table 250
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D059 Wiring connection 40-301 40-635
to work lights wiring
loom
D059 Wiring connector for 40-301 40-612
roof wiring loom
D060 Wiring connection 40-301 40-635
to work lights wiring
loom
D060 Wiring connector for 40-301 40-612
roof wiring loom
D061 Wiring connection 40-301 40-635
to work lights wiring
loom
D061 Wiring connector for 40-301 40-612
roof wiring loom
D063 Wiring connection 40-301 40-612
to work lights wiring
loom
D066 Wiring connector for 40-179 40-606
rear wiring loom

40-95
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D066 Wiring connector for 40-179 40-650
electric pump wiring
loom
Table 251
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
D069 Wiring connector to 40-261 40-586
cab wiring loom 40-586
D069 Wiring connector 40-261 40-638
for lower front work 40-301
lights wiring loom
D070 Wiring connector to 40-261 40-586
cab wiring loom 40-301
D070 Wiring connector 40-261 40-638
for lower front work 40-301
lights wiring loom
D076 Wiring connector for 40-235 40-606
rear wiring loom
D076 Wiring connector for 40-235 40-645
SDD wiring loom
D078 Wiring connector for 40-424 40-606
rear wiring loom
D078 Wiring connector for 40-424 40-648
wiring loom 7/8
D079 Wiring connector for 40-424 40-606
rear wiring loom
D079 Wiring connector for 40-424 40-644
wiring loom 100/110
HP
D080 Wiring connector for 40-424 40-606
rear wiring loom
D080 Wiring connector for 40-424 40-644
wiring loom 100/110
HP
D081 Wiring connector for 40-474 40-606
rear wiring loom
D081 Wiring connector for 40-474 40-642
STOLL wiring loom
D082 Wiring connector to 40-474 40-642
STOLL wiring loom
D082 Wiring connector for 40-474 40-642
STOLL wiring loom

40.2.21 - E - On-board instruments and visual and audible indicators (5090 C -> ZK-
DY360200TD10001)
Table 252
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E002 Trailer braking sys- 40-531 40-586
tem air pressure
gauge
E004 2.8419.007.0 Horn 40-459 40-623

40-96
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E007 2.8339.278.0/10 Instrument panel 40-167 40-586
40-192
40-246
40-338
40-488
40-531
40-540
E008 Instrument panel 40-167 40-586
40-192
40-338
40-399
40-437
40-488
40-521
40-531
40-540

40.2.22 - E - On-board instruments and visual and audible indicators (5100 C -> ZK-
DY400200TD10001)
Table 253
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E002 Trailer braking sys- 40-531 40-586
tem air pressure
gauge
E004 2.8419.007.0 Horn 40-459 40-625
E007 2.8339.278.0/10 Instrument panel 40-167 40-586
40-192
40-246
40-338
40-488
40-531
40-540
E008 Instrument panel 40-167 40-586
40-192
40-338
40-399
40-437
40-488
40-521
40-531
40-540

40.2.23 - E - On-board instruments and visual and audible indicators (5110 C -> ZK-
DY440200TD10001)
Table 254
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E002 Trailer braking sys- 40-531 40-586
tem air pressure
gauge
E004 2.8419.007.0 Horn 40-459 40-627
E007 2.8339.278.0/10 Instrument panel 40-167 40-586
40-192
40-246
40-338
40-488
40-531
40-540

40-97
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E008 Instrument panel 40-167 40-586
40-192
40-338
40-399
40-437
40-488
40-521
40-531
40-540

40.2.24 - E - On-board instruments and visual and audible indicators (5100 C -> ZK-
DY480200TD10001)
Table 255
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E002 Trailer braking sys- 40-567 40-586
tem air pressure
gauge
E004 2.8419.007.0 Horn 40-474 40-629
E007 2.8339.278.0/10 Instrument panel 40-179 40-586
40-200
40-261
40-354
40-499
40-567
40-540
E008 Instrument panel 40-179 40-586
40-200
40-354
40-411
40-448
40-499
40-558
40-567
40-540

40.2.25 - E - On-board instruments and visual and audible indicators (5110 C -> ZK-
DY520200TD10001)
Table 256
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E002 Trailer braking sys- 40-567 40-586
tem air pressure
gauge
E004 2.8419.007.0 Horn 40-474 40-631
E007 2.8339.278.0/10 Instrument panel 40-179 40-586
40-200
40-261
40-354
40-499
40-567
40-540

40-98
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E008 Instrument panel 40-179 40-586
40-200
40-354
40-424
40-448
40-499
40-558
40-567
40-540

40.2.26 - E - On-board instruments and visual and audible indicators (5120 C -> ZK-
DY560200TD10001)
Table 257
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
E002 Trailer braking sys- 40-567 40-586
tem air pressure
gauge
E004 2.8419.007.0 Horn 40-474 40-633
E007 2.8339.278.0/10 Instrument panel 40-179 40-586
40-200
40-261
40-354
40-499
40-567
40-540
E008 Instrument panel 40-179 40-586
40-200
40-354
40-424
40-448
40-499
40-558
40-567
40-540

40.2.27 - F - External lights (rotating beacon) (5090 C -> ZKDY360200TD10001)

Table 258
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F001 0.013.0868.4 Rotating beacon 40-276 40-637
connection

F002 0.013.0868.4 Rotating beacon 40-276 40-637

connection 2

40-99
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F003 2.8039.295.0/10 Front work light on 40-276 40-635
cab

F007 2.8059.500.0/10 Rear RH turn indica- 40-246 40-586

tor
F008 2.8059.500.0/10 Sidelight/rear right 40-246 40-586
brake light 40-521
F009 2.8059.510.0/10 Rear LH turn indica- 40-246 40-586
tor R5W
GND

P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-246 40-586

brake light R5W
GND
40-521
P21W

GND

F011 2.8039.021.0/10 Rh high beam head- POSITION

40-246 40-623
light 40-338
GND

F012 2.8039.021.0/10 Rh low beam head- POSITION

40-246 40-623
light
GND

F013 RH work light 40-276 40-623

F014 Right LED light 40-246 40-623
F015 2.8039.022.0/10 Lh low beam head- 40-246 40-623
light
F016 2.8039.022.0/10 Lh high beam head- 40-246 40-623
light 40-338

40-100
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F017 Left LED light 40-246 40-623
F018 LH work light 40-276 40-623
F025 Left hand ambient 40-459 40-612
light
F026 Spot light 40-459 40-612
F027 Right hand ambient 40-459 40-612
light
F042 2.8039.295.0/10 Front work light on 40-276 40-635
cab

F044 Hazard Light 40-276 40-635

F045 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

F046 2.8039.295.0/10 Rear work light on 40-276 40-635

cab

F047 Lower front work 40-276 40-638

light
F048 Lower front work 40-276 40-638
light
F065 Hazard Light 40-276 40-635
F066 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

40-101
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F067 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

40.2.28 - F - External lights (rotating beacon) (5100 C -> ZKDY400200TD10001)

Table 259
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F001 0.013.0868.4 Rotating beacon 40-276 40-637
connection

F002 0.013.0868.4 Rotating beacon 40-276 40-637

connection 2

F003 2.8039.295.0/10 Front work light on 40-276 40-635

cab

F007 2.8059.500.0/10 Rear RH turn indica- 40-246 40-586

tor
F008 2.8059.500.0/10 Sidelight/rear right 40-246 40-586
brake light 40-521
F009 2.8059.510.0/10 Rear LH turn indica- 40-246 40-586
tor R5W
GND

P21W

GND

40-102
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F010 2.8059.510.0/10 Sidelight/rear left 40-246 40-586
brake light R5W
GND
40-521
P21W

GND

F011 2.8039.021.0/10 Rh high beam head- POSITION

40-246 40-625
light 40-338
GND

F012 2.8039.021.0/10 Rh low beam head- POSITION

40-246 40-625
light
GND

F013 RH work light 40-276 40-625

F014 Right LED light 40-246 40-625
F015 2.8039.022.0/10 Lh low beam head- 40-246 40-625
light
F016 2.8039.022.0/10 Lh high beam head- 40-246 40-625
light 40-338
F017 Left LED light 40-246 40-625
F018 LH work light 40-276 40-625
F025 Left hand ambient 40-459 40-612
light
F026 Spot light 40-459 40-612
F027 Right hand ambient 40-459 40-612
light
F042 2.8039.295.0/10 Front work light on 40-276 40-635
cab

F044 Hazard Light 40-276 40-635

40-103
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F045 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

F046 2.8039.295.0/10 Rear work light on 40-276 40-635

cab

F047 Lower front work 40-276 40-638

light
F048 Lower front work 40-276 40-638
light
F065 Hazard Light 40-276 40-635
F066 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-276 40-635

cab

40-104
Wiring diagrams
40.2.29 - F - External lights (rotating beacon) (5110 C -> ZKDY440200TD10001)
Table 260
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F001 0.013.0868.4 Rotating beacon 40-276 40-637
connection

F002 0.013.0868.4 Rotating beacon 40-276 40-637

connection 2

F003 2.8039.295.0/10 Front work light on 40-276 40-635

cab

F007 2.8059.500.0/10 Rear RH turn indica- 40-246 40-586

tor
F008 2.8059.500.0/10 Sidelight/rear right 40-246 40-586
brake light 40-521
F009 2.8059.510.0/10 Rear LH turn indica- 40-246 40-586
tor R5W
GND

P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-246 40-586

brake light R5W
GND
40-521
P21W

GND

40-105
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F011 2.8039.021.0/10 Rh high beam head- POSITION
40-246 40-627
light 40-338
GND

F012 2.8039.021.0/10 Rh low beam head- POSITION

40-246 40-627
light
GND

F013 RH work light 40-276 40-627

F014 Right LED light 40-246 40-627
F015 2.8039.022.0/10 Lh low beam head- 40-246 40-627
light
F016 2.8039.022.0/10 Lh high beam head- 40-246 40-627
light 40-338
F017 Left LED light 40-246 40-627
F018 LH work light 40-276 40-627
F025 Left hand ambient 40-459 40-612
light
F026 Spot light 40-459 40-612
F027 Right hand ambient 40-459 40-612
light
F042 2.8039.295.0/10 Front work light on 40-276 40-635
cab

F044 Hazard Light 40-276 40-635

F045 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

40-106
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F046 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

F047 Lower front work 40-276 40-638

light
F048 Lower front work 40-276 40-638
light
F065 Hazard Light 40-276 40-635
F066 2.8039.295.0/10 Rear work light on 40-276 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-276 40-635

cab

40-107
 Wiring diagrams
40.2.30 - F - External lights (rotating beacon) (5100 C -> ZKDY480200TD10001)
Table 261
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F001 0.013.0868.4 Rotating beacon 40-301 40-637
connection

F002 0.013.0868.4 Rotating beacon 40-301 40-637

connection 2

F003 2.8039.295.0/10 Front work light on 40-301 40-635

cab

F007 2.8059.500.0/10 Rear RH turn indica- 40-261 40-586

tor
F008 2.8059.500.0/10 Sidelight/rear right 40-261 40-586
brake light 40-558
F009 2.8059.510.0/10 Rear LH turn indica- 40-261 40-586
tor R5W
GND

P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-261 40-586

brake light R5W
GND
40-558
P21W

GND

40-108
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F011 2.8039.021.0/10 Rh high beam head- POSITION
40-261 40-629
light 40-354
GND

F012 2.8039.021.0/10 Rh low beam head- POSITION

40-261 40-629
light
GND

F013 RH work light 40-301 40-629

F014 Right LED light 40-261 40-629
F015 2.8039.022.0/10 Lh low beam head- 40-261 40-629
light
F016 2.8039.022.0/10 Lh high beam head- 40-261 40-629
light 40-354
F017 Left LED light 40-261 40-629
F018 LH work light 40-301 40-629
F025 Left hand ambient 40-474 40-612
light
F026 Spot light 40-474 40-612
F027 Right hand ambient 40-474 40-612
light
F042 2.8039.295.0/10 Front work light on 40-301 40-635
cab

F044 Hazard Light 40-301 40-635

F045 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

40-109
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F046 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

F047 Lower front work 40-301 40-638

light
F048 Lower front work 40-301 40-638
light
F065 Hazard Light 40-301 40-635
F066 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-301 40-635

cab

40-110
Wiring diagrams
40.2.31 - F - External lights (rotating beacon) (5110 C -> ZKDY520200TD10001)
Table 262
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F001 0.013.0868.4 Rotating beacon 40-301 40-637
connection

F002 0.013.0868.4 Rotating beacon 40-301 40-637

connection 2

F003 2.8039.295.0/10 Front work light on 40-301 40-635

cab

F007 2.8059.500.0/10 Rear RH turn indica- 40-261 40-586

tor
F008 2.8059.500.0/10 Sidelight/rear right 40-261 40-586
brake light 40-558
F009 2.8059.510.0/10 Rear LH turn indica- 40-261 40-586
tor R5W
GND

P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-261 40-586

brake light R5W
GND
40-558
P21W

GND

40-111
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F011 2.8039.021.0/10 Rh high beam head- POSITION
40-261 40-631
light 40-354
GND

F012 2.8039.021.0/10 Rh low beam head- POSITION

40-261 40-631
light
GND

F013 RH work light 40-301 40-631

F014 Right LED light 40-261 40-631
F015 2.8039.022.0/10 Lh low beam head- 40-261 40-631
light
F016 2.8039.022.0/10 Lh high beam head- 40-261 40-631
light 40-354
F017 Left LED light 40-261 40-631
F018 LH work light 40-301 40-631
F025 Left hand ambient 40-474 40-612
light
F026 Spot light 40-474 40-612
F027 Right hand ambient 40-474 40-612
light
F042 2.8039.295.0/10 Front work light on 40-301 40-635
cab

F044 Hazard Light 40-301 40-635

F045 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

40-112
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F046 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

F047 Lower front work 40-301 40-638

light
F048 Lower front work 40-301 40-638
light
F065 Hazard Light 40-301 40-635
F066 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-301 40-635

cab

40-113
 Wiring diagrams
40.2.32 - F - External lights (rotating beacon) (5120 C -> ZKDY560200TD10001)
Table 263
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F001 0.013.0868.4 Rotating beacon 40-301 40-637
connection

F002 0.013.0868.4 Rotating beacon 40-301 40-637

connection 2

F003 2.8039.295.0/10 Front work light on 40-301 40-635

cab

F007 2.8059.500.0/10 Rear RH turn indica- 40-261 40-586

tor
F008 2.8059.500.0/10 Sidelight/rear right 40-261 40-586
brake light 40-558
F009 2.8059.510.0/10 Rear LH turn indica- 40-261 40-586
tor R5W
GND

P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-261 40-586

brake light R5W
GND
40-558
P21W

GND

40-114
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F011 2.8039.021.0/10 Rh high beam head- POSITION
40-261 40-633
light 40-354
GND

F012 2.8039.021.0/10 Rh low beam head- POSITION

40-261 40-633
light
GND

F013 RH work light 40-301 40-633

F014 Right LED light 40-261 40-633
F015 2.8039.022.0/10 Lh low beam head- 40-261 40-633
light
F016 2.8039.022.0/10 Lh high beam head- 40-261 40-633
light 40-354
F017 Left LED light 40-261 40-633
F018 LH work light 40-301 40-633
F025 Left hand ambient 40-474 40-612
light
F026 Spot light 40-474 40-612
F027 Right hand ambient 40-474 40-612
light
F042 2.8039.295.0/10 Front work light on 40-301 40-635
cab

F044 Hazard Light 40-301 40-635

F045 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

40-115
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
F046 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

F047 Lower front work 40-301 40-638

light
F048 Lower front work 40-301 40-638
light
F065 Hazard Light 40-301 40-635
F066 2.8039.295.0/10 Rear work light on 40-301 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-301 40-635

cab

40-116
Wiring diagrams
40.2.33 - G - Interior lights
Table 264
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
G007 Cab light 40-369 40-612

40.2.34 - H - Manual electrical controls (steering column switch) (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001)
Table 265
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
H001 H/L selection lever 40-399 40-586
H003 Accelerator pedal 40-167 40-586
H004 Rear PTO rotation 40-437 40-596
mode selection lever
(Standard-Econom-
ic)
H005 Synchronised rear 40-437 40-596
PTO selection lever
H006 Rear PTO rotation 40-437 40-586
speed selection le-
ver
H007 2.3729.719.0/10 Handbrake 40-338 40-586
40-521

H009 Hicth control instru- 40-488 40-620

ment panel
H020 2.7099.740.0/10 Mechanical hand 40-167 40-620
throttle
H023 Lights selector 40-246 40-586
switch 40-276
40-459
H024 Single lever Stoll 40-459
controller

40.2.35 - H - Manual electrical controls (steering column stalk) (5100 C -> ZK-
DY480200TD10001)
Table 266
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
H001 H/L selection lever 40-411 40-586
H003 Accelerator pedal 40-179 40-586
H004 Rear PTO rotation 40-448 40-606
mode selection lever
(Standard-Econom-
ic)
H005 Synchronised rear 40-448 40-606
PTO selection lever
H006 Rear PTO rotation 40-448 40-586
speed selection le-
ver

40-117
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
H007 2.3729.719.0/10 Handbrake 40-354 40-586
40-558

H009 Lift control instru- 40-499 40-620

ment panel
H020 2.7099.740.0/10 Mechanical hand 40-179 40-620
throttle
H023 Lights selector 40-261 40-586
switch 40-301
40-474
H024 Single lever Stoll 40-474 40-642
controller

40.2.36 - H - Manual electrical controls (steering column switch) (5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Table 267
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
H001 H/L selection lever 40-424 40-586
H003 Accelerator pedal 40-179 40-586
H004 Rear PTO rotation 40-448 40-606
mode selection lever
(Standard-Econom-
ic)
H005 Synchronised rear 40-448 40-606
PTO selection lever
H006 Rear PTO rotation 40-448 40-586
speed selection le-
ver
H007 2.3729.719.0/10 Handbrake 40-354 40-586
40-558

H009 lift control instrument 40-499 40-620

panel
H020 2.7099.740.0/10 Mechanical hand 40-179 40-620
throttle
H023 Lights selector 40-261 40-586
switch 40-301
40-474
H024 Single lever Stoll 40-474 40-642
controller

40-118
Wiring diagrams
40.2.37 - I - Circuit breakers (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001)
Table 268
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-167 40-596
40-208

3,9 Ohm
I002 2.7659.429.0 ECO Saving switch 40-545 40-620
60 l/min
I004 2.7659.281.0 LH brake pedal 40-521 40-586
switch

4 3 2 1

4 1

3 2

NC
NO

I005 0.015.0485.4 Starter switch 40-167 40-586

40-192
40-208
40-540
40-246
40-276
40-326
40-338
40-369
40-377
40-545
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-214
I006 2.7659.444.0 SDD switch 40-214 40-586
I010 2.7659.470.0 LED lights control 40-246 40-586
switch
I025 RH rear hitch ‘Down’ 40-214 40-586
button
I026 Rear PTO control 40-437 40-586
pushbutton
I027 RH rear hitch ‘Up’ 40-214 40-586
button
I028 LH rear hitch ‘Down’ 40-214 40-586
button
I029 Rear PTO control 40-437 40-586
pushbutton
I030 LH rear hitch ‘Up’ 40-214 40-586
button

40-119
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-167 40-652
switch 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
I031b 2.7659.351.0 Battery disconnect 40-167 40-652
switch 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
I033 Hazard warning 40-246 40-586
lights switch

40-120
Wiring diagrams
Table 269
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I037 2.7659.159.0 Rotating beacon 0
1
40-276 40-612
switch 7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

I039 2.7659.461.0 Rear screen wiper 40-326 40-612

switch
I040 2.7659.283.0/10 Top/Low work lights 40-246 40-586
switch 40-276
8 1 2 3
40-338
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch 40-246 40-586

40-276
40-326
40-338
I042 2.7659.157.0 Switch for front work 40-276 40-586
lights on cab

I044 Low work lights 40-276 40-586

switch
I061 Automatic PTO con- 40-437 40-620
trol switch
I062 0.019.5354.0/10 Front PTO clutch 1 3 40-437 40-620
control push button
4 6

4 5

I063 0.019.8573.0/10 Rear PTO clutch 40-437 40-620

control push button
I065 2.7659.424.0 Rear hitch up push- 40-214 40-620
button
I066 2.7659.428.0 Rear hitch stop 40-214 40-620
push-button
I067 Rear hitch down 40-214 40-620
push-button
I068 2.7659.410.0 Engine memory but- 40-167 40-620
ton 1
I070 Dual traction activa- 40-399 40-620
tion push button
I071 2.7659.416.0 Differential lock acti- 40-399 40-620
vation switch
I073 Front hitch control 40-214 40-586
switch in cab

40-121
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I078 Switch for rear work 40-276 40-612
lights on roof
I079 Switch for front work 40-276 40-612
lights on roof
I080 Windscreen wiper 40-326 40-612
switch
I081 Windscreen washer 40-326 40-612
pump switch
I082 Distributor 7/8 switch 40-399 40-586
I083 Comfort Drive switch 40-459
I084 Hydro Lock switch 40-459
I085 Return to level / 3rd 40-459
function switch
I086 Quick empty / 4th 40-459
function switch

40.2.38 - I - Circuit breakers (5110 C -> ZKDY440200TD10001)

Table 270
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-167 40-596
40-208
3,9 Ohm

I002 2.7659.429.0 ECO Saving switch 40-545 40-620

60 l/min
I004 2.7659.281.0 LH brake pedal 40-521 40-586
switch

4 3 2 1

4 1

3 2

NC
NO

40-122
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-167 40-586
40-192
40-208
40-540
40-246
40-276
40-326
40-338
40-369
40-377
40-545
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-224
I006 2.7659.444.0 SDD switch 40-224 40-586
I010 2.7659.470.0 LED lights control 40-246 40-586
switch
I025 RH rear hitch ‘Down’ 40-224 40-586
button
I026 Rear PTO control 40-437 40-586
pushbutton
I027 RH rear hitch ‘Up’ 40-224 40-586
button
I028 LH rear hitch ‘Down’ 40-224 40-586
button
I029 Rear PTO control 40-437 40-586
pushbutton
I030 LH rear hitch ‘Up’ 40-224 40-586
button
I031a 2.7659.351.0 Battery disconnect 40-167 40-652
switch 40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545

40-123
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-167 40-652
switch 40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
I033 Hazard warning 40-246 40-586
lights switch
Table 271
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I037 2.7659.159.0 Rotating beacon 0
1
40-276 40-612
switch 7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

I039 2.7659.461.0 Rear screen wiper 40-326 40-612

switch
I040 2.7659.283.0/10 Top/Low work lights 40-246 40-586
switch 40-276
8 1 2 3
40-338
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch 40-246 40-586

40-276
40-326
40-338
I042 2.7659.157.0 Switch for front work 40-276 40-586
lights on cab

I044 Low work lights 40-276 40-586

switch
I061 Automatic PTO con- 40-437 40-620
trol switch

40-124
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I062 0.019.5354.0/10 Front PTO clutch 1 3 40-437 40-620
control push button
4 6

4 5

I063 0.019.8573.0/10 Rear PTO clutch 40-437 40-620

control push button
I065 2.7659.424.0 Rear hitch up push- 40-224 40-620
button
I066 2.7659.428.0 Rear hitch stop 40-224 40-620
push-button
I067 Rear hitch down 40-224 40-620
push-button
I068 2.7659.410.0 Engine memory but- 40-167 40-620
ton 1
I070 Dual traction activa- 40-399 40-620
tion push button
I071 2.7659.416.0 Differential lock acti- 40-399 40-620
vation switch
I073 Front hitch control 40-224 40-586
switch in cab
I078 Switch for rear work 40-276 40-612
lights on roof
I079 Switch for front work 40-276 40-612
lights on roof
I080 Windscreen wiper 40-326 40-612
switch
I081 Windscreen washer 40-326 40-612
pump switch
I082 Distributor 7/8 switch 40-399 40-586
I083 Comfort Drive switch 40-459
I084 Hydro Lock switch 40-459
I085 Return to level / 3rd 40-459
function switch
I086 Quick empty / 4th 40-459
function switch

40-125
 Wiring diagrams
40.2.39 - I - Circuit breakers (5100 C -> ZKDY480200TD10001)
Table 272
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-179 40-606
40-552

3,9 Ohm
I002 2.7659.429.0 ECO Saving switch 40-576 40-620
60 l/min
I004 2.7659.281.0 LH brake pedal 40-558 40-586
switch

4 3 2 1

4 1

3 2

NC
NO

I005 0.015.0485.4 Starter switch 40-179 40-586

40-200
40-552
40-540
40-261
40-301
40-326
40-354
40-369
40-388
40-576
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-235
I006 2.7659.444.0 SDD switch 40-235 40-586
I010 2.7659.470.0 LED lights control 40-261 40-586
switch
I025 RH rear lift ‘Down’ 40-235 40-586
button
I026 Rear PTO control 40-448 40-586
pushbutton
I027 RH rear lift ‘Up’ but- 40-235 40-586
ton
I028 LH rear lift ‘Down’ 40-235 40-586
button
I029 Rear PTO control 40-448 40-586
pushbutton
I030 LH rear lift ‘Up’ but- 40-235 40-586
ton

40-126
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-179 40-652
switch 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
I031b 2.7659.351.0 Battery disconnect 40-179 40-652
switch 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
I033 Hazard warning 40-261 40-586
lights switch

40-127
 Wiring diagrams
Table 273
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I037 2.7659.159.0 Rotating beacon 0
1
40-301 40-612
switch 7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

I039 2.7659.461.0 Rear windscreen 40-326 40-612

wiper switch
I040 2.7659.283.0/10 Top/Low work lights 40-261 40-586
switch 40-301
8 1 2 3
40-354
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch 40-261 40-586

40-301
40-326
40-354
I042 2.7659.157.0 Switch for front work 40-301 40-586
lights on cab

I044 Low work lights 40-301 40-586

switch
I061 Automatic PTO con- 40-448 40-620
trol switch
I062 0.019.5354.0/10 Front PTO clutch 1 3 40-448 40-620
control push button
4 6

4 5

I063 0.019.8573.0/10 Rear PTO clutch 40-448 40-620

control push button
I065 2.7659.424.0 Rear lift up push- 40-235 40-620
button
I066 2.7659.428.0 Rear lift stop push- 40-235 40-620
button
I067 Rear lift down push- 40-235 40-620
button
I068 2.7659.410.0 Engine memory but- 40-179 40-620
ton 1
I070 Dual traction activa- 40-411 40-620
tion push button
I071 2.7659.416.0 Differential lock acti- 40-411 40-620
vation switch
I073 Front lift control 40-235 40-586
switch in cab

40-128
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I078 Switch for rear work 40-301 40-612
lights on roof
I079 Switch for front work 40-301 40-612
lights on roof
I080 Windscreen wiper 40-326 40-612
switch
I081 Windscreen washer 40-326 40-612
pump switch
I082 Distributor 7/8 switch 40-411 40-586
I083 Comfort Drive switch 40-474 40-642
I084 Hydro Lock switch 40-474 40-642
I085 Return to level / 3rd 40-474 40-642
function switch
I086 Quick empty / 4th 40-474 40-642
function switch

40.2.40 - I - Circuit breakers (5110 C -> ZKDY520200TD10001, 5120 C -> ZK-

DY560200TD10001)
Table 274
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-179 40-606
40-552
3,9 Ohm

I002 2.7659.429.0 ECO Saving switch 40-576 40-620

60 l/min
I004 2.7659.281.0 LH brake pedal 40-558 40-586
switch

4 3 2 1

4 1

3 2

NC
NO

40-129
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-179 40-586
40-200
40-552
40-540
40-261
40-301
40-326
40-354
40-369
40-388
40-576
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-235
I006 2.7659.444.0 SDD switch 40-235 40-586
I010 2.7659.470.0 LED lights control 40-261 40-586
switch
I025 RH rear lift ‘Down’ 40-235 40-586
button
I026 Rear PTO control 40-448 40-586
pushbutton
I027 RH rear lift ‘Up’ but- 40-235 40-586
ton
I028 LH rear lift ‘Down’ 40-235 40-586
button
I029 Rear PTO control 40-448 40-586
pushbutton
I030 LH rear lift ‘Up’ but- 40-235 40-586
ton
I031a 2.7659.351.0 Battery disconnect 40-179 40-652
switch 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576

40-130
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-179 40-652
switch 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
I033 Hazard warning 40-261 40-586
lights switch
Table 275
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I037 2.7659.159.0 Rotating beacon 0
1
40-301 40-612
switch 7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

I039 2.7659.461.0 Rear screen wiper 40-326 40-612

switch
I040 2.7659.283.0/10 Top/Low work lights 40-261 40-586
switch 40-301
8 1 2 3
40-354
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch 40-261 40-586

40-301
40-326
40-354
I042 2.7659.157.0 Switch for front work 40-301 40-586
lights on cab

I044 Low work lights 40-301 40-586

switch
I061 Automatic PTO con- 40-448 40-620
trol switch

40-131
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
I062 0.019.5354.0/10 Front PTO clutch 1 3 40-448 40-620
control push button
4 6

4 5

I063 0.019.8573.0/10 Rear PTO clutch 40-448 40-620

control push button
I065 2.7659.424.0 Rear lift up push- 40-235 40-620
button
I066 2.7659.428.0 Rear lift stop push- 40-235 40-620
button
I067 Rear lift down push- 40-235 40-620
button
I068 2.7659.410.0 Engine memory but- 40-179 40-620
ton 1
I070 Dual traction activa- 40-424 40-620
tion push button
I071 2.7659.416.0 Differential lock acti- 40-424 40-620
vation switch
I073 Front lift control 40-235 40-586
switch in cab
I078 Switch for rear work 40-301 40-612
lights on roof
I079 Switch for front work 40-301 40-612
lights on roof
I080 Windscreen wiper 40-326 40-612
switch
I081 Windscreen washer 40-326 40-612
pump switch
I082 Distributor 7/8 switch 40-424 40-586
I083 Comfort Drive switch 40-474 40-642
I084 Hydro Lock switch 40-474 40-642
I085 Return to level / 3rd 40-474 40-642
function switch
I086 Quick empty / 4th 40-474 40-642
function switch

40-132
Wiring diagrams
40.2.41 - J - Relays (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)

Jf001 Je005

Je006
Jf003
Je003 Jf002

Jg001
Jg002
Je004
Jf004

J013 J012
(GS) (GS)

Jc001

Fig. 2504
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l J012 - Not used
l J013 - Not used
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jf004 - Electric pump relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay
Table 276
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J001 Windscreen wiper 40-326 40-612
relay

40-133
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J005 Air conditioning 40-377 40-586
compressor relay
J007 Right hand air condi- 40-377 40-612
tioning fan relay
Jc001 Start relay (70A - 40-167 40-586
12V) 40-192
40-208
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
Je003 Right corner lights 40-276 40-586
relay
Je004 Beacon relay 40-276 40-586
Je005 Low front work lights 40-276 40-586
relay
Je006 Trailer braking relay 40-338 40-586
40-531
Jf001 Sidelights relay 40-167 40-586
40-192
40-214
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-531
40-545
Jf002 High beam head- 40-246 40-586
lights relay 40-276
Jf003 Low beam head- 40-246 40-586
lights relay 40-276
Jf004 Electric pump relay 40-167 40-596
Jg001 Rear roof work lights 40-276 40-586
relay
Jg002 Front roof work lights 40-276 40-586
relay

40-134
Wiring diagrams
40.2.42 - J - Relays (5110 C -> ZKDY440200TD10001)

Jf001 Je005

Je006
Jf003
Je003 Jf002

Jg001
Jg002
Je004
Jf004

J013 J012
(GS) (GS)

Jc001

Fig. 2505
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l J012 - Not used
l J013 - Not used
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jf004 - Electric pump relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay
Table 277
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J001 Windscreen wiper 40-326 40-612
relay

40-135
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J005 Air conditioning 40-377 40-586
compressor relay
J007 Right hand air condi- 40-377 40-612
tioning fan relay
Jc001 Start relay (70A - 40-167 40-586
12V) 40-192
40-208
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-488
40-510
40-521
40-531
40-540
40-545
Je003 Right corner lights 40-276 40-586
relay
Je004 Beacon relay 40-276 40-586
Je005 Low front work lights 40-276 40-586
relay
Je006 Trailer braking relay 40-338 40-586
40-531
Jf001 Sidelights relay 40-167 40-586
40-192
40-224
40-246
40-276
40-326
40-338
40-369
40-377
40-399
40-437
40-459
40-531
40-545
Jf002 High beam head- 40-246 40-586
lights relay 40-276
Jf003 Low beam head- 40-246 40-586
lights relay 40-276
Jf004 Electric pump relay 40-167 40-596
Jg001 Rear roof work lights 40-276 40-586
relay
Jg002 Front roof work lights 40-276 40-586
relay

40-136
Wiring diagrams
40.2.43 - J - Relays (5100 C -> ZKDY480200TD10001)

Jf001 Je005

Je006
Jf003
Je003 Jf002

Jg001
Jg002
Je004
Jf004

J013 J012
(GS) (GS)

Jc001

Fig. 2506
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l J012 - Not used
l J013 - Not used
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jf004 - Electric pump relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay
Table 278
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J001 Windscreen wiper 40-326 40-612
relay

40-137
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J005 Air conditioning 40-388 40-586
compressor relay
J007 Right hand air condi- 40-388 40-612
tioning fan relay
Jc001 Start relay (70A - 40-179 40-586
12V) 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
Je003 Right corner lights 40-301 40-586
relay
Je004 Beacon relay 40-301 40-586
Je005 Low front work lights 40-301 40-586
relay
Je006 Trailer braking relay 40-354 40-586
40-567
Jf001 Sidelights relay 40-179 40-586
40-200
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-411
40-448
40-474
40-567
40-576
Jf002 High beam head- 40-261 40-586
lights relay 40-301
Jf003 Low beam head- 40-261 40-586
lights relay 40-301
Jf004 Electric pump relay 40-179 40-606
Jg001 Rear roof work lights 40-301 40-586
relay
Jg002 Front roof work lights 40-301 40-586
relay

40-138
Wiring diagrams
40.2.44 - J - Relays (5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

Jf001 Je005

Je006
Jf003
Je003 Jf002

Jg001
Jg002
Je004
Jf004

J013 J012
(GS) (GS)

Jc001

Fig. 2507
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l J012 - Not used
l J013 - Not used
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jf004 - Electric pump relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay
Table 279
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J001 Windscreen wiper 40-326 40-612
relay

40-139
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
J005 Air conditioning 40-388 40-586
compressor relay
J007 Right hand air condi- 40-388 40-612
tioning fan relay
Jc001 Start relay (70A - 40-179 40-586
12V) 40-200
40-552
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-499
40-515
40-558
40-567
40-540
40-576
Je003 Right corner lights 40-301 40-586
relay
Je004 Beacon relay 40-301 40-586
Je005 Low front work lights 40-301 40-586
relay
Je006 Trailer braking relay 40-354 40-586
40-567
Jf001 Sidelights relay 40-179 40-586
40-200
40-235
40-261
40-301
40-326
40-354
40-369
40-388
40-424
40-448
40-474
40-567
40-576
Jf002 High beam head- 40-261 40-586
lights relay 40-301
Jf003 Low beam head- 40-261 40-586
lights relay 40-301
Jf004 Electric pump relay 40-179 40-606
Jg001 Rear roof work lights 40-301 40-586
relay
Jg002 Front roof work lights 40-301 40-586
relay

40-140
Wiring diagrams
40.2.45 - K - Sensors and transmitters (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001)
Table 280
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi- 40-214
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K002 0.011.9428.0 Trailer braking low Power 12V DC 40-531 40-644
pressure switch Resistance at 0 bar
10-13 Ohm
Resistance at 6 Bar
119-129 Ohm

K003 2.7099.999.0 Speed sensor 40-399

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-399 40-596

sor checked using an
ordinary tester; use
the ART.
K005 2.7099.740.0/10 Rear hitch position Pin 1 = power (Nomi- 40-214 40-596
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K006 2.7099.996.0 PTO speed sensor This cannot be 40-437 40-596
checked using an
ordinary tester; use
the ART.
K007 2.7099.034.0 Brake fluid sensor 40-521 40-596

Pin C: Output

Pin A: +
Pin B: -

40-141
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K010 2.7099.035.0/10 Fuel level sensor 40-338 40-596
relay
coil

+ S

1 2 3

Pin 1: +

Pin 2: -
Pin 3: Signal

Fig. 2508
K012 Gearbox output 40-399 40-596
shaft speed sensor
K013 2.7099.690.0/10 Transmission oil Normally closed 40-399 40-596
temperature sensor (NC) contact
Switching pressure:
4 Bar
K015 Air conditioning 40-377 40-583
pressure switch
K016 Air filter pressure 40-338 40-583
sensor
K017 Air conditioning 40-377 40-583
compressor
K018 Water in fuel sensor 40-167 40-596
40-208
K019 Engine coolant tem- 40-167 40-596
perature sensor
K023 Start enable seat 40-208 40-586
sensor

K032 SDD proximity sen- 40-214

sor
K035 2.7099.960.0 Trailer hydraulic Normally closed 40-338 40-596
braking pressure (NC) contact
sensor Switching pressure: 40-531
11 bar

40-142
Wiring diagrams
Table 281
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-338 40-586
switch 15 Bar +- 1
Max. operating volt- 40-521
age: 24 V
Max. continuous
pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

K038 Transmission filter 40-338 40-596

sensor
K040 Right hand hitch 40-214 40-596
draft tie-rod sensor
K043 0.020.0800.0 Clogged Pal filter 40-338 40-596
sensor
K046 Evaporator sensor 40-377 40-612

40.2.46 - K - Sensors and transmitters (5110 C -> ZKDY440200TD10001)

Table 282
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi- 40-224 40-641
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K002 0.011.9428.0 Trailer braking low Power 12V DC 40-531 40-644
pressure switch Resistance at 0 bar
10-13 Ohm
Resistance at 6 Bar
119-129 Ohm

40-143
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K003 2.7099.999.0 Speed sensor 40-399

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-399 40-596

sor checked using an
ordinary tester; use
the ART.
K005 2.7099.740.0/10 Rear hitch position Pin 1 = power (Nomi- 40-224 40-596
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K006 2.7099.996.0 PTO speed sensor This cannot be 40-437 40-596
checked using an
ordinary tester; use
the ART.
K007 2.7099.034.0 Brake fluid sensor 40-521 40-596

Pin C: Output

Pin A: +
Pin B: -

K010 2.7099.035.0/10 Fuel level sensor 40-338 40-596

relay
coil

+ S

1 2 3

Pin 1: +

Pin 2: -
Pin 3: Signal

K012 Gearbox output 40-399 40-596

shaft speed sensor
K013 2.7099.690.0/10 Transmission oil Normally closed 40-399 40-596
temperature sensor (NC) contact
Switching pressure:
4 Bar
K015 Air conditioning 40-377 40-583
pressure switch
K016 Air filter pressure 40-338 40-583
sensor
K017 Air conditioning 40-377 40-583
compressor
K018 Water in fuel sensor 40-167 40-596
40-208
K019 Engine coolant tem- 40-167 40-596
perature sensor

40-144
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K023 Start enable seat 40-208 40-586
sensor

K032 SDD proximity sen- 40-224 40-645

sor
K035 2.7099.960.0 Trailer hydraulic Normally closed 40-338 40-596
braking pressure (NC) contact
sensor Switching pressure: 40-531
11 bar
Table 283
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-338 40-586
switch 15 Bar +- 1
Max. operating volt- 40-521
age: 24 V
Max. continuous
pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

K038 Transmission filter 40-338 40-596

sensor
K040 Right hand hitch 40-224 40-596
draft tie-rod sensor
K043 0.020.0800.0 Clogged Pal filter 40-338 40-596
sensor
K046 Evaporator sensor 40-377 40-612

40.2.47 - K - Sensors and transmitters (5100 C -> ZKDY480200TD10001)

Table 284
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi- 40-235 40-641
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal

40-145
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K002 0.011.9428.0 Trailer braking low Power 12V DC 40-567 40-644
pressure switch Resistance at 0 bar
10-13 Ohm
Resistance at 6 Bar
119-129 Ohm

K003 2.7099.999.0 Speed sensor 40-411 40-606

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-411 40-606

sor checked using an
ordinary tester; use
the ART.
K005 2.7099.740.0/10 Rear lift position Pin 1 = power (Nomi- 40-235 40-606
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K006 2.7099.996.0 PTO speed sensor This cannot be 40-448 40-606
checked using an
ordinary tester; use
the ART.
K007 2.7099.034.0 Brake oil sensor 40-558 40-606

Pin C: Output

Pin A: +
Pin B: -

K010 2.7099.035.0/10 Fuel level sensor 40-354 40-606

relay
coil

+ S

1 2 3

Pin 1: +

Pin 2: -
Pin 3: Signal

K012 Gearbox output 40-411 40-606

shaft speed sensor

40-146
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K013 2.7099.690.0/10 Transmission oil Normally closed 40-411 40-606
temperature sensor (NC) contact
Switching pressure:
4 Bar
K015 Air conditioning 40-388 40-583
pressure switch
K016 Air filter pressure 40-354 40-583
sensor
K017 Air conditioning 40-388 40-583
compressor
K018 Water in fuel sensor 40-179 40-606
40-552
K019 Engine coolant tem- 40-179 40-606
perature sensor
K023 Start enable seat 40-552 40-586
sensor

K032 SDD proximity sen- 40-235 40-645

sor
K035 2.7099.960.0 Trailer hydraulic Normally closed 40-354 40-606
braking pressure (NC) contact
sensor Switching pressure: 40-567
11 bar
Table 285
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-354 40-586
switch 15 Bar +- 1
Max. operating volt- 40-558
age: 24 V
Max. continuous
pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

K038 Transmission filter 40-354 40-606

sensor

40-147
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K040 Right hand lift draft 40-235 40-606
tie-rod sensor
K043 0.020.0800.0 Clogged Pal filter 40-354 40-606
sensor
K046 Evaporator sensor 40-388 40-612

40.2.48 - K - Sensors and transmitters (5110 C -> ZKDY520200TD10001, 5120 C -> ZK-
DY560200TD10001)
Table 286
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi- 40-235 40-641
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K002 0.011.9428.0 Trailer braking low Power 12V DC 40-567 40-644
pressure switch Resistance at 0 bar
10-13 Ohm
Resistance at 6 Bar
119-129 Ohm

K003 2.7099.999.0 Speed sensor 40-424 40-606

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-424 40-606

sor checked using an
ordinary tester; use
the ART.
K005 2.7099.740.0/10 Rear lift position Pin 1 = power (Nomi- 40-235 40-606
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K006 2.7099.996.0 PTO speed sensor This cannot be 40-448 40-606
checked using an
ordinary tester; use
the ART.

40-148
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K007 2.7099.034.0 Brake fluid sensor 40-558 40-606

Pin C: Output

Pin A: +
Pin B: -

K010 2.7099.035.0/10 Fuel level sensor 40-354 40-606

relay
coil

+ S

1 2 3

Pin 1: +

Pin 2: -
Pin 3: Signal

K012 Gearbox output 40-424 40-606

shaft speed sensor
K013 2.7099.690.0/10 Transmission oil Normally closed 40-424 40-606
temperature sensor (NC) contact
Switching pressure:
4 Bar
K015 Air conditioning 40-388 40-583
pressure switch
K016 Air filter pressure 40-354 40-583
sensor
K017 Air conditioning 40-388 40-583
compressor
K018 Water in fuel sensor 40-179 40-606
40-552
K019 Engine coolant tem- 40-179 40-606
perature sensor
K023 Start enable seat 40-552 40-586
sensor

K032 SDD proximity sen- 40-235 40-645

sor
K035 2.7099.960.0 Trailer hydraulic Normally closed 40-354 40-606
braking pressure (NC) contact
sensor Switching pressure: 40-567
11 bar

40-149
 Wiring diagrams
Table 287
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-354 40-586
switch 15 Bar +- 1
Max. operating volt- 40-558
age: 24 V
Max. continuous
pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

K038 Transmission filter 40-354 40-606

sensor
K040 Right hand lift draft 40-235 40-606
tie-rod sensor
K043 0.020.0800.0 Clogged Pal filter 40-354 40-606
sensor
K046 Evaporator sensor 40-388 40-612

40.2.49 - L - Electromagnets and solenoid valves (5090 C -> ZKDY360200TD10001, 5100

C -> ZKDY400200TD10001)
Table 288
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
L001 Front PTO control 40-437 40-640
solenoid valve
L002 Trailer parking brake 40-338 40-647
control solenoid 40-531
valve
L003 Rear PTO control 40-437 40-596
solenoid valve
L004 Rear hitch DOWN 40-214 40-596
control solenoid
valve
L005 Rear hitch ‘UP’ con- 40-214 40-596
trol solenoid valve
L007 Differential lock con- 40-399 40-596
trol solenoid valve
L008 Eco saving solenoid 40-545 40-596
valve 60 l/min
L009 ECO solenoid valve 40-545 40-596
L010 “High” range sole- 40-399
noid valve
L011 “Medium” range so- 40-399
lenoid valve

40-150
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
L012 “Low” range sole- 40-399
noid valve
L013 Reverse proportion- 40-399
al solenoid valve
L014 Forward drive sole- 40-399
noid valve
L019 SDD solenoid valve 40-214
L020 Four-wheel drive so- 40-399 40-596
lenoid valve
L021 Solenoid valve SV 1 40-399 40-648
L022 Solenoid valve SV 2 40-399 40-648
L023 COM SV solenoid 40-399 40-648
valve
L024 R solenoid valve 40-399
L025 HI/LO solenoid valve 40-437 40-596

40.2.50 - L - Electromagnets and solenoid valves (5110 C -> ZKDY440200TD10001)

Table 289
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
L001 Front PTO control 40-437 40-640
solenoid valve
L002 Trailer parking brake 40-338 40-647
control solenoid 40-531
valve
L003 Rear PTO control 40-437 40-596
solenoid valve
L004 Rear hitch DOWN 40-224 40-596
control solenoid
valve
L005 Rear hitch ‘UP’ con- 40-224 40-596
trol solenoid valve
L007 Differential lock con- 40-399 40-596
trol solenoid valve
L008 Eco saving solenoid 40-545 40-596
valve 60 l/min
L009 ECO solenoid valve 40-545 40-596
L010 “High” range sole- 40-399
noid valve
L011 “Medium” range so- 40-399
lenoid valve
L012 “Low” range sole- 40-399
noid valve
L013 Reverse proportion- 40-399
al solenoid valve
L014 Forward drive sole- 40-399
noid valve
L019 SDD solenoid valve 40-224 40-645
L020 Four-wheel drive so- 40-399 40-596
lenoid valve
L021 Solenoid valve SV 1 40-399 40-648
L022 Solenoid valve SV 2 40-399 40-648
L023 COM SV solenoid 40-399 40-648
valve
L024 R solenoid valve 40-399
L025 HI/LO solenoid valve 40-437 40-596

40-151
 Wiring diagrams
40.2.51 - L - Electromagnets and solenoid valves (5100 C -> ZKDY480200TD10001)
Table 290
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
L001 Front PTO control 40-448 40-640
solenoid valve
L002 Trailer parking brake 40-354 40-647
control solenoid 40-567
valve
L003 Rear PTO control 40-448 40-606
solenoid valve
L004 Rear lift DOWN con- 40-235 40-606
trol solenoid valve
L005 Rear lift ‘UP’ control 40-235 40-606
solenoid valve
L007 Differential lock con- 40-411 40-606
trol solenoid valve
L008 Eco saving solenoid 40-576 40-606
valve 60 l/min
L009 ECO solenoid valve 40-576 40-606
L010 “High” range sole- 40-411 40-606
noid valve
L011 “Medium” range so- 40-411 40-606
lenoid valve
L012 “Low” range sole- 40-411 40-606
noid valve
L013 Reverse proportion- 40-411 40-606
al solenoid valve
L014 Forward drive sole- 40-411 40-606
noid valve
L019 SDD solenoid valve 40-235 40-645
L020 Four-wheel drive so- 40-411 40-606
lenoid valve
L021 Solenoid valve SV 1 40-411 40-648
L022 Solenoid valve SV 2 40-411 40-648
L023 COM SV solenoid 40-411 40-648
valve
L024 R solenoid valve 40-411 40-606
L025 HI/LO solenoid valve 40-448 40-606

40.2.52 - L - Electromagnets and solenoid valves (5110 C -> ZKDY520200TD10001, 5120

C -> ZKDY560200TD10001)
Table 291
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
L001 Front PTO control 40-448 40-640
solenoid valve
L002 Trailer parking brake 40-354 40-647
control solenoid 40-567
valve
L003 Rear PTO control 40-448 40-606
solenoid valve
L004 Rear lift DOWN con- 40-235 40-606
trol solenoid valve
L005 Rear lift ‘UP’ control 40-235 40-606
solenoid valve
L007 Differential lock con- 40-424 40-606
trol solenoid valve

40-152
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
L008 Eco saving solenoid 40-576 40-606
valve 60 l/min
L009 ECO solenoid valve 40-576 40-606
L010 “High” range sole- 40-424
noid valve
L011 “Medium” range so- 40-424
lenoid valve
L012 “Low” range sole- 40-424
noid valve
L013 Reverse proportion- 40-424
al solenoid valve
L014 Forward drive sole- 40-424 40-644
noid valve
L019 SDD solenoid valve 40-235 40-645
L020 Four-wheel drive so- 40-424 40-606
lenoid valve
L021 Solenoid valve SV 1 40-424 40-648
L022 Solenoid valve SV 2 40-424 40-648
L023 COM SV solenoid 40-424 40-648
valve
L024 R solenoid valve 40-424 40-606
40-644
L025 HI/LO solenoid valve 40-448 40-606

40.2.53 - M - Electrical/electronic devices, Flasher units and Timers (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001)
Table 292
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M001 HLHP unit 40-208 40-586
40-214
40-246
40-338
40-399
40-437
40-488
40-521
40-540
40-545
M003 ECU control unit 40-167 40-596
40-192
40-208
40-338
40-488
40-510
M004 ECU control unit 40-167 40-596
40-192
M005 Control unit USA 40-246 40-586
40-338
M008 2.8519.148.0 ECU 11786 control 40-488 40-658
unit

FUSE
15 C8

10A MAX

31 B8

40-153
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M012 Air conditioning con- 40-377 40-612
trol unit

40.2.54 - M - Electrical/electronic devices, Flasher units and Timers (5110 C -> ZK-
DY440200TD10001)
Table 293
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M001 HLHP unit 40-208 40-586
40-224
40-246
40-338
40-399
40-437
40-488
40-521
40-540
40-545
M003 ECU control unit 40-167 40-596
40-192
40-208
40-338
40-488
40-510
M004 ECU control unit 40-167 40-596
40-192
M005 Control unit USA 40-246 40-586
40-338
M008 2.8519.148.0 ECU 11786 control 40-488 40-658
unit

FUSE
15 C8

10A MAX

31 B8

M012 Air conditioning con- 40-377 40-612

trol unit

40.2.55 - M - Electrical/electronic devices, Flasher units and Timers (5100 C -> ZK-
DY480200TD10001)
Table 294
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M001 HLHP unit 40-552 40-586
40-235
40-261
40-354
40-411
40-448
40-499
40-558
40-540
40-576

40-154
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M003 ECU control unit 40-179 40-606
40-200
40-552
40-354
40-499
40-515
M004 ECU control unit 40-179 40-606
40-200
M005 Control unit USA 40-261 40-586
40-354
M008 2.8519.148.0 ECU 11786 control 40-499 40-658
unit

FUSE
15 C8

10A MAX

31 B8

Fig. 2509
M012 Air conditioning con- 40-388 40-612
trol unit

40.2.56 - M - Electrical/electronic devices, Flasher units and Timers (5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Table 295
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M001 HLHP unit 40-552 40-586
40-235
40-261
40-354
40-424
40-448
40-499
40-558
40-540
40-576
M003 ECU control unit 40-179 40-606
40-200
40-552
40-354
40-499
40-515
M004 ECU control unit 40-179 40-606
40-200
M005 Control unit USA 40-261 40-586
40-354
M008 2.8519.148.0 ECU 11786 control 40-499 40-658
unit

FUSE
15 C8

10A MAX

31 B8

Fig. 2510

40-155
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
M012 Air conditioning con- 40-388 40-612
trol unit

40.2.57 - N - Electric motors and actuators (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001)
Table 296
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
N001 Windscreen wiper 40-326 40-611
motor
N002 Windscreen wiper 40-326 40-611
motor (fixed wind-
screen)
N004 Front windscreen 40-326 40-586
wiper water pump
N005 Rear windscreen 40-326 40-586
wiper water pump
N007 Air-conditioning fan 40-377 40-612
N013 Rear window wiper 40-326 40-612
motor
N014 Pump + power 40-167 40-650
N015 Pump - power 40-167 40-650
N019 Temperature control 40-377 40-612
valve

40.2.58 - O - Resistors and rheostats (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
Table 297
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
O003 Wiring connector for 40-510 40-596
resistor (120 Ohm)
O009 Resistance: 120 40-510 40-586
ohm

40.2.59 - O - Resistors and rheostats (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Table 298
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
O003 Wiring connector for 40-515 40-606
resistor (120 Ohm)
O009 Resistance: 120 40-515 40-586
ohm

40.2.60 - P - Various services (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-

DY400200TD10001, 5110 C -> ZKDY440200TD10001)
Table 299
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
P006 Cigarette lighter 40-459 40-586
P007 25 A socket 40-459 40-586
P010 Socket in cab +12 V 40-459 40-586

40-156
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
P011 0.013.2161.0 Lh loudspeaker 40-369 40-612

P013 0.012.1725.0 RH loudspeaker 40-369 40-612

P014 Outlet power and 40-488 40-658

signals ISO 11786
P015 Radio 40-369 40-612
P028 Services connector 40-338 40-596
P029 Seat socket 40-459 40-586

40.2.61 - P - Various services (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-

DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Table 300
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
P006 Cigarette lighter 40-474 40-586
P007 25 A socket 40-474 40-586
P010 Socket in cab +12 V 40-474 40-586
P011 0.013.2161.0 Lh loudspeaker 40-369 40-612

P013 0.012.1725.0 RH loudspeaker 40-369 40-612

P014 Outlet power and 40-499 40-658

signals ISO 11786
P015 Radio 40-369 40-612
P028 Services connector 40-354 40-606
P029 Seat socket 40-474 40-586

40-157
 Wiring diagrams
40.2.62 - R - Diagnostics (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001)
Table 301
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
R001 CAN Diagnostics 40-488 40-586
socket 40-510
R002 Diagnostics socket 40-338 40-586
in cab 40-540
R005 Diagnostics socket 40-488 40-596

40.2.63 - R - Diagnostics (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,

5120 C -> ZKDY560200TD10001)
Table 302
System code P/N Description CHARACTERISTICS/ Link to system Link to wiring
NOTES
R001 CAN Diagnostics 40-499 40-586
socket 40-515
R002 Diagnostics socket 40-354 40-586
in cab 40-540
R005 Diagnostics socket 40-499 40-606

40.2.64 - 04217755 - Engine control unit

5 6 73 82 94

7 16 28
1 2

Fig. 2511

Connector M003 pins

Table 303
Pin Voltage Description
1 +12V Engine ECU
2 0V GND
3 +12V Engine ECU
4 0V GND
5 +12V Engine ECU
6 0V GND
13 Coolant level, Signal
18 Memory 1 button
26 Electric pump relay
27 Engine oil pressure warning lamp
28 Starter relay
29 Coolant level, Power
31 Start enable
35 +12V Power
44 +5V EGR, Power
46 +5V Accelerator pedal and hand throttle, Power
53 CAN L, Engine

40-158
Wiring diagrams
Pin Voltage Description
54 CAN L, Vehicle
57 Water/Fuel Sensor
61 Low fuel pressure
62 Accelerator pedal, Ground
63 Accelerator pedal, Signal
64 Water/Fuel Sensor
68 Memory button, Common GND
70 Preheat indicator lamp (1-19)
73 Starter relay
75 CAN H, Engine
76 CAN H, Vehicle
82 EGR
85 EGR, Signal
87 Coolant level, GND
88 +12V Engine ECU
90 Electric pump relay
Connector M004 pins

15 1

30 16

45 31

60 46

Fig. 2512

Table 304
Pin Voltage Description
2 Cylinder #3
3 Cylinder #2
4 Dosing unit solenoid valve
5 Dosing unit solenoid valve
7 Rail sensor
10 Hand throttle, Signal
16 Cylinder #1
18 Cylinder #4
19 EGR, Power
20 EGR, GND
23 Heater
24 +5V Turbo sensor power feed
25 Rail sensor
26 Rail sensor
27 Turbo temperature, Signal
28 Engine coolant temperature
29 Low fuel pressure
32 Cylinder #3
33 Cylinder #1
35 Heater relay
37 Camshaft sensor, GND
38 Crankshaft sensor, Shielding
39 Crankshaft sensor, GND
40 Turbo temperature and pressure sensor, GND
43 Turbo pressure, Signal

40-159
 Wiring diagrams
Pin Voltage Description
44 Engine oil pressure
45 Heater relay
46 Cylinder #2
48 Cylinder #4
52 Camshaft sensor, Signal
53 Camshaft sensor, Shielding
54 Crankshaft sensor, Signal

40.2.65 - 2.8519.171.0/20 - HLHP2 ECU (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)

Fig. 2513

Connector M001 pins

Version with mechanical shuttle
Table 305
Pin Voltage Description
1 12V (Battery)
2 0V Ground (-VDC)
3 12V (Battery)
4 Ground (-VDC)
5 12V (Battery)
6 Ground (-VDC)
7 Hitch Up solenoid valve
8 +15 HLHP

40-160
Wiring diagrams
Pin Voltage Description
9 Common GND
10 Gearbox oil temperature
15 Hitch DOWN button
16 Utility pressure switch
18 PTO sensor
19 Wheel sensor
21 ISO 9141 K
22 SBA sensor signal
23 Hitch position sensor
26 SDD proximity sensor
29 Hitch DOWN SV
31 Common GND
34 Draft sensor
35 Front PTO button 1
36 Front PTO button 2
37 Rear PTO button 1
38 Rear PTO button 2
39 Seat:
40 Left hand brake switch
41 External DOWN button
42 External UP button
43 Hitch STOP button
44 SDD button
47 Hitch UP button
49 CAN L, Vehicle
50 CAN H, Vehicle
51 Hitch UP SV
53 Common GND
56 LED bar signal
58 Park Brake pressure switch
59 60 ECO button
65 PTO Auto button
67 HML/Hi-Lo increment button
68 HML/Hi-Lo decrease button
69 Clutch switch
70 5V HLHP draft sensors
71 5V Cab
72 5V Trailer
73 Hitch DOWN SV
75 SDD SV
76 Front PTO SV
78 Rear PTO SV
79 Eco SV
81 PTO brake SV
85 60 ECO SV
87 LED bar output
88 60 ECO button LED
89 External PTO controls
93 DT SV (dual traction)
94 DF SV (differential)

40-161
 Wiring diagrams
40.2.66 - 2.8519.171.0/20 - HLHP2 ECU (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)

Fig. 2514

Connector M001 pins

Version with hydraulic reverse shuttle
Table 306
Pin Voltage Description
1 12V (Battery)
2 0V Ground (-VDC)
3 12V (Battery)
4 Ground (-VDC)
5 12V (Battery)
6 Ground (-VDC)
7 Hitch Up solenoid valve
8 +15 HLHP
9 Common GND
10 Gearbox oil temperature
11 Comfort Clutch
12 Shuttle speed sensor
15 Hitch DOWN button
16 Utility pressure switch
17 Prop. SV pressure switch
18 PTO sensor

40-162
Wiring diagrams
Pin Voltage Description
19 Wheel sensor
21 ISO 9141 K
22 SBA sensor signal
23 Hitch position sensor
24 Clutch pedal potentiometer, Signal
25 Right hand brake pressure transducer
26 SDD proximity sensor
29 Hitch DOWN SV
31 Common GND
33 Smart Wheel
34 Draft sensor
35 Front PTO button 1
36 Front PTO button 2
37 Rear PTO button 1
38 Rear PTO button 2
39 Seat:
40 Left hand brake switch
41 External DOWN button
42 External UP button
43 Hitch STOP button
44 SDD button
46 HML sensor signal
47 Hitch UP button
49 CAN L, Vehicle
50 CAN H, Vehicle
51 Hitch UP SV
52 Reverse shuttle Prop. SV
53 Common GND
56 LED bar signal
58 Park Brake pressure switch
59 60 ECO button
62 FORWARD direction lever
63 Lever in NEUTRAL
64 Lever in REVERSE
65 PTO Auto button
66 Stop&Go button
67 HML/Hi-Lo increment button
68 HML/Hi-Lo decrease button
69 Clutch switch
70 5V HLHP draft sensors
71 5V Cab
72 5V Trailer
73 Hitch DOWN SV
74 Reverse SV
75 SDD SV
76 Front PTO SV
77 Delivery proportional SV
78 Rear PTO SV
79 Eco SV
80 Forward SV
81 PTO brake SV
82 High + SV
83 Medium + SV
84 Low + SV
85 60 ECO SV
87 LED bar output
88 60 ECO button LED
89 External PTO controls
90 Slow - SV
91 Medium - SV
92 High - SV
93 DT SV (dual traction)
94 DF SV (differential)

40-163
 Wiring diagrams
40.2.67 - 2.8339.285.0/30 - Digital instrument cluster (MTA 2.0)

Fig. 2515

Connector E008 3K pins

Table 307
Pin Voltage Description
1
2
3
4 Fuel reserve warning lamp
5 Air filter clogged warning lamp
6 Engine oil pressure warning lamp
7 Brake oil level warning light
8 0V GND
9 PTO Eco indicator lamp
10 PTO 1000 indicator lamp
11 PTO 540 indicator lamp
12 Trailer pressure indicator lamp
13
14 + 12V +15 power
15 + 12V +30 power
16 Differential Lock indicator lamp
17
18 Transmission filter clogged warning lamp
19 General utility pressure indicator lamp

40-164
Wiring diagrams
Pin Voltage Description
20 D+ Alternator
21 + 12V +30 power
22 Handbrake indicator lamp
23
24 Ground speed PTO indicator lamp
25 Dual Traction indicator lamp
26 Park brake signal
Connector E007 5K pins
Table 308
Pin Voltage Description
1 ISO
2 CAN H, Vehicle
3 CAN L, Vehicle
4 CAN, Resistance
5
6
7
8 Running lights
9 Full beams
10 Turn signals
11 Trailer turn signals 1
12 Trailer turn signals 2
13 0V GND
14
15 Pre-heat indicator lamp
16
17
18
19
20
21 Fuel level
22
23
24
25
26

40-165
 Wiring diagrams
40.2.68 - 2.8519.148.0 - ISO 11786 ECU

Fig. 2516

Connector M008 pins

Table 309
Pin Voltage Description
B2 CAN L
B3 Hitch ON/OFF
B4 PTO signal
B5 Wheel signal
B6 Radar signal
B7 Hitch position signal
B8 + 12V +12 Volts
C2 +15 HLHP
C8 0V GND

40-166
Wiring diagrams
40.3 - Systems
40.3.1 - S001 - Electronic engine throttle (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
E008 E007

E
I005 Jc001 Jf001 H003 Jf004 K019

OI L ENGINE PRESSUR
V t

PRE-HE ATIN G
30
50 15
C006 C004

+15

-31

-31
50 15 30 87 85 86 30 87 86 85 30 2 1 4 14 6 8 15 13 30 85 86 87 3 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 Bb019 Bd004 Ba004 B003

7,5A

7,5A

20A
15A

3A

3A

15A

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1
D025A
D015 D066
D043 12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

B001
150A

0.020.0726.4
1 2 3 4 4 1 2

V
N014 N015
I068 H020
P
0.020.7971.4
C0 11
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2517
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom

40-167
 Wiring diagrams
E008 E007

E
I005 Jc001 Jf001 H003 Jf004 K019

OI L ENGINE PRESSUR
V t

PRE-HE ATIN G
30
50 15
C006 C004

+15

-31

-31
50 15 30 87 85 86 30 87 86 85 30 2 1 4 14 6 8 15 13 30 85 86 87 3 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 7,5A Bb019 Bd004 Ba004 B003

7,5A

20A
15A

3A

3A

15A

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1
D025A
D015 D066
D043 12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

B001
150A

0.020.0726.4
1 2 3 4 4 1 2

V
N014 N015
I068 H020
P
0.020.7971.4
C0 11
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2517
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power
l N015 - Pump - power

40-168
Wiring diagrams
M003 M004

ATION SI G

T SPEE D

T SPEE D

T SPEE D

T SPEE D
ATION 5 V

ATION +

ATION -
ATUR E
ATIO N
S
L SENSO R

E
L GAS/HAND GA
PEDAL/HAND GAS GROUND
I001 K018

COOLAN T LEVE L SW +
E

E
COOLAN T LEVE L SW -

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

L PR.LAM P

BOOS T PRESS/TEMPER

CABLE SH.2 CRANKSHAF

CABLE SH.2 CRANKSHAF

CABLE SH.1 CRANKSHAF

CABLE SH.1 CRANKSHAF

COOLAN T LEVE L S W

L PRESSUR
CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

P

L
FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE
T

PRE-HE ATING LAM

PEDA L GAS SIGNA

HOLD SWITCH COM

COOLAN T TEM P
SPOUM P REL AY

SPOUM P REL AY

HAND GAS SIGNAL

S TA RT CONSEN

+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT REL AY

S TA RT REL AY
HOLD SWITCH 1
W ATER IN FUE

ENGINE OI

ENGINE OI
+5V PEDA
t

MPROP

MPROP
C002

CYL.3

CYL.3

CYL.2

CYL.2

CYL.1

CYL.1

CYL.4

CYL.4
+50
-31

-31

-31
1 2 2 1 64 57 2 4 6 26 90 31 29 87 13 1 3 5 70 27 63 88 35 18 68 62 46 28 73 44 82 85 61 10 24 29 19 20 2 32 3 46 4 5 7 25 26 16 33 18 48 28 37 52 40 27 43 44 39 54

B002

30A

0.020.2857.4/10
0.020.3229.4/30
D044 2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

5 4 3 2 1 1 2 3 4 2 1 2 1 2 1 3 1 2 2 1 2 1 2 1 2 1 1 2 3 4 1 4 3 2 2 1

F F
P P t P P
F F

Fig. 2519
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom

40-169
 Wiring diagrams
M003 M004

ATION SI G

T SPEE D

T SPEE D

T SPEE D

T SPEE D
ATION 5 V

ATION +

ATION -
ATUR E
ATIO N
S
L SENSO R

E
L GAS/HAND GA
PEDAL/HAND GAS GROUND
I001 K018

COOLAN T LEVE L SW +
E

E
COOLAN T LEVE L SW -

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

L PR.LAM P

BOOS T PRESS/TEMPER

CABLE SH.2 CRANKSHAF

CABLE SH.2 CRANKSHAF

CABLE SH.1 CRANKSHAF

CABLE SH.1 CRANKSHAF

COOLAN T LEVE L S W

L PRESSUR
CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

P

L
FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE
T

PRE-HE ATING LAM

PEDA L GAS SIGNA

HOLD SWITCH COM

COOLAN T TEM P
SPOUM P REL AY

SPOUM P REL AY

HAND GAS SIGNAL

S TA RT CONSEN

+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT REL AY

S TA RT REL AY
HOLD SWITCH 1
W ATER IN FUE

ENGINE OI

ENGINE OI
+5V PEDA
t

MPROP

MPROP
C002

CYL.3

CYL.3

CYL.2

CYL.2

CYL.1

CYL.1

CYL.4

CYL.4
+50
-31

-31

-31
1 2 2 1 64 57 2 4 6 26 90 31 29 87 13 1 3 5 70 27 63 88 35 18 68 62 46 28 73 44 82 85 61 10 24 29 19 20 2 32 3 46 4 5 7 25 26 16 33 18 48 28 37 52 40 27 43 44 39 54

B002

30A

0.020.2857.4/10
0.020.3229.4/30
D044 2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

5 4 3 2 1 1 2 3 4 2 1 2 1 2 1 3 1 2 2 1 2 1 2 1 2 1 1 2 3 4 1 4 3 2 2 1

F F
P P t P P
F F

Fig. 2519
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power
l N015 - Pump - power

40-170
Wiring diagrams

Fig. 2521
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom

40-171
 Wiring diagrams

Fig. 2521
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power
l N015 - Pump - power

40-172
Wiring diagrams

Fig. 2523
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom

40-173
 Wiring diagrams

Fig. 2523
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power

40-174
Wiring diagrams

Fig. 2523
l N015 - Pump - power
Table 310
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

Fig. 2526
A006 +30 Battery 40-654

A006

Fig. 2527
B001 Power fuse (150A) 40-586
40-654
B002 Outlet power fuse 40-596
ISO 11783 (60A)

40-175
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
B003 Outlet power fuse 40-596
ISO 11783 (25A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bb004 Russia Kit/25A fuse 40-586
+15 (7.5A)
C002 Grounding point 40-596

C002

Fig. 2528
C004 Grounding point C004
40-586

Fig. 2529
C006 Grounding point 40-586

C006

Fig. 2530
C011 Battery earth C011
40-652

Fig. 2531
D015 Wiring connector to 40-586
cab wiring loom
D015

Fig. 2532
D015 Wiring connector for 40-620
console wiring loom
D015

Fig. 2533

40-176
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector to 40-586
cab wiring loom

D025

Fig. 2534
D025 Wiring connector for 40-596
rear wiring loom D025

Fig. 2535
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D044 Wiring connector for 40-596
engine wiring loom
D066 Wiring connector for 40-596
rear wiring loom D066

Fig. 2536
D066 Wiring connector for 40-650
electric pump wiring D066

loom

E007 2.8339.278.0/10 Instrument panel E007

40-586

Fig. 2537
E008 Instrument panel E008
40-586

H003 Throttle pedal 40-586

H003

H020 2.7099.740.0/10 Mechanical hand 40-620

throttle

40-177
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-596

I001

3,9 Ohm
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I068 2.7659.410.0 Engine memory but- 40-620

ton 1
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
Jf004 Electric pump relay 40-596
K018 Water in fuel sensor 40-596
K019 Engine coolant tem- 40-596
perature sensor
M003 ECU control unit 40-596
M004 ECU control unit 40-596
N014 Pump + power N014
40-650

40-178
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
N015 Pump - power N015
40-650

40.3.2 - S001 - Electronic engine throttle (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
E008 E007

E
I005 Jc001 Jf001 H003 Jf004 K019

OI L ENGINE PRESSUR
V t

PRE-HE ATIN G
30
50 15
C006 +15
C004
-31

-31
50 15 30 87 85 86 30 87 86 85 30 2 1 4 14 6 8 15 13 30 85 86 87 3 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 Bb019 Bd004 Ba004 B003

7,5A

7,5A

20A
15A

3A

3A

15A

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1
D025A

D015 D066
D043 12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

B001
150A

0.020.0726.4

1 2 3 4 4 1 2

V
N014 N015
I068 H020
P
0.020.7971.4
C0 11
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2538
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear lift fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point

40-179
 Wiring diagrams
E008 E007

E
I005 Jc001 Jf001 H003 Jf004 K019

OI L ENGINE PRESSUR
V t

PRE-HE ATIN G
30
50 15
C006 C004

+15

-31

-31
50 15 30 87 85 86 30 87 86 85 30 2 1 4 14 6 8 15 13 30 85 86 87 3 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 7,5A Bb019 Bd004 Ba004 B003

7,5A

20A
15A

3A

3A

15A

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1
D025A
D015 D066
D043 12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

B001
150A

0.020.0726.4
1 2 3 4 4 1 2

V
N014 N015
I068 H020
P
0.020.7971.4
C0 11
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2538
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay

40-180
Wiring diagrams
E008 E007

E
I005 Jc001 Jf001 H003 Jf004 K019

OI L ENGINE PRESSUR
V t

PRE-HE ATIN G
30
50 15
C006 C004

+15

-31

-31
50 15 30 87 85 86 30 87 86 85 30 2 1 4 14 6 8 15 13 30 85 86 87 3 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 7,5A Bb019 Bd004 Ba004 B003

7,5A

20A
15A

3A

3A

15A

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1

A7 B4 B5 B7 B1 B2 A6 B6 B8 C1
D025A
D015 D066
D043 12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

12-1 14-13 14-10 14- 11 14-9 14-7 14-8 1 2

B001
150A

0.020.0726.4
1 2 3 4 4 1 2

V
N014 N015
I068 H020
P
0.020.7971.4
C0 11
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2538
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power
l N015 - Pump - power

40-181
 Wiring diagrams
M003 M004

ATION SI G

T SPEE D

T SPEE D

T SPEE D

T SPEE D
ATION 5 V

ATION +

ATION -
ATUR E
ATIO N
S
L SENSO R

E
L GAS/HAND GA
PEDAL/HAND GAS GROUND
I001 K018

COOLAN T LEVE L SW +
E

E
COOLAN T LEVE L SW -

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

L PR.LAM P

BOOS T PRESS/TEMPER

CABLE SH.2 CRANKSHAF

CABLE SH.2 CRANKSHAF

CABLE SH.1 CRANKSHAF

CABLE SH.1 CRANKSHAF

COOLAN T LEVE L S W

L PRESSUR
CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

P

L
FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE
T

PRE-HE ATING LAM

PEDA L GAS SIGNA

HOLD SWITCH COM

COOLAN T TEM P
SPOUM P REL AY

SPOUM P REL AY

HAND GAS SIGNAL

S TA RT CONSEN

+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT REL AY

S TA RT REL AY
HOLD SWITCH 1
W ATER IN FUE

ENGINE OI

ENGINE OI
+5V PEDA
t

MPROP

MPROP
C002

CYL.3

CYL.3

CYL.2

CYL.2

CYL.1

CYL.1

CYL.4

CYL.4
+50
-31

-31

-31
1 2 2 1 64 57 2 4 6 26 90 31 29 87 13 1 3 5 70 27 63 88 35 18 68 62 46 28 73 44 82 85 61 10 24 29 19 20 2 32 3 46 4 5 7 25 26 16 33 18 48 28 37 52 40 27 43 44 39 54

B002

30A

0.020.2857.4/10
0.020.3229.4/30
D044 2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

5 4 3 2 1 1 2 3 4 2 1 2 1 2 1 3 1 2 2 1 2 1 2 1 2 1 1 2 3 4 1 4 3 2 2 1

F F
P P t P P
F F

Fig. 2541
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear lift fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom

40-182
Wiring diagrams
M003 M004

ATION SI G

T SPEE D

T SPEE D

T SPEE D

T SPEE D
ATION 5 V

ATION +

ATION -
ATUR E
ATIO N
S
L SENSO R

E
L GAS/HAND GA
PEDAL/HAND GAS GROUND
I001 K018

COOLAN T LEVE L SW +
E

E
COOLAN T LEVE L SW -

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

EXAUS T GAS RECIRCUL

L PR.LAM P

BOOS T PRESS/TEMPER

CABLE SH.2 CRANKSHAF

CABLE SH.2 CRANKSHAF

CABLE SH.1 CRANKSHAF

CABLE SH.1 CRANKSHAF

COOLAN T LEVE L S W

L PRESSUR
CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

CHARGE AIR PRESSURE

P

L
FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUE L LOW PRESSUR

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE

FUEL/RAI PRESSURE
T

PRE-HE ATING LAM

PEDA L GAS SIGNA

HOLD SWITCH COM

COOLAN T TEM P
SPOUM P REL AY

SPOUM P REL AY

HAND GAS SIGNAL

S TA RT CONSEN

+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT REL AY

S TA RT REL AY
HOLD SWITCH 1
W ATER IN FUE

ENGINE OI

ENGINE OI
+5V PEDA
t

MPROP

MPROP
C002

CYL.3

CYL.3

CYL.2

CYL.2

CYL.1

CYL.1

CYL.4

CYL.4
+50
-31

-31

-31
1 2 2 1 64 57 2 4 6 26 90 31 29 87 13 1 3 5 70 27 63 88 35 18 68 62 46 28 73 44 82 85 61 10 24 29 19 20 2 32 3 46 4 5 7 25 26 16 33 18 48 28 37 52 40 27 43 44 39 54

B002

30A

0.020.2857.4/10
0.020.3229.4/30
D044 2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

2 3 50 51 46 17 22 27 47 48 61 38 41 40 19 20 32 31 25 35 62 37 42 24 14 13 28 29 23 26 15 21

5 4 3 2 1 1 2 3 4 2 1 2 1 2 1 3 1 2 2 1 2 1 2 1 2 1 1 2 3 4 1 4 3 2 2 1

F F
P P t P P
F F

Fig. 2541
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power
l N015 - Pump - power

40-183
 Wiring diagrams

Fig. 2543
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear lift fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom

40-184
Wiring diagrams

Fig. 2543
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power
l N015 - Pump - power

40-185
 Wiring diagrams

Fig. 2545
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l B003 – FBAT 2 fuse (20 A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb010 - Rear lift fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom

40-186
Wiring diagrams

Fig. 2545
l D044 - Wiring connector for rear wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H003 - Accelerator pedal
l H020 - Mechanical hand throttle
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I068 - Engine memory button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf004 - Electric pump relay
l K018 - Water in fuel sensor
l K019 - Engine coolant temperature sensor
l M003 - ECU control unit
l M004 - ECU control unit
l N014 - Pump + power

40-187
 Wiring diagrams

Fig. 2545
l N015 - Pump - power
Table 311
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

Fig. 2548
A006 +30 Battery 40-654

A006

Fig. 2549
B001 Power fuse (150A) 40-586
40-654
B002 Outlet power fuse 40-606
ISO 11783 (60A)

40-188
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
B003 Outlet power fuse 40-606
ISO 11783 (25A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bb004 Russia Kit/25A fuse 40-586
+15 (7.5A)
C002 Grounding point 40-606

C002

Fig. 2550
C004 Grounding point C004
40-586

Fig. 2551
C006 Grounding point 40-586

C006

Fig. 2552
C011 Battery earth C011
40-652

Fig. 2553
D015 Wiring connector to 40-586
cab wiring loom
D015

Fig. 2554
D015 Wiring connector for 40-620
console wiring loom
D015

Fig. 2555

40-189
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector to 40-586
cab wiring loom

D025

Fig. 2556
D025 Wiring connector for 40-606
rear wiring loom D025

Fig. 2557
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D044 Wiring connector for 40-606
engine wiring loom
D066 Wiring connector for 40-606
rear wiring loom D066

Fig. 2558
D066 Wiring connector for 40-650
electric pump wiring D066

loom

E007 2.8339.278.0/10 Instrument panel E007

40-586

Fig. 2559
E008 Instrument panel E008
40-586

H003 Throttle pedal 40-586

H003

H020 2.7099.740.0/10 Mechanical hand 40-620

throttle

40-190
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-606

I001

3,9 Ohm
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I068 2.7659.410.0 Engine memory but- 40-620

ton 1
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
Jf004 Electric pump relay 40-606
K018 Water in fuel sensor 40-606
K019 Engine coolant tem- 40-606
perature sensor
M003 ECU control unit 40-606
M004 ECU control unit 40-606
N014 Pump + power N014
40-650

40-191
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
N015 Pump - power N015
40-650

40.3.3 - S002 - Preheating (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,

5110 C -> ZKDY440200TD10001)

0.020.2857.4/10

E008 E007 M003 M004

AY

AY
PRE-HE ATING LAM
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

I005 Jf001 Jc001

HE ATING FLANGE REL

HE ATING FLANGE REL

E
ATO R

HE ATING FLANG
30

PRE-HE ATIN G

-31

-31

-31
D+ GENER
50 15
1 3 5 2 4 6 70 88
C006 C004
+15

-31

-31
+58
50 15 30 87 86 85 30 87 85 86 30 14 8 20 8 13 15 23 45 35

B002

30A
C002

D025A C1 A6 A6 D025B
C1 A6 A6

Bd002 Bd006 Ba004 Bb001 Bb008 Bb006

7,5A

7,5A
15A
15A

3A
3A
0.020.6707.4/20

D044 D024
D043 8 7 6
A6

A6
8 7 6

B001

0.019.3018.4/30
150A

D042
150A

A005 2 4 3 1 A001
C0 11
0.021.1202.4

0.020.6714.4

A006
A002 A003 I031a I031b

D+
B ATTE RY B+
G
3 B-

Fig. 2560
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l B004 - Preheat relay power fuse
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)

40-192
Wiring diagrams
0.020.2857.4/10

E008 E007 M003 M004

AY

AY
PRE-HE ATING LAM
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

I005 Jf001 Jc001

HE ATING FLANGE REL

HE ATING FLANGE REL

E
ATO R

HE ATING FLANG
30

PRE-HE ATIN G

-31

-31

-31
D+ GENER
50 15
1 3 5 2 4 6 70 88
C006 C004

+15

-31

-31
+58
50 15 30 87 86 85 30 87 85 86 30 14 8 20 8 13 15 23 45 35

B002

30A
C002

D025A C1 A6 A6 D025B
C1 A6 A6

Bd002 Bd006 Ba004 Bb001 Bb008 Bb006

7,5A

7,5A
15A
15A

3A
3A
0.020.6707.4/20

D044 D024
D043 8 7 6
A6

A6
8 7 6

B001

0.019.3018.4/30
150A

D042

150A
A005 2 4 3 1 A001
C0 11
0.021.1202.4

0.020.6714.4

A006
A002 A003 I031a I031b

D+
B ATTE RY B+
G
3 B-

Fig. 2560
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l M003 - ECU control unit
l M004 - ECU control unit

40-193
 Wiring diagrams

Fig. 2562
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l B004 - Preheat relay power fuse
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch

40-194
Wiring diagrams

Fig. 2562
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l M003 - ECU control unit
l M004 - ECU control unit

40-195
 Wiring diagrams

Fig. 2564
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l B004 - Preheat relay power fuse
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button

40-196
Wiring diagrams

Fig. 2564
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l M003 - ECU control unit
l M004 - ECU control unit
Table 312
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A001 Alternator “D+” 40-583
A002 +30 Battery 40-654

A002

A003 Battery negative 40-652

A003

A005 Alternator “B+” A005

-

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

B002 Outlet power fuse 40-596
ISO 11783 (60A)

40-197
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
B004 Pre-heat power fuse -
(150 A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C004 Grounding point C004
40-586

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D024 Wiring connector for 40-583

front wiring loom D024

D024 Wiring connector for 40-596

rear wiring loom D024

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D042 Wiring connector 40-654

D042 Wiring connector 40-654
D043 Wiring connector for 40-654
battery wiring loom

40-198
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D043 Wiring connector to 40-586
cab wiring loom
D044 Wiring connector for 40-596
engine wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
M003 ECU control unit 40-596
M004 ECU control unit 40-596

40-199
 Wiring diagrams
40.3.4 - S002 - Preheating (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)

0.020.2857.4/10

E008 E007 M003 M004

AY

AY
PRE-HE ATING LAM
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

I005 Jf001 Jc001

HE ATING FLANGE REL

HE ATING FLANGE REL

E
ATO R

HE ATING FLANG
30

PRE-HE ATIN G

-31

-31

-31
D+ GENER
50 15
1 3 5 2 4 6 70 88
C006 C004

+15

-31

-31
+58
50 15 30 87 86 85 30 87 85 86 30 14 8 20 8 13 15 23 45 35

B002

30A
C002

D025A C1 A6 A6 D025B
C1 A6 A6

Bd002 Bd006 Ba004 Bb001 Bb008 Bb006

7,5A

7,5A
15A
15A

3A
3A
0.020.6707.4/20

D044 D024
D043 8 7 6
A6

A6
8 7 6

B001

0.019.3018.4/30
150A

D042

150A
A005 2 4 3 1 A001
C0 11
0.021.1202.4

0.020.6714.4

A006
A002 A003 I031a I031b

D+
B ATTE RY B+
G
3 B-

Fig. 2566
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l B004 - Preheat relay power fuse
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D042 - Wiring connector

40-200
Wiring diagrams
0.020.2857.4/10

E008 E007 M003 M004

AY

AY
PRE-HE ATING LAM
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

I005 Jf001 Jc001

HE ATING FLANGE REL

HE ATING FLANGE REL

E
ATO R

HE ATING FLANG
30

PRE-HE ATIN G

-31

-31

-31
D+ GENER
50 15
1 3 5 2 4 6 70 88
C006 C004

+15

-31

-31
+58
50 15 30 87 86 85 30 87 85 86 30 14 8 20 8 13 15 23 45 35

B002

30A
C002

D025A C1 A6 A6 D025B
C1 A6 A6

Bd002 Bd006 Ba004 Bb001 Bb008 Bb006

7,5A

7,5A
15A
15A

3A
3A
0.020.6707.4/20

D044 D024
D043 8 7 6
A6

A6
8 7 6

B001

0.019.3018.4/30
150A

D042

150A
A005 2 4 3 1 A001
C0 11
0.021.1202.4

0.020.6714.4

A006
A002 A003 I031a I031b

D+
B ATTE RY B+
G
3 B-

Fig. 2566
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l M003 - ECU control unit
l M004 - ECU control unit

40-201
 Wiring diagrams

Fig. 2568
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l B004 - Preheat relay power fuse
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch

40-202
Wiring diagrams

Fig. 2568
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l M003 - ECU control unit
l M004 - ECU control unit

40-203
 Wiring diagrams

Fig. 2570
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l B004 - Preheat relay power fuse
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button

40-204
Wiring diagrams

Fig. 2570
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l M003 - ECU control unit
l M004 - ECU control unit
Table 313
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A001 Alternator “D+” 40-583
A002 +30 Battery 40-654

A002

A003 Battery negative 40-652

A003

A005 Alternator “B+” A005

-

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

B002 Outlet power fuse 40-606
ISO 11783 (60A)

40-205
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
B004 Pre-heat power fuse -
(150 A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C004 Grounding point C004
40-586

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D024 Wiring connector for 40-583

front wiring loom D024

D024 Wiring connector for 40-606

rear wiring loom D024

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D042 Wiring connector 40-654

D042 Wiring connector 40-654
D043 Wiring connector for 40-654
battery wiring loom

40-206
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D043 Wiring connector to 40-586
cab wiring loom
D044 Wiring connector for 40-606
engine wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
M003 ECU control unit 40-606
M004 ECU control unit 40-606

40-207
 Wiring diagrams
40.3.5 - S003 - Starter (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001)
M001
I005 Jc001 K023
30

+5 V HLHP

GND COM

GND COM

GND COM
15 50
C006 C005

SE AT

+30

+30

+30

-31

-31

-31
30 15 50 87 85 86 30 3 1 2 39 71 9 53 31 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bc004

20A
15A

3A

D025A
D043 B2 A6

B2 A6

B001
150A

C002 B002 Bb006

7,5A
30A

0.020.2857.4/10
C0 11

D044 2 3

2 1 31 2 4 6 1 3 5 35 88 73 28 64 57 2 1
0.020.6714.4

-31

-31

-31

+50

E
T

S TA RT REL AY

S TA RT REL AY
0.021.1202.4

L SENSO R

2 3
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT CONSEN

FUE L LOW PRESSUR

t
W ATER IN FUE

I001 K018

A006 A003 I031a I031b M003

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2572
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l Bb006 - Engine fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button

40-208
Wiring diagrams
M001
I005 Jc001 K023
30

+5 V HLHP

GND COM

GND COM

GND COM
15 50
C006 C005

SE AT

+30

+30

+30

-31

-31

-31
30 15 50 87 85 86 30 3 1 2 39 71 9 53 31 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bc004

20A
15A

3A

D025A
D043 B2 A6

B2 A6

B001
150A

C002 B002 Bb006

7,5A
30A

0.020.2857.4/10
C0 11

D044 2 3

2 1 31 2 4 6 1 3 5 35 88 73 28 64 57 2 1
0.020.6714.4

-31

-31

-31

+50

E
T

S TA RT REL AY

S TA RT REL AY
0.021.1202.4

L SENSO R

2 3
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT CONSEN

FUE L LOW PRESSUR

t
W ATER IN FUE

I001 K018

A006 A003 I031a I031b M003

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2572
l Jc001 - Start relay (70A - 12V)
l K018 - Water in fuel sensor
l K023 - Start enable seat sensor
l M001 - HLHP control unit
l M003 - HLHP control unit

40-209
 Wiring diagrams

Fig. 2574
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l Bb006 - Engine fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K018 - Water in fuel sensor
l K023 - Start enable seat sensor
l M001 - HLHP control unit
l M003 - HLHP control unit

40-210
Wiring diagrams

Fig. 2575
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l Bb006 - Engine fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K018 - Water in fuel sensor
l K023 - Start enable seat sensor
l M001 - HLHP control unit
l M003 - HLHP control unit

40-211
 Wiring diagrams
Table 314
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

B002 Outlet power fuse 40-596
ISO 11783 (60A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
C002 Grounding point 40-596

C002

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D044 Wiring connector for 40-596
engine wiring loom

40-212
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-596

I001

3,9 Ohm
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
K018 Water in fuel sensor 40-596
K023 Start enable seat 40-586
sensor

K023

M001 HLHP unit 40-586

M001

M003 ECU control unit 40-596

40-213
 Wiring diagrams
40.3.6 - S004 - Hitch (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001)
M001
I073

+5V HLH P DRAF T SENSO R

RIGH T DRAF T SENSO R
I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
30

EV LIF T DOWN

EV U P LIF T +
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C005

EV DW

EV UP

SDD
+30

+30

+30

-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 72 23 47 43 15 2 4 6 9 31 53 42 41 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 A5 A3 B3 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 A5 A3 B3 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30
C0 11
B001
150A

1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V V
kg
L004 L004 K040 K005 I065 I066 I067
0.021.1202.4

0.020.6714.4

A006 A003 I031a I031b

B ATTE R Y

Fig. 2576
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom

40-214
Wiring diagrams
M001
I073

+5V HLH P DRAF T SENSO R

RIGH T DRAF T SENSO R
I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
30

EV LIF T DOWN

EV U P LIF T +
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C005

EV DW

EV UP

SDD
+30

+30

+30

-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 72 23 47 43 15 2 4 6 9 31 53 42 41 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 A5 A3 B3 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 A5 A3 B3 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30
C0 11
B001
150A

1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V V
kg
L004 L004 K040 K005 I065 I066 I067
0.021.1202.4

0.020.6714.4

A006 A003 I031a I031b

B ATTE R Y

Fig. 2576
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear hitch down button
l I027 - RH rear hitch up button
l I028 - LH rear hitch down button
l I030 - LH rear hitch up button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I065 - Rear hitch up push-button
l I066 - Rear hitch stop push-button
l I067 - Rear hitch down push-button
l I073 - Front hitch control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear hitch position sensor
l K032 - SDD proximity sensor
l K040 - Right hand hitch draft tie rod sensor
l L004 - Rear hitch ‘DOWN’ control solenoid valve
l L005 - Rear hitch ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

40-215
 Wiring diagrams

Fig. 2578
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear hitch down button
l I027 - RH rear hitch up button
l I028 - LH rear hitch down button
l I030 - LH rear hitch up button
l I031a - Battery master switch button

40-216
Wiring diagrams

Fig. 2578
l I031b - Battery master switch button
l I065 - Rear hitch up push-button
l I066 - Rear hitch stop push-button
l I067 - Rear hitch down push-button
l I073 - Front hitch control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear hitch position sensor
l K032 - SDD proximity sensor
l K040 - Right hand hitch draft tie rod sensor
l L004 - Rear hitch ‘DOWN’ control solenoid valve
l L005 - Rear hitch ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

40-217
 Wiring diagrams

Fig. 2580
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom

40-218
Wiring diagrams

Fig. 2580
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear hitch down button
l I027 - RH rear hitch up button
l I028 - LH rear hitch down button
l I030 - LH rear hitch up button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I065 - Rear hitch up push-button
l I066 - Rear hitch stop push-button
l I067 - Rear hitch down push-button
l I073 - Front hitch control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear hitch position sensor
l K032 - SDD proximity sensor
l K040 - Right hand hitch draft tie rod sensor
l L004 - Rear hitch ‘DOWN’ control solenoid valve

40-219
 Wiring diagrams

Fig. 2580
l L005 - Rear hitch ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

Table 315
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)

40-220
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb007 Climate control fuse 40-586
+15 (20A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D029 Wiring connector for 40-596

rear wiring loom

40-221
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D029 Wiring connector -
for SBA/ASM wiring
loom
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D076 Wiring connector for 40-596
rear wiring loom

D076

D076 Wiring connector for -

SDD wiring loom

D076

I005 0.015.0485.4 Starter switch 40-586

I005

I006 2.7659.444.0 SDD switch 40-586

I025 RH rear hitch ‘Down’ I025
40-586
button

I027 RH rear hitch ‘Up’ 40-586

button
I027

I028 LH rear hitch ‘Down’ 40-586

button
I028

I030 LH rear hitch ‘Up’ 40-586

button
I030

40-222
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I065 2.7659.424.0 Rear hitch up push- 40-620

button
I066 2.7659.428.0 Rear hitch stop 40-620
push-button
I067 Rear hitch down 40-620
push-button
I073 Front hitch control 40-586
switch in cab
I073

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi-
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K005 2.7099.740.0/10 Rear hitch position Pin 1 = power (Nomi- 40-596
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K032 SDD proximity sen-
sor
K040 Right hand hitch 40-596
draft tie-rod sensor

K040

L004 Rear hitch DOWN 40-596

control solenoid
valve
L004

40-223
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
L005 Rear hitch ‘UP’ con- 40-596
trol solenoid valve
L005

L019 SDD solenoid valve

M001 HLHP unit 40-586

M001

40.3.7 - S004 - Lift (5110 C -> ZKDY440200TD10001)

M001
I006 I073
+5V HLH P DRAF T SENSO R
RIGH T DRAF T SENSO R

I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
SDD PROSSIMITY

30
EV LIF T DOWN

EV U P LIF T +

SDD VA LV E
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C009 C005
EV DW

EV UP

ASM

SDD
+30

+30

+30

-31

-31

-31

50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 75 26 72 23 22 47 43 15 2 4 6 9 31 53 42 41 44 4 3 2 1 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
C0 11 0.020.3229.4/30
B001
150A

D076 1 2 4 5 3 D029 3 1 2
1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V 1 2 4 5 3
C002 V 3 1 2

kg
0.019.8827.4

0.019.3797.3

L004 L004 K040 K005 I065 I066 I067

0.021.1202.4

0.020.6714.4

1 2 1 2 3 2 1 4

A006 A003 I031a I031b L019 K032 K001

B ATTE R Y

Fig. 2583
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)

40-224
Wiring diagrams
M001
I006 I073

+5V HLH P DRAF T SENSO R

RIGH T DRAF T SENSO R
I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
SDD PROSSIMITY
30

EV LIF T DOWN

EV U P LIF T +

SDD VA LV E
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C009 C005

EV DW

EV UP

ASM

SDD
+30

+30

+30

-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 75 26 72 23 22 47 43 15 2 4 6 9 31 53 42 41 44 4 3 2 1 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30
C0 11
B001
150A

D076 1 2 4 5 3 D029 3 1 2
1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V 1 2 4 5 3
C002 V 3 1 2

kg
0.019.8827.4

0.019.3797.3

L004 L004 K040 K005 I065 I066 I067

0.021.1202.4

0.020.6714.4

1 2 1 2 3 2 1 4

A006 A003 I031a I031b L019 K032 K001

B ATTE R Y

Fig. 2583
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear lift down button
l I027 - RH rear lift up button
l I028 - LH rear lift down button
l I030 - LH rear lift up button
l I031a - Battery disconnect switch
l I031b - Battery disconnect switch

40-225
 Wiring diagrams
M001
I006 I073

+5V HLH P DRAF T SENSO R

RIGH T DRAF T SENSO R
I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
SDD PROSSIMITY
30

EV LIF T DOWN

EV U P LIF T +

SDD VA LV E
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C009 C005

EV DW

EV UP

ASM

SDD
+30

+30

+30

-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 75 26 72 23 22 47 43 15 2 4 6 9 31 53 42 41 44 4 3 2 1 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30
C0 11
B001
150A

D076 1 2 4 5 3 D029 3 1 2
1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V 1 2 4 5 3
C002 V 3 1 2

kg
0.019.8827.4

0.019.3797.3

L004 L004 K040 K005 I065 I066 I067

0.021.1202.4

0.020.6714.4

1 2 1 2 3 2 1 4

A006 A003 I031a I031b L019 K032 K001

B ATTE R Y

Fig. 2583
l I065 - Rear lift up push-button
l I066 - Rear lift stop push-button
l I067 - Rear lift down push-button
l I073 - Front lift control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear lift position sensor
l K032 - SDD proximity sensor
l K040 - Right hand lift draft tie-rod sensor
l L004 - Rear lift ‘DOWN’ control solenoid valve
l L005 - Rear lift ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

40-226
Wiring diagrams

Fig. 2586
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear lift down button
l I027 - RH rear lift up button
l I028 - LH rear lift down button
l I030 - LH rear lift up button
l I031a - Battery disconnect switch

40-227
 Wiring diagrams

Fig. 2586
l I031b - Battery disconnect switch
l I065 - Rear lift up push-button
l I066 - Rear lift stop push-button
l I067 - Rear lift down push-button
l I073 - Front lift control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear lift position sensor
l K032 - SDD proximity sensor
l K040 - Right hand lift draft tie-rod sensor
l L004 - Rear lift ‘DOWN’ control solenoid valve
l L005 - Rear lift ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

40-228
Wiring diagrams

Fig. 2588
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom

40-229
 Wiring diagrams

Fig. 2588
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear lift down button
l I027 - RH rear lift up button
l I028 - LH rear lift down button
l I030 - LH rear lift up button
l I031a - Battery disconnect switch
l I031b - Battery disconnect switch
l I065 - Rear lift up push-button
l I066 - Rear lift stop push-button
l I067 - Rear lift down push-button
l I073 - Front lift control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear lift position sensor
l K032 - SDD proximity sensor
l K040 - Right hand lift draft tie-rod sensor
l L004 - Rear lift ‘DOWN’ control solenoid valve

40-230
Wiring diagrams

Fig. 2588
l L005 - Rear lift ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

Table 316
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)

40-231
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb007 Climate control fuse 40-586
+15 (20A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D029 Wiring connector for 40-596

rear wiring loom

40-232
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D029 Wiring connector 40-641
for SBA/ASM wiring
loom
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D076 Wiring connector for -
rear wiring loom

D076

D076 Wiring connector for 40-645

SDD wiring loom

D076

I005 0.015.0485.4 Starter switch 40-586

I005

I006 2.7659.444.0 SDD switch 40-586

I025 RH rear lift ‘Down’ I025
40-586
button

I027 RH rear lift ‘Up’ but- 40-586

ton
I027

I028 LH rear lift ‘Down’ 40-586

button
I028

I030 LH rear lift ‘Up’ but- 40-586

ton
I030

40-233
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I065 2.7659.424.0 Rear lift up push- 40-620

button
I066 2.7659.428.0 Rear lift stop push- 40-620
button
I067 Rear lift down push- 40-620
button
I073 Front lift control 40-586
switch in cab
I073

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi-
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K005 2.7099.740.0/10 Rear lift position Pin 1 = power (Nomi- 40-596
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K032 SDD proximity sen-
sor
K040 Right hand lift draft 40-596
tie-rod sensor
L004 Rear lift DOWN con- 40-596
trol solenoid valve
L004

40-234
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
L005 Rear lift ‘UP’ control 40-596
solenoid valve
L005

L019 SDD solenoid valve

M001 HLHP unit 40-586

M001

40.3.8 - S004 - Lift (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120
C -> ZKDY560200TD10001)
M001
I006 I073
+5V HLH P DRAF T SENSO R
RIGH T DRAF T SENSO R

I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
SDD PROSSIMITY

30
EV LIF T DOWN

EV U P LIF T +

SDD VA LV E
+15V HLHP

GND COM

GND COM

GND COM

50 15
C006 C009 C005
EV DW

EV UP

ASM

SDD
+30

+30

+30

-31

-31

-31

50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 75 26 72 23 22 47 43 15 2 4 6 9 31 53 42 41 44 4 3 2 1 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30

C0 11
B001
150A

D076 1 2 4 5 3 D029 3 1 2
1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V 1 2 4 5 3
C002 V 3 1 2

kg
0.019.8827.4

0.019.3797.3

L004 L004 K040 K005 I065 I066 I067

0.021.1202.4

0.020.6714.4

1 2 1 2 3 2 1 4

A006 A003 I031a I031b L019 K032 K001

B ATTE R Y

Fig. 2591
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)

40-235
 Wiring diagrams
M001
I006 I073

+5V HLH P DRAF T SENSO R

RIGH T DRAF T SENSO R
I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
SDD PROSSIMITY
30

EV LIF T DOWN

EV U P LIF T +

SDD VA LV E
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C009 C005

EV DW

EV UP

ASM

SDD
+30

+30

+30

-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 75 26 72 23 22 47 43 15 2 4 6 9 31 53 42 41 44 4 3 2 1 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30
C0 11
B001
150A

D076 1 2 4 5 3 D029 3 1 2
1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V 1 2 4 5 3
C002 V 3 1 2

kg
0.019.8827.4

0.019.3797.3

L004 L004 K040 K005 I065 I066 I067

0.021.1202.4

0.020.6714.4

1 2 1 2 3 2 1 4

A006 A003 I031a I031b L019 K032 K001

B ATTE R Y

Fig. 2591
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear lift down button
l I027 - RH rear lift up button
l I028 - LH rear lift down button
l I030 - LH rear lift up button
l I031a - Battery master switch button

40-236
Wiring diagrams
M001
I006 I073

+5V HLH P DRAF T SENSO R

RIGH T DRAF T SENSO R
I005 Jc001 Jc001 I025 I027 I028 I030

LIF T SW EX T DOW N
LIF T S T O P BUT T O N
POS.LIF T SENSO R

LIF T DW BUT T O N
LIF T U P BUT T O N
+

LIF T SW EX T U P
5V HLH P BOD Y
SDD PROSSIMITY
30

EV LIF T DOWN

EV U P LIF T +

SDD VA LV E
+15V HLHP

GND COM

GND COM

GND COM
50 15
C006 C009 C005

EV DW

EV UP

ASM

SDD
+30

+30

+30

-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 8 73 29 7 51 34 70 75 26 72 23 22 47 43 15 2 4 6 9 31 53 42 41 44 4 3 2 1 10 3 1 2 8 7 9 2 1 1 2 2 1 1 2
0.020.6707.4/20

Bd002 Bd001 Bb007 Bd004 Ba004 Bc004

7,5A

7,5A
15A

15A

20A
3A

D043 D025A C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 D025B 14-13 14-3 12-4 12-2 12-1 12-5 D015
C4 C5 C7 C6 D6 D7 C3 D5 A5 A3 B3 D2 14-13 12-3 12-4 12-2 12-1 12-5

0.020.2857.4/10
0.020.3229.4/30
C0 11
B001
150A

D076 1 2 4 5 3 D029 3 1 2
1 2 1 2 2 3 1 1 4 2 2 3 4 1 2 3 4 1 2 3 4 1

V 1 2 4 5 3
C002 V 3 1 2

kg
0.019.8827.4

0.019.3797.3

L004 L004 K040 K005 I065 I066 I067

0.021.1202.4

0.020.6714.4

1 2 1 2 3 2 1 4

A006 A003 I031a I031b L019 K032 K001

B ATTE R Y

Fig. 2591
l I031b - Battery master switch button
l I065 - Rear lift up push-button
l I066 - Rear lift stop push-button
l I067 - Rear lift down push-button
l I073 - Front lift control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear lift position sensor
l K032 - SDD proximity sensor
l K040 - Right hand lift draft tie-rod sensor
l L004 - Rear lift ‘DOWN’ control solenoid valve
l L005 - Rear lift ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

40-237
 Wiring diagrams

Fig. 2594
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear lift down button
l I027 - RH rear lift up button
l I028 - LH rear lift down button
l I030 - LH rear lift up button
l I031a - Battery master switch button

40-238
Wiring diagrams

Fig. 2594
l I031b - Battery master switch button
l I065 - Rear lift up push-button
l I066 - Rear lift stop push-button
l I067 - Rear lift down push-button
l I073 - Front lift control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear lift position sensor
l K032 - SDD proximity sensor
l K040 - Right hand lift draft tie-rod sensor
l L004 - Rear lift ‘DOWN’ control solenoid valve
l L005 - Rear lift ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

40-239
 Wiring diagrams

Fig. 2596
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom

40-240
Wiring diagrams

Fig. 2596
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l I005 - Ignition switch
l I006 - SDD switch
l I025 - RH rear lift down button
l I027 - RH rear lift up button
l I028 - LH rear lift down button
l I030 - LH rear lift up button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I065 - Rear lift up push-button
l I066 - Rear lift stop push-button
l I067 - Rear lift down push-button
l I073 - Front lift control switch in cab
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K001 - Steering angle sensor (SBA)
l K005 - Rear lift position sensor
l K032 - SDD proximity sensor
l K040 - Right hand lift draft tie-rod sensor
l L004 - Rear lift ‘DOWN’ control solenoid valve

40-241
 Wiring diagrams

Fig. 2596
l L005 - Rear lift ‘UP’ control solenoid valve
l L019 - SDD Solenoid valve
l M001 - HLHP control unit

Table 317
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)

40-242
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb007 Climate control fuse 40-586
+15 (20A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D029 Wiring connector for 40-606

rear wiring loom

40-243
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D029 Wiring connector 40-641
for SBA/ASM wiring
loom
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D076 Wiring connector for -
rear wiring loom

D076

D076 Wiring connector for 40-645

SDD wiring loom

D076

I005 0.015.0485.4 Starter switch 40-586

I005

I006 2.7659.444.0 SDD switch 40-586

I025 RH rear lift ‘Down’ I025
40-586
button

I027 RH rear lift ‘Up’ but- 40-586

ton
I027

I028 LH rear lift ‘Down’ 40-586

button
I028

I030 LH rear lift ‘Up’ but- 40-586

ton
I030

40-244
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I065 2.7659.424.0 Rear lift up push- 40-620

button
I066 2.7659.428.0 Rear lift stop push- 40-620
button
I067 Rear lift down push- 40-620
button
I073 Front lift control 40-586
switch in cab
I073

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
K001 2.7099.740.0/10 Steering angle sen- Pin 1 = power (Nomi-
sor (SBA) nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K005 2.7099.740.0/10 Rear lift position Pin 1 = power (Nomi- 40-606
sensor nal 5.0V)
Pin 2 = ground
Pin 4 = analogue
signal
K032 SDD proximity sen-
sor
K040 Right hand lift draft 40-606
tie-rod sensor
L004 Rear lift DOWN con- 40-606
trol solenoid valve
L004

40-245
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
L005 Rear lift ‘UP’ control 40-606
solenoid valve
L005

L019 SDD solenoid valve

M001 HLHP unit 40-586

M001

40.3.9 - S005 - Lights (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,

5110 C -> ZKDY440200TD10001)
I005 Jc001 Jf001 Jf002 Jf003
30
50 15
C006
50 15 30 30 86 85 87 87 86 85 30 30 85 86 87 87 86 85 30
0.020.6707.4/20

Bd002 Bd001 Bb002 Bb001 Bd004 Bd006 Ba004 Ba003 Ba006 Ba005
7,5A

7,5A
15A

3A

15A

15A

15A

15A
5A
5A

D043

C0 11

B001
150A

0.020.6714.4

D069 D070
0.021.1202.4

4 3 2 5 5 2 4 3 9 7 8 10 5 3 2 6 8 6 2 5 1 4 7 8 9 10 11 12 13

C009 C004
-31
+58

DIRECTIONS

I TRAILER LIGHT

II TRAILER LIGHT
HIGH BEAM LIGHTS

A006 A003 I031a I031b I041 I040

BATTE RY E007

Fig. 2599
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)

40-246
Wiring diagrams
I005 Jc001 Jf001 Jf002 Jf003
30
50 15
C006
50 15 30 30 86 85 87 87 86 85 30 30 85 86 87 87 86 85 30
0.020.6707.4/20

Bd002 Bd001 Bb002 Bb001 Bd004 Bd006 Ba004 Ba003 Ba006 Ba005

7,5A

7,5A
15A

3A

15A

15A

15A

15A
5A
5A

D043

C0 11

B001
150A

0.020.6714.4

D069 D070
0.021.1202.4

4 3 2 5 5 2 4 3 9 7 8 10 5 3 2 6 8 6 2 5 1 4 7 8 9 10 11 12 13

C009 C004

-31
+58

DIRECTIONS

I TRAILER LIGHT

II TRAILER LIGHT
HIGH BEAM LIGHTS
A006 A003 I031a I031b I041 I040

BATTE RY E007

Fig. 2599
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector
l E007 - Instrument panel
l F007 - Rear RH turn indicator

40-247
 Wiring diagrams
I005 Jc001 Jf001 Jf002 Jf003
30
50 15
C006
50 15 30 30 86 85 87 87 86 85 30 30 85 86 87 87 86 85 30
0.020.6707.4/20

Bd002 Bd001 Bb002 Bb001 Bd004 Bd006 Ba004 Ba003 Ba006 Ba005

7,5A

7,5A
15A

3A

15A

15A

15A

15A
5A
5A

D043

C0 11

B001
150A

0.020.6714.4

D069 D070
0.021.1202.4

4 3 2 5 5 2 4 3 9 7 8 10 5 3 2 6 8 6 2 5 1 4 7 8 9 10 11 12 13

C009 C004

-31
+58

DIRECTIONS

I TRAILER LIGHT

II TRAILER LIGHT
HIGH BEAM LIGHTS
A006 A003 I031a I031b I041 I040

BATTE RY E007

Fig. 2599
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-248
Wiring diagrams

M001 I010
H023
F007 F009 F008 F010

LED BAR OUTPUT

LED BAR INPUT

GND COM

GND COM

GND COM
C005 C007

+30

+30

+30

-31

-31

-31
3 4 1 6 5 7 8 9 1 3 5 87 56 9 31 53 2 4 6 9 2 7 8 3 10 2 1 1 2 2 1 2 1

D045

5
1
3
4
7
Bc004 Bd003

3A
20A

0.020.6707.4/20
Bc006
20A

D8 D025A A1 D7 D025B
D8 A1 D7

0.020.3229.4/30
0.020.2857.4/10
12 13 14 17 5 7 9 D028
12 13 14 17 5 7 9
C002

0.019.3870.4/10
3 2 5 4 1 6 2 5 7 4 3 1 6 2 1 2 1 2 1 2 1 2 1 2 1
-31

49(+)
DIRECTIONS
I TRAILER LIGHT
II TRAILER LIGHT

DIRECTION COM

OFF

ON

F012 F015 F0 11 F016 F014 F017

M005 I033

Fig. 2602
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom

40-249
 Wiring diagrams

M001 I010
H023
F007 F009 F008 F010

LED BAR OUTPUT

LED BAR INPUT

GND COM

GND COM

GND COM
C005 C007

+30

+30

+30

-31

-31

-31
3 4 1 6 5 7 8 9 1 3 5 87 56 9 31 53 2 4 6 9 2 7 8 3 10 2 1 1 2 2 1 2 1

D045

5
1
3
4
7
Bc004 Bd003

3A
20A

0.020.6707.4/20
Bc006
20A

D8 D025A A1 D7 D025B
D8 A1 D7

0.020.3229.4/30
0.020.2857.4/10
12 13 14 17 5 7 9 D028
12 13 14 17 5 7 9
C002

0.019.3870.4/10
3 2 5 4 1 6 2 5 7 4 3 1 6 2 1 2 1 2 1 2 1 2 1 2 1
-31

49(+)
DIRECTIONS
I TRAILER LIGHT
II TRAILER LIGHT

DIRECTION COM

OFF

ON

F012 F015 F0 11 F016 F014 F017

M005 I033

Fig. 2602
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector
l E007 - Instrument panel
l F007 - Rear RH turn indicator
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch

40-250
Wiring diagrams

M001 I010
H023
F007 F009 F008 F010

LED BAR OUTPUT

LED BAR INPUT

GND COM

GND COM

GND COM
C005 C007

+30

+30

+30

-31

-31

-31
3 4 1 6 5 7 8 9 1 3 5 87 56 9 31 53 2 4 6 9 2 7 8 3 10 2 1 1 2 2 1 2 1

D045

5
1
3
4
7
Bc004 Bd003

3A
20A

0.020.6707.4/20
Bc006
20A

D8 D025A A1 D7 D025B
D8 A1 D7

0.020.3229.4/30
0.020.2857.4/10
12 13 14 17 5 7 9 D028
12 13 14 17 5 7 9
C002

0.019.3870.4/10
3 2 5 4 1 6 2 5 7 4 3 1 6 2 1 2 1 2 1 2 1 2 1 2 1
-31

49(+)
DIRECTIONS
I TRAILER LIGHT
II TRAILER LIGHT

DIRECTION COM

OFF

ON

F012 F015 F0 11 F016 F014 F017

M005 I033

Fig. 2602
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-251
 Wiring diagrams

Fig. 2605
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector

40-252
Wiring diagrams

Fig. 2605
l E007 - Instrument panel
l F007 - Rear RH turn indicator
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-253
 Wiring diagrams

Fig. 2607
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector
l E007 - Instrument panel
l F007 - Rear RH turn indicator

40-254
Wiring diagrams

Fig. 2607
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-255
 Wiring diagrams
Table 318
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba003 Monitor fuse +30 40-586
(15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Ba005 High beam head- 40-586
lights fuse +30 (15A)
Bb002 Radio/amplifier fuse 40-586
+15 (5A)
Bc006 Sidelights fuse 40-586
(7.5A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd003 Rear cab roof work- 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-596

C002

C004 Grounding point C004

40-586

C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

40-256
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
C009 Grounding point C009
40-586

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-596

rear wiring loom D028

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D045 Wiring connector for 40-586
trailer wiring loom

D045

D069 Wiring connector to 40-586

cab wiring loom D069

D069 Wiring connector 40-638

for lower front work D069

lights wiring loom

D070 Wiring connector to D070

40-586
cab wiring loom

40-257
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D070 Wiring connector D070
40-638
for lower front work
lights wiring loom

E007 2.8339.278.0/10 Instrument panel E007

40-586

F007 2.8059.500.0/10 Rear RH turn indica- F007

40-586
tor

F008 2.8059.500.0/10 Sidelight/rear right F008

40-586
brake light

F009 2.8059.510.0/10 Rear LH turn indica- 40-586

tor R5W
GND

F009
P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-586

brake light R5W
GND

P21W F010

GND

F011 2.8039.021.0/10 Rh high beam head- POSITION

-
light
GND

F011

40-258
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
F012 2.8039.021.0/10 Rh low beam head- POSITION
-
light
GND

F012

F014 Right LED light -

F014

F015 2.8039.022.0/10 LH low beam head- -

light

F015

F016 2.8039.022.0/10 LH high beam head- -

light

F016

F017 Left LED light -

F017

H023 Lights selector H023

40-586
switch

I005 0.015.0485.4 Starter switch 40-586

I005

I010 2.7659.470.0 LED lights control 40-586

switch
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

40-259
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

I033 Hazard warning 40-586

lights switch
I033

I040 2.7659.283.0/10 Top/Low work lights I040

40-586
switch
8 1 2 3
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch I041

40-586

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
Jf002 High beam head- 40-586
lights relay
Jf003 Low beam head- 40-586
lights relay
M001 HLHP unit 40-586

M001

M005 Control unit USA 40-586

40-260
Wiring diagrams
40.3.10 - S005 - Lights (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
I005 Jc001 Jf001 Jf002 Jf003
30
50 15
C006
50 15 30 30 86 85 87 87 86 85 30 30 85 86 87 87 86 85 30
0.020.6707.4/20

Bd002 Bd001 Bb002 Bb001 Bd004 Bd006 Ba004 Ba003 Ba006 Ba005

7,5A

7,5A
15A

3A

15A

15A

15A

15A
5A
5A

D043

C0 11

B001
150A

0.020.6714.4

D069 D070
0.021.1202.4

4 3 2 5 5 2 4 3 9 7 8 10 5 3 2 6 8 6 2 5 1 4 7 8 9 10 11 12 13

C009 C004

-31
+58

DIRECTIONS

I TRAILER LIGHT

II TRAILER LIGHT
HIGH BEAM LIGHTS

A006 A003 I031a I031b I041 I040

BATTE RY E007

Fig. 2609
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom

40-261
 Wiring diagrams
I005 Jc001 Jf001 Jf002 Jf003
30
50 15
C006
50 15 30 30 86 85 87 87 86 85 30 30 85 86 87 87 86 85 30
0.020.6707.4/20

Bd002 Bd001 Bb002 Bb001 Bd004 Bd006 Ba004 Ba003 Ba006 Ba005

7,5A

7,5A
15A

3A

15A

15A

15A

15A
5A
5A

D043

C0 11

B001
150A

0.020.6714.4

D069 D070
0.021.1202.4

4 3 2 5 5 2 4 3 9 7 8 10 5 3 2 6 8 6 2 5 1 4 7 8 9 10 11 12 13

C009 C004

-31
+58

DIRECTIONS

I TRAILER LIGHT

II TRAILER LIGHT
HIGH BEAM LIGHTS
A006 A003 I031a I031b I041 I040

BATTE RY E007

Fig. 2609
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector
l E007 - Instrument panel
l F007 - Rear RH turn indicator
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch

40-262
Wiring diagrams
I005 Jc001 Jf001 Jf002 Jf003
30
50 15
C006
50 15 30 30 86 85 87 87 86 85 30 30 85 86 87 87 86 85 30
0.020.6707.4/20

Bd002 Bd001 Bb002 Bb001 Bd004 Bd006 Ba004 Ba003 Ba006 Ba005

7,5A

7,5A
15A

3A

15A

15A

15A

15A
5A
5A

D043

C0 11

B001
150A

0.020.6714.4

D069 D070
0.021.1202.4

4 3 2 5 5 2 4 3 9 7 8 10 5 3 2 6 8 6 2 5 1 4 7 8 9 10 11 12 13

C009 C004

-31
+58

DIRECTIONS

I TRAILER LIGHT

II TRAILER LIGHT
HIGH BEAM LIGHTS
A006 A003 I031a I031b I041 I040

BATTE RY E007

Fig. 2609
l I041 – Lights switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-263
 Wiring diagrams

M001 I010
H023
F007 F009 F008 F010

LED BAR OUTPUT

LED BAR INPUT

GND COM

GND COM

GND COM
C005 C007

+30

+30

+30

-31

-31

-31
3 4 1 6 5 7 8 9 1 3 5 87 56 9 31 53 2 4 6 9 2 7 8 3 10 2 1 1 2 2 1 2 1

D045

5
1
3
4
7
Bc004 Bd003

3A
20A

0.020.6707.4/20
Bc006
20A

D8 D025A A1 D7 D025B
D8 A1 D7

0.020.3229.4/30
0.020.2857.4/10
12 13 14 17 5 7 9 D028
12 13 14 17 5 7 9
C002

0.019.3870.4/10
3 2 5 4 1 6 2 5 7 4 3 1 6 2 1 2 1 2 1 2 1 2 1 2 1
-31

49(+)
DIRECTIONS
I TRAILER LIGHT
II TRAILER LIGHT

DIRECTION COM

OFF

ON

F012 F015 F0 11 F016 F014 F017

M005 I033

Fig. 2612
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom

40-264
Wiring diagrams

M001 I010
H023
F007 F009 F008 F010

LED BAR OUTPUT

LED BAR INPUT

GND COM

GND COM

GND COM
C005 C007

+30

+30

+30

-31

-31

-31
3 4 1 6 5 7 8 9 1 3 5 87 56 9 31 53 2 4 6 9 2 7 8 3 10 2 1 1 2 2 1 2 1

D045

5
1
3
4
7
Bc004 Bd003

3A
20A

0.020.6707.4/20
Bc006
20A

D8 D025A A1 D7 D025B
D8 A1 D7

0.020.3229.4/30
0.020.2857.4/10
12 13 14 17 5 7 9 D028
12 13 14 17 5 7 9
C002

0.019.3870.4/10
3 2 5 4 1 6 2 5 7 4 3 1 6 2 1 2 1 2 1 2 1 2 1 2 1
-31

49(+)
DIRECTIONS
I TRAILER LIGHT
II TRAILER LIGHT

DIRECTION COM

OFF

ON

F012 F015 F0 11 F016 F014 F017

M005 I033

Fig. 2612
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector
l E007 - Instrument panel
l F007 - Rear RH turn indicator
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch

40-265
 Wiring diagrams

M001 I010
H023
F007 F009 F008 F010

LED BAR OUTPUT

LED BAR INPUT

GND COM

GND COM

GND COM
C005 C007

+30

+30

+30

-31

-31

-31
3 4 1 6 5 7 8 9 1 3 5 87 56 9 31 53 2 4 6 9 2 7 8 3 10 2 1 1 2 2 1 2 1

D045

5
1
3
4
7
Bc004 Bd003

3A
20A

0.020.6707.4/20
Bc006
20A

D8 D025A A1 D7 D025B
D8 A1 D7

0.020.3229.4/30
0.020.2857.4/10
12 13 14 17 5 7 9 D028
12 13 14 17 5 7 9
C002

0.019.3870.4/10
3 2 5 4 1 6 2 5 7 4 3 1 6 2 1 2 1 2 1 2 1 2 1 2 1
-31

49(+)
DIRECTIONS
I TRAILER LIGHT
II TRAILER LIGHT

DIRECTION COM

OFF

ON

F012 F015 F0 11 F016 F014 F017

M005 I033

Fig. 2612
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-266
Wiring diagrams

Fig. 2615
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector

40-267
 Wiring diagrams

Fig. 2615
l E007 - Instrument panel
l F007 - Rear RH turn indicator
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-268
Wiring diagrams

Fig. 2617
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bc006 - Hazard lights fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom - horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Left low working lights/wiring connector
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Right low working lights/wiring connector
l E007 - Instrument panel
l F007 - Rear RH turn indicator

40-269
 Wiring diagrams

Fig. 2617
l F008 - Rear LH turn indicator
l F009 - Rear LH turn indicator
l F010 - Rear RH turn indicator
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l H023 - Lights selector switch
l I005 - Ignition switch
l I010 - LED lights control switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 – Lights switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l M001 - HLHP control unit
l M005 - USA ECU

40-270
Wiring diagrams
Table 319
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba003 Monitor fuse +30 40-586
(15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Ba005 High beam head- 40-586
lights fuse +30 (15A)
Bb002 Radio/amplifier fuse 40-586
+15 (5A)
Bc006 Sidelights fuse 40-586
(7.5A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd003 Rear cab roof work- 40-586
ing lights fuse +30
(25A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-606

C002

C004 Grounding point C004

40-586

C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

40-271
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
C009 Grounding point C009
40-586

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-606

rear wiring loom D028

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D045 Wiring connector for 40-586
trailer wiring loom

D045

D069 Wiring connector to 40-586

cab wiring loom D069

D069 Wiring connector 40-638

for lower front work D069

lights wiring loom

D070 Wiring connector to D070

40-586
cab wiring loom

40-272
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D070 Wiring connector D070
40-638
for lower front work
lights wiring loom

E007 2.8339.278.0/10 Instrument panel E007

40-586

F007 2.8059.500.0/10 Rear RH turn indica- F007

40-586
tor

F008 2.8059.500.0/10 Sidelight/rear right F008

40-586
brake light

F009 2.8059.510.0/10 Rear LH turn indica- 40-586

tor R5W
GND

F009
P21W

GND

F010 2.8059.510.0/10 Sidelight/rear left 40-586

brake light R5W
GND

P21W F010

GND

F011 2.8039.021.0/10 Rh high beam head- POSITION

-
light
GND

F011

40-273
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
F012 2.8039.021.0/10 Rh low beam head- POSITION
-
light
GND

F012

F014 Right LED light -

F014

F015 2.8039.022.0/10 LH low beam head- -

light

F015

F016 2.8039.022.0/10 LH high beam head- -

light

F016

F017 Left LED light -

F017

H023 Lights selector H023

40-586
switch

I005 0.015.0485.4 Starter switch 40-586

I005

I010 2.7659.470.0 LED lights control 40-586

switch
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

40-274
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

I033 Hazard warning 40-586

lights switch
I033

I040 2.7659.283.0/10 Top/Low work lights I040

40-586
switch
8 1 2 3
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch I041

40-586

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
Jf002 High beam head- 40-586
lights relay
Jf003 Low beam head- 40-586
lights relay
M001 HLHP unit 40-586

M001

M005 Control unit USA 40-586

40-275
 Wiring diagrams
40.3.11 - S006 - Work lights (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001)
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010
7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2619
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point

40-276
Wiring diagrams
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010

7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2619
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom

40-277
 Wiring diagrams
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010

7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2619
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch

40-278
Wiring diagrams
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010

7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2619
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-279
 Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2623
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point

40-280
Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2623
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom

40-281
 Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2623
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab

40-282
Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2623
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-283
 Wiring diagrams

Fig. 2627
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point

40-284
Wiring diagrams

Fig. 2627
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom

40-285
 Wiring diagrams

Fig. 2627
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch

40-286
Wiring diagrams

Fig. 2627
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-287
 Wiring diagrams

Fig. 2631
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom

40-288
Wiring diagrams

Fig. 2631
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light

40-289
 Wiring diagrams

Fig. 2631
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-290
Wiring diagrams

Fig. 2634
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom

40-291
 Wiring diagrams

Fig. 2634
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab

40-292
Wiring diagrams

Fig. 2634
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-293
 Wiring diagrams
Table 320
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba002 Low beam head- 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-586
(15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Ba005 High beam head- 40-586
lights fuse +30 (15A)
Ba008 Cluster fuse +30 40-586
(3A)
Ba010 Power fuse +30 40-586
(15A)
Bb002 Radio/amplifier fuse 40-586
+15 (5A)
Bb013 Wolp fuse +15 (3A) 40-276 40-586
Bb014 Trailer braking fuse 40-369 40-586
+15 (7.5A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
Bg001 Front windscreen 40-586
wiper motor fuse +15
(15A)
Bg002 Rear windscreen 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-586
(10A)
C002 Grounding point 40-596

C002

C006 Grounding point 40-586

C006

40-294
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
C009 Grounding point C009
40-586

C011 Battery earth C011

40-652

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-596

rear wiring loom D028

D030 Wiring connector for 40-612

roof wiring loom
D030

40-295
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D030 Wiring connector for 40-637
flashing beacon wir-
D030

ing loom

D031 Wiring connector for 40-612

roof wiring loom/Ro-
tating beacon 2
D031

D031 Wiring connector for 40-637

flashing beacon wir-
ing loom
D031

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D058 Wiring connection 40-635
to work lights wiring D058

loom

D058 Wiring connector for 40-612

roof wiring loom D058

D059 Wiring connection 40-635

to work lights wiring
loom D059

D059 Wiring connector for 40-612

roof wiring loom
D059

D060 Wiring connection 40-635

to work lights wiring
loom D060

D060 Wiring connector for 40-612

roof wiring loom
D060

D061 Wiring connection D061

40-635
to work lights wiring
loom

40-296
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D061 Wiring connector for D061
40-612
roof wiring loom

D063 Wiring connection 40-612

to work lights wiring
loom
D069 Wiring connector to 40-586
cab wiring loom D069

D069 Wiring connector 40-638

for lower front work D069

lights wiring loom

D070 Wiring connector to D070

40-586
cab wiring loom

D070 Wiring connector D070

40-638
for lower front work
lights wiring loom

F001 0.013.0868.4 Rotating beacon 40-637

connection

F002 0.013.0868.4 Rotating beacon 40-637

connection 2

40-297
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
F003 2.8039.295.0/10 Front work light on 40-635
cab

F013 RH work light -

F018 LH work light -

F018

F042 2.8039.295.0/10 Front work light on 40-635

cab

F044 Hazard Light 40-635

F045 2.8039.295.0/10 Rear work light on 40-635
cab

F046 2.8039.295.0/10 Rear work light on 40-635

cab

F047 Lower front work 40-638

light
F048 Lower front work 40-638
light
F065 Hazard Light 40-635

40-298
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
F066 2.8039.295.0/10 Rear work light on 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-635

cab

H023 Lights selector H023

40-586
switch

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I037 2.7659.159.0 Rotating beacon 0

1
40-612
switch 7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8 I037
Pos

40-299
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I040 2.7659.283.0/10 Top/Low work lights I040
40-586
switch
8 1 2 3
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch I041

40-586

I042 2.7659.157.0 Switch for front work 40-586

lights on cab
I042

I044 Low work lights I044

40-586
switch

I078 Switch for rear work 40-612

lights on roof

I078

I079 Switch for front work 40-612

lights on roof
I079

Jc001 Start relay (70A - 40-586

12V)
Je003 Right corner lights 40-586
relay
Je004 Beacon relay 40-586
Je005 Low front work lights 40-586
relay
Jf001 Sidelights relay 40-586
Jf002 High beam head- 40-586
lights relay
Jf003 Low beam head- 40-586
lights relay
Jg001 Rear roof work lights 40-586
relay
Jg002 Front roof work lights 40-586
relay

40-300
Wiring diagrams
40.3.12 - S006 - Work lights (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010
7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2637
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point

40-301
 Wiring diagrams
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010

7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2637
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom

40-302
Wiring diagrams
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010

7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2637
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch

40-303
 Wiring diagrams
I005 Jc001 Jf001 I044 I042 Jf003 H023 Jf002 Je005
30
50 15
C006 C009
50 15 30 87 85 86 30 87 86 85 30 2 7 8 3 2 7 8 3 87 86 85 30 6 5 3 4 87 86 85 30 87 86 85 30
0.020.6707.4/20

to S005
Bd002 Bd001 Bb013 Bb002 Bb013 Bd004 Bd006 Ba004 Bq005 Ba003 Ba006 Ba010

7,5A
7,5A
7,5A

7,5A

5A

15A
15A

15A
15A

15A
5A
3A

D043 5 1 D069 5 1 D070 D001 7 10 5 9 2 8 3 4

5 10 8 3 2 6 9 7 2 7 8 3
5 1 5 1 7 10 5 9 2 8 3 4
-
+

I041 I040

2 7 8 3 3 8 7 2 7 8 2 3

C0 11
0.021. 1196. 4

I078 I079 I037

B001
150A

2 1 2 1
0.020.8203.4
0.020.6714.4

F047 F048
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2637
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-304
Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2641
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point

40-305
 Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2641
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom

40-306
Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2641
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab

40-307
 Wiring diagrams

Jg002 Jg001 Je004 Je003 F018 F013

87 86 85 30 87 86 85 30 87 86 85 30 87 86 85 30 2 1 2 1

0.019.3870.4/10
Bg002 Bg001 Bg003
15A

15A

15A

Bq008 Bq002

15A

15A
D028 15 2 3 4

15 2 3 4

0.020.3229.4/30
0.020.2857.4/10
C002

D025B

A8

A8
0.020.6706.4/20

D061 4 1 3 2 D063 1 2 4 1 2 3 D059 D060 4 1 2 3 2 1 4 3 D058 1 2 D030 1 2 D031

4 1 3 2 1 2 4 1 2 3
C017 4 1 2 3 2 1 4 3 1 2 1 2

0.020.9462.4/10
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

1 2 1 2

F042 F044 F045 F046 F003 F065 F066 F067

F001 F002

Fig. 2641
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-308
Wiring diagrams

Fig. 2645
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point

40-309
 Wiring diagrams

Fig. 2645
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom

40-310
Wiring diagrams

Fig. 2645
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch

40-311
 Wiring diagrams

Fig. 2645
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-312
Wiring diagrams

Fig. 2649
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom

40-313
 Wiring diagrams

Fig. 2649
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light

40-314
Wiring diagrams

Fig. 2649
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-315
 Wiring diagrams

Fig. 2652
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D030 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom

40-316
Wiring diagrams

Fig. 2652
l D031 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l D063 - Wiring connection for work lights wiring loom
l D063 - Wiring connector for roof wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D069 - Wiring connector to cab wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab wiring loom
l F001 - Rotating beacon 1 connection
l F002 - Rotating beacon 2 connection
l F003 - Front work light on cab
l F013 - RH work light
l F018 - LH work light
l F042 - Front work light on cab
l F044 - Hazard light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F047 - Lower front work light
l F048 - Lower front work light
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab

40-317
 Wiring diagrams

Fig. 2652
l H023 - Lights selector switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I037 - Rotating beacon switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Lower work lights switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l Jc001 - Start relay (70A - 12V)
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay

40-318
Wiring diagrams
Table 321
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba002 Low beam head- 40-586
lights fuse +30 (15A)
Ba003 Monitor fuse +30 40-586
(15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Ba005 High beam head- 40-586
lights fuse +30 (15A)
Ba008 Cluster fuse +30 40-586
(3A)
Ba010 Power fuse +30 40-586
(15A)
Bb002 Radio/amplifier fuse 40-586
+15 (5A)
Bb013 Wolp fuse +15 (3A) 40-586
Bb014 Trailer braking fuse 40-586
+15 (7.5A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
Bg001 Front windscreen 40-586
wiper motor fuse +15
(15A)
Bg002 Rear windscreen 40-586
wiper motor fuse +15
(15A)
Bg003 Compressor fuse 40-586
(10A)
C002 Grounding point 40-606

C002

C006 Grounding point 40-586

C006

40-319
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
C009 Grounding point C009
40-586

C011 Battery earth C011

40-652

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-606

rear wiring loom D028

D030 Wiring connector for 40-612

roof wiring loom
D030

40-320
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D030 Wiring connector for 40-637
flashing beacon wir-
D030

ing loom

D031 Wiring connector for 40-612

roof wiring loom/Ro-
tating beacon 2
D031

D031 Wiring connector for 40-637

flashing beacon wir-
ing loom
D031

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D058 Wiring connection 40-635
to work lights wiring D058

loom

D058 Wiring connector for 40-612

roof wiring loom D058

D059 Wiring connection 40-635

to work lights wiring
loom D059

D059 Wiring connector for 40-612

roof wiring loom
D059

D060 Wiring connection 40-635

to work lights wiring
loom D060

D060 Wiring connector for 40-612

roof wiring loom
D060

D061 Wiring connection D061

40-635
to work lights wiring
loom

40-321
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D061 Wiring connector for D061
40-612
roof wiring loom

D063 Wiring connection 40-612

to work lights wiring
loom
D069 Wiring connector to 40-586
cab wiring loom D069

D069 Wiring connector 40-638

for lower front work D069

lights wiring loom

D070 Wiring connector to D070

40-586
cab wiring loom

D070 Wiring connector D070

40-638
for lower front work
lights wiring loom

F001 0.013.0868.4 Rotating beacon 40-637

connection

F002 0.013.0868.4 Rotating beacon 40-637

connection 2

40-322
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
F003 2.8039.295.0/10 Front work light on 40-635
cab

F013 RH work light -

F018 LH work light -

F018

F042 2.8039.295.0/10 Front work light on 40-635

cab

F044 Hazard Light 40-635

F045 2.8039.295.0/10 Rear work light on 40-635
cab

F046 2.8039.295.0/10 Rear work light on 40-635

cab

F047 Lower front work 40-638

light
F048 Lower front work 40-638
light
F065 Hazard Light 40-635

40-323
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
F066 2.8039.295.0/10 Rear work light on 40-635
cab

F067 2.8039.295.0/10 Rear work light on 40-635

cab

H023 Lights selector H023

40-586
switch

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I037 2.7659.159.0 Rotating beacon 0

1
40-612
switch 7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8 I037
Pos

40-324
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I040 2.7659.283.0/10 Top/Low work lights I040
40-586
switch
8 1 2 3
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch I041

40-586

I042 2.7659.157.0 Switch for front work 40-586

lights on cab
I042

I044 Low work lights I044

40-586
switch

I078 Switch for rear work 40-612

lights on roof

I078

I079 Switch for front work 40-612

lights on roof
I079

Jc001 Start relay (70A - 40-586

12V)
Je003 Right corner lights 40-586
relay
Je004 Beacon relay 40-586
Je005 Low front work lights 40-586
relay
Jf001 Sidelights relay 40-586
Jf002 High beam head- 40-586
lights relay
Jf003 Low beam head- 40-586
lights relay
Jg001 Rear roof work lights 40-586
relay
Jg002 Front roof work lights 40-586
relay

40-325
 Wiring diagrams
40.3.13 - S007 - Windscreen wiper

N005 N004
I005 Jc001 Jf001
30 M M

50 15
C006 C007
50 15 30 87 85 86 30 30 85 86 87 2 1 2 1
0.020.6707.4/20

Bd002 Bd001 Bb020 Bd006 Bg019

7,5A
15A

15A
10A
3A

D001
D043 12 21 10 14 19 17 18 20

12 21 10 14 19 17 18 20
J001
I080 I081

87a
B001
C0 11

87
86

85
30
2 5 1 3 7 3 5 8 6 4 2 3 1 7 8
150A

1 1
2 2
3 3
4 4

D033
0.020.6706.4/20

0.014.1567.4/20
0.014.8453.4*
0.021.1202.4

0.020.6714.4

A006 A003 I031a I031b 1 2 6 7 8 5 3 1 4 3 2 4 3 2 1

53/1Sp

53a/+12V

31b/ZE R O

GND

C017
B ATTE RY - +

N013 N001
N002*

I053

Fig. 2655
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D033 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I039 - Rear screen wiper switch
l I041 - Lights switch

40-326
Wiring diagrams
N005 N004
I005 Jc001 Jf001
30 M M

50 15
C006 C007
50 15 30 87 85 86 30 30 85 86 87 2 1 2 1
0.020.6707.4/20

Bd002 Bd001 Bb020 Bd006 Bg019

7,5A
15A

15A
10A
3A

D001
D043 12 21 10 14 19 17 18 20

12 21 10 14 19 17 18 20
J001
I080 I081

87a
B001
C0 11

87
86

85
30
2 5 1 3 7 3 5 8 6 4 2 3 1 7 8
150A

1 1
2 2
3 3
4 4

D033
0.020.6706.4/20

0.014.1567.4/20
0.014.8453.4*
0.021.1202.4

0.020.6714.4

A006 A003 I031a I031b 1 2 6 7 8 5 3 1 4 3 2 4 3 2 1

53/1Sp

53a/+12V

31b/ZE R O

GND

C017
B ATTE RY - +

N013 N001
N002*

I053

Fig. 2655
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l N001 - Windscreen wiper motor
l N002 - Windscreen wiper motor (fixed windscreen)
l N004 - Front windscreen wiper water pump
l N005 - Rear windscreen wiper water pump
l N013 - Rear window wiper motor

40-327
 Wiring diagrams

Fig. 2657
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D033 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I039 - Rear screen wiper switch
l I041 - Lights switch
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l N001 - Windscreen wiper motor
l N002 - Windscreen wiper motor (fixed windscreen)

40-328
Wiring diagrams

Fig. 2657
l N004 - Front windscreen wiper water pump
l N005 - Rear windscreen wiper water pump
l N013 - Rear window wiper motor

40-329
 Wiring diagrams

Fig. 2659
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D033 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I039 - Rear screen wiper switch
l I041 - Lights switch

40-330
Wiring diagrams

Fig. 2659
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l N001 - Windscreen wiper motor
l N002 - Windscreen wiper motor (fixed windscreen)
l N004 - Front windscreen wiper water pump
l N005 - Rear windscreen wiper water pump
l N013 - Rear window wiper motor

40-331
 Wiring diagrams

Fig. 2661
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D033 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I039 - Rear screen wiper switch
l I041 - Lights switch
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l N001 - Windscreen wiper motor
l N002 - Windscreen wiper motor (fixed windscreen)

40-332
Wiring diagrams

Fig. 2661
l N004 - Front windscreen wiper water pump
l N005 - Rear windscreen wiper water pump
l N013 - Rear window wiper motor

40-333
 Wiring diagrams

Fig. 2663
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D033 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I039 - Rear screen wiper switch
l I041 - Lights switch
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l N001 - Windscreen wiper motor

40-334
Wiring diagrams

Fig. 2663
l N002 - Windscreen wiper motor (fixed windscreen)
l N004 - Front windscreen wiper water pump
l N005 - Rear windscreen wiper water pump
l N013 - Rear window wiper motor
Table 322
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Bb019 IC/WOD/MM1 fuse 40-586
+15 (3A)
Bb020 Line fuse ISO 11786 40-586
+15 (10A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)

40-335
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bd006 Electric Pump fuse 40-586
+30 (20A)
C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

C011 Battery earth C011

40-652

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D033 Wiring connector for 40-612

roof wiring loom

D033

D033 Wiring connector for 40-611

windscreen wiper
wiring loom
D033

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I005 0.015.0485.4 Starter switch 40-586
I005

40-336
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I039 2.7659.461.0 Rear screen wiper 40-612

switch

I039

I041 Lights switch I041

40-586

I080 Windscreen wiper 40-612

switch

I080

I081 Windscreen washer 40-612

pump switch

I081

J001 Windscreen wiper 40-612

relay
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
N001 Windscreen wiper 40-611
motor
N002 Windscreen wiper 40-611
motor (fixed wind-
screen)
N004 Front windscreen 40-586
wiper water pump
N004

40-337
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
N005 Rear windscreen 40-586
wiper water pump
N005

N013 Rear window wiper 40-612

motor

40.3.14 - S008 - Instrument panel (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)

I005 Jc001 I041 I040 Jf001 Je006 K037

30 +
50 15
C006 C003
-

50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006

Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A

D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005
0.020.2857.4/10
0.020.3229.4/30

B001
150A

1 3 5 88 70 27 2 4 6
-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI

C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2665
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)

40-338
Wiring diagrams
I005 Jc001 I041 I040 Jf001 Je006 K037
30

+
50 15
C006 C003

-
50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006
Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A
D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005

0.020.2857.4/10
0.020.3229.4/30
B001
150A

1 3 5 88 70 27 2 4 6

-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI
C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2665
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom

40-339
 Wiring diagrams
I005 Jc001 I041 I040 Jf001 Je006 K037
30

+
50 15
C006 C003

-
50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006
Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A
D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005

0.020.2857.4/10
0.020.3229.4/30
B001
150A

1 3 5 88 70 27 2 4 6

-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI
C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2665
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector

40-340
Wiring diagrams
I005 Jc001 I041 I040 Jf001 Je006 K037
30

+
50 15
C006 C003

-
50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006
Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A
D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005

0.020.2857.4/10
0.020.3229.4/30
B001
150A

1 3 5 88 70 27 2 4 6

-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI
C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2665
l R002 - Diagnostics socket in cab

40-341
 Wiring diagrams

M005 E007 E008

M001
R002

.
H007
W

T CLUS .

AIR FI LTER OBSTRUC

OI L ENGINE PRESSUR
SE R VICE PRESS S

AT O R
II TRAILER LIGHT

ISO(Dig)-RX(Preh)
II TRAILER LIGHT
I TRAILER LIGHT

PRE-HE ATIN G

TRAILER PRESS.
I TRAILER LIGHT

HYDR./TRANSM.
FUE L LEVE L

FUE L LIGH T
HAND BRAKE

P.B.SIGNA L
DIRECTIONS

DIRECTIONS
INSTRUMEN

SE R VIC E

D+ GENER
HPB PREX

+12V(+30)
+15 HLHP

+12V(+30)
C005 C007 C009 C004

+58
-31

-31
+30

+30

+30

+15
-31
-31
-31

-31

-31

58 16 1 3 5 2 4 6 1 2 10 1 2 1 2 3 5 10 12 11 1 8 13 15 21 8 14 22 26 15 21 6 12 4 18 19 5 20

Bc004 Bb008 Ba001

3A

3A
20A

B8 C5 C7 C8 C4 A7 A1 C6 A6 D025B
B8 C5 C7 C8 C4 A7 A1 C6 A6

2 1 D040 7 13 D028 5 4 D023 2 D024

2 2 1 3 1 2 1 1
2 1
C002 7 13 5 4 2

K035 K010 K043 K038 P028

0.016.1001.4/20

0.019.3870.4/10

0.019.3018.4/30
A001
2 1 2 1 1 2 2 1

L002 F0 11 F016 K016

Fig. 2669
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom

40-342
Wiring diagrams

M005 E007 E008

M001
R002

.
H007
W

T CLUS .

AIR FI LTER OBSTRUC

OI L ENGINE PRESSUR
SE R VICE PRESS S

AT O R
II TRAILER LIGHT

ISO(Dig)-RX(Preh)
II TRAILER LIGHT
I TRAILER LIGHT

PRE-HE ATIN G

TRAILER PRESS.
I TRAILER LIGHT

HYDR./TRANSM.
FUE L LEVE L

FUE L LIGH T
HAND BRAKE

P.B.SIGNA L
DIRECTIONS

DIRECTIONS
INSTRUMEN

SE R VIC E

D+ GENER
HPB PREX

+12V(+30)
+15 HLHP

+12V(+30)
C005 C007 C009 C004

+58
-31

-31
+30

+30

+30

+15
-31
-31
-31

-31

-31

58 16 1 3 5 2 4 6 1 2 10 1 2 1 2 3 5 10 12 11 1 8 13 15 21 8 14 22 26 15 21 6 12 4 18 19 5 20

Bc004 Bb008 Ba001

3A

3A
20A

B8 C5 C7 C8 C4 A7 A1 C6 A6 D025B
B8 C5 C7 C8 C4 A7 A1 C6 A6

2 1 D040 7 13 D028 5 4 D023 2 D024

2 2 1 3 1 2 1 1
2 1
C002 7 13 5 4 2

K035 K010 K043 K038 P028

0.016.1001.4/20

0.019.3870.4/10

0.019.3018.4/30
A001
2 1 2 1 1 2 2 1

L002 F0 11 F016 K016

Fig. 2669
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor

40-343
 Wiring diagrams

M005 E007 E008

M001
R002

.
H007
W

T CLUS .

AIR FI LTER OBSTRUC

OI L ENGINE PRESSUR
SE R VICE PRESS S

AT O R
II TRAILER LIGHT

ISO(Dig)-RX(Preh)
II TRAILER LIGHT
I TRAILER LIGHT

PRE-HE ATIN G

TRAILER PRESS.
I TRAILER LIGHT

HYDR./TRANSM.
FUE L LEVE L

FUE L LIGH T
HAND BRAKE

P.B.SIGNA L
DIRECTIONS

DIRECTIONS
INSTRUMEN

SE R VIC E

D+ GENER
HPB PREX

+12V(+30)
+15 HLHP

+12V(+30)
C005 C007 C009 C004

+58
-31

-31
+30

+30

+30

+15
-31
-31
-31

-31

-31

58 16 1 3 5 2 4 6 1 2 10 1 2 1 2 3 5 10 12 11 1 8 13 15 21 8 14 22 26 15 21 6 12 4 18 19 5 20

Bc004 Bb008 Ba001

3A

3A
20A

B8 C5 C7 C8 C4 A7 A1 C6 A6 D025B
B8 C5 C7 C8 C4 A7 A1 C6 A6

2 1 D040 7 13 D028 5 4 D023 2 D024

2 2 1 3 1 2 1 1
2 1
C002 7 13 5 4 2

K035 K010 K043 K038 P028

0.016.1001.4/20

0.019.3870.4/10

0.019.3018.4/30
A001
2 1 2 1 1 2 2 1

L002 F0 11 F016 K016

Fig. 2669
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-344
Wiring diagrams

Fig. 2672
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom

40-345
 Wiring diagrams

Fig. 2672
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-346
Wiring diagrams

Fig. 2674
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector

40-347
 Wiring diagrams

Fig. 2674
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-348
Wiring diagrams
Table 323
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A001 Alternator “D+” 40-583
A002 +30 Battery 40-654

A002

A003 Battery negative 40-652

A003

A005 Alternator “B+” A005

40-657

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bb017 Engine fuse +15 40-586
(7.5A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-596

C002

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

40-349
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
C007 Grounding point 40-586

C007

C009 Grounding point C009

40-586

D023 Wiring connector for 40-583

front wiring loom
D023

D023 Wiring connector for 40-596

rear wiring loom
D023

D024 Wiring connector for 40-583

front wiring loom D024

D024 Wiring connector for 40-596

rear wiring loom D024

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-596

rear wiring loom D028

40-350
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D040 Wiring connector 40-647
for hydraulic trailer
braking solenoid
valve wiring loom
D040 Wiring connector for 40-596
rear wiring loom D040

D042 Wiring connector 40-654

D042 Wiring connector 40-654
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

F011 2.8039.021.0/10 Rh high beam head- POSITION

-
light
GND

F011

F016 2.8039.022.0/10 LH high beam head- -

light

F016

H007 2.3729.719.0/10 Handbrake 40-586

H007

I005 0.015.0485.4 Starter switch 40-586

I005

40-351
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I040 2.7659.283.0/10 Top/Low work lights I040

40-586
switch
8 1 2 3
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch I041

40-586

Jc001 Start relay (70A - 40-586

12V)
Je006 Trailer braking relay 40-586
Jf001 Sidelights relay 40-586
K010 2.7099.035.0/10 Fuel level sensor 40-596

K010

Pin C: Output

Pin A: +
Pin B: -

K016 Air filter pressure 40-583

sensor
K035 2.7099.960.0 Trailer hydraulic Normally closed 40-596
braking pressure (NC) contact
sensor Switching pressure:
11 bar

40-352
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-586
switch 15 Bar +- 1
Max. operating volt-
age: 24 V
Max. continuous K037

pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

K038 Transmission filter 40-596

sensor

K038

K043 0.020.0800.0 Clogged Pal filter K043

40-596
sensor

L002 Trailer parking brake 40-647

control solenoid
valve
M001 HLHP unit 40-586

M001

M003 ECU control unit 40-596

M005 Control unit USA 40-586

M005

P028 Services connector 40-596

P028

40-353
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
R002 Diagnostics socket 40-586
in cab
R002

40.3.15 - S008 - Instrument panel (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)

I005 Jc001 I041 I040 Jf001 Je006 K037

30

+
50 15
C006 C003

-
50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006

Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A
D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005
0.020.2857.4/10
0.020.3229.4/30

B001
150A

1 3 5 88 70 27 2 4 6
-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI

C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2676
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)

40-354
Wiring diagrams
I005 Jc001 I041 I040 Jf001 Je006 K037
30

+
50 15
C006 C003

-
50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006
Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A
D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005

0.020.2857.4/10
0.020.3229.4/30
B001
150A

1 3 5 88 70 27 2 4 6

-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI
C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2676
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight

40-355
 Wiring diagrams
I005 Jc001 I041 I040 Jf001 Je006 K037
30

+
50 15
C006 C003

-
50 15 30 30 86 85 87 5 10 3 8 2 6 9 7 2 7 8 3 87 86 85 30 87a 87 86 85 30 1 1
0.020.6207.4/20

to S006
to S006

to S006
Bd002 Bd001 Bb002 Bd006 Ba004 Bb017

7,5A
15A

15A

15A
5A
3A

Bb006

7,5A
D043 A6 C1 B8 D025A
A6 C1 B8

D042 A005

0.020.2857.4/10
0.020.3229.4/30
B001
150A

1 3 5 88 70 27 2 4 6

-31

-31

-31
L PR.LAM P
P
+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

+30 ENGINE ECU

PRE-HE ATING LAM

ENGINE OI
C0 11

M003
0.020.6714.4
0.021.1202.4

A006 A002 A003 I031a I031b

B ATTE R Y

D+
B+
G
3 B-

Fig. 2676
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-356
Wiring diagrams

M005 E007 E008

M001
R002

.
H007
W

T CLUS .

AIR FI LTER OBSTRUC

OI L ENGINE PRESSUR
SE R VICE PRESS S

AT O R
II TRAILER LIGHT

ISO(Dig)-RX(Preh)
II TRAILER LIGHT
I TRAILER LIGHT

PRE-HE ATIN G

TRAILER PRESS.
I TRAILER LIGHT

HYDR./TRANSM.
FUE L LEVE L

FUE L LIGH T
HAND BRAKE

P.B.SIGNA L
DIRECTIONS

DIRECTIONS
INSTRUMEN

SE R VIC E

D+ GENER
HPB PREX

+12V(+30)
+15 HLHP

+12V(+30)
C005 C007 C009 C004

+58
-31

-31
+30

+30

+30

+15
-31
-31
-31

-31

-31

58 16 1 3 5 2 4 6 1 2 10 1 2 1 2 3 5 10 12 11 1 8 13 15 21 8 14 22 26 15 21 6 12 4 18 19 5 20

Bc004 Bb008 Ba001

3A

3A
20A

B8 C5 C7 C8 C4 A7 A1 C6 A6 D025B
B8 C5 C7 C8 C4 A7 A1 C6 A6

2 1 D040 7 13 D028 5 4 D023 2 D024

2 2 1 3 1 2 1 1
2 1
C002 7 13 5 4 2

K035 K010 K043 K038 P028

0.016.1001.4/20

0.019.3870.4/10

0.019.3018.4/30
A001
2 1 2 1 1 2 2 1

L002 F0 11 F016 K016

Fig. 2679
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom

40-357
 Wiring diagrams

M005 E007 E008

M001
R002

.
H007
W

T CLUS .

AIR FI LTER OBSTRUC

OI L ENGINE PRESSUR
SE R VICE PRESS S

AT O R
II TRAILER LIGHT

ISO(Dig)-RX(Preh)
II TRAILER LIGHT
I TRAILER LIGHT

PRE-HE ATIN G

TRAILER PRESS.
I TRAILER LIGHT

HYDR./TRANSM.
FUE L LEVE L

FUE L LIGH T
HAND BRAKE

P.B.SIGNA L
DIRECTIONS

DIRECTIONS
INSTRUMEN

SE R VIC E

D+ GENER
HPB PREX

+12V(+30)
+15 HLHP

+12V(+30)
C005 C007 C009 C004

+58
-31

-31
+30

+30

+30

+15
-31
-31
-31

-31

-31

58 16 1 3 5 2 4 6 1 2 10 1 2 1 2 3 5 10 12 11 1 8 13 15 21 8 14 22 26 15 21 6 12 4 18 19 5 20

Bc004 Bb008 Ba001

3A

3A
20A

B8 C5 C7 C8 C4 A7 A1 C6 A6 D025B
B8 C5 C7 C8 C4 A7 A1 C6 A6

2 1 D040 7 13 D028 5 4 D023 2 D024

2 2 1 3 1 2 1 1
2 1
C002 7 13 5 4 2

K035 K010 K043 K038 P028

0.016.1001.4/20

0.019.3870.4/10

0.019.3018.4/30
A001
2 1 2 1 1 2 2 1

L002 F0 11 F016 K016

Fig. 2679
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor

40-358
Wiring diagrams

M005 E007 E008

M001
R002

.
H007
W

T CLUS .

AIR FI LTER OBSTRUC

OI L ENGINE PRESSUR
SE R VICE PRESS S

AT O R
II TRAILER LIGHT

ISO(Dig)-RX(Preh)
II TRAILER LIGHT
I TRAILER LIGHT

PRE-HE ATIN G

TRAILER PRESS.
I TRAILER LIGHT

HYDR./TRANSM.
FUE L LEVE L

FUE L LIGH T
HAND BRAKE

P.B.SIGNA L
DIRECTIONS

DIRECTIONS
INSTRUMEN

SE R VIC E

D+ GENER
HPB PREX

+12V(+30)
+15 HLHP

+12V(+30)
C005 C007 C009 C004

+58
-31

-31
+30

+30

+30

+15
-31
-31
-31

-31

-31

58 16 1 3 5 2 4 6 1 2 10 1 2 1 2 3 5 10 12 11 1 8 13 15 21 8 14 22 26 15 21 6 12 4 18 19 5 20

Bc004 Bb008 Ba001

3A

3A
20A

B8 C5 C7 C8 C4 A7 A1 C6 A6 D025B
B8 C5 C7 C8 C4 A7 A1 C6 A6

2 1 D040 7 13 D028 5 4 D023 2 D024

2 2 1 3 1 2 1 1
2 1
C002 7 13 5 4 2

K035 K010 K043 K038 P028

0.016.1001.4/20

0.019.3870.4/10

0.019.3018.4/30
A001
2 1 2 1 1 2 2 1

L002 F0 11 F016 K016

Fig. 2679
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-359
 Wiring diagrams

Fig. 2682
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom

40-360
Wiring diagrams

Fig. 2682
l D042 - Wiring connector
l D042 - Wiring connector
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-361
 Wiring diagrams

Fig. 2684
l A001 - Alternator “D+”
l A002 - +30 Battery
l A003 - Battery negative
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C009 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom
l D042 - Wiring connector
l D042 - Wiring connector

40-362
Wiring diagrams

Fig. 2684
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l F011 - RH high beam headlight
l F016 - LH high beam headlight
l H007 - Handbrake
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I040 - Top/Low work lights switch
l I041 - Lights switch
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K010 - Fuel level sensor
l K016 - Air pressure sensor
l K035 - Trailer hydraulic braking pressure sensor
l K037 - Handbrake pressure switch
l K038 - Transmission filter sensor
l K043 - Clogged Pal filter sensor
l L002 - Trailer parking brake control solenoid valve
l M001 - HLHP control unit
l M003 - ECU control unit
l M005 - USA ECU
l P028 - Services connector
l R002 - Diagnostics socket in cab

40-363
 Wiring diagrams
Table 324
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A001 Alternator “D+” 40-583
A002 +30 Battery 40-654

A002

A003 Battery negative 40-652

A003

A005 Alternator “B+” A005

-

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bb017 Engine fuse +15 40-586
(7.5A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-606

C002

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

40-364
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
C007 Grounding point 40-586

C007

C009 Grounding point C009

40-586

D023 Wiring connector for 40-583

front wiring loom
D023

D023 Wiring connector for 40-606

rear wiring loom
D023

D024 Wiring connector for 40-583

front wiring loom D024

D024 Wiring connector for 40-606

rear wiring loom D024

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-606

rear wiring loom D028

40-365
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D040 Wiring connector 40-647
for hydraulic trailer
braking solenoid
valve wiring loom
D040 Wiring connector for 40-606
rear wiring loom D040

D042 Wiring connector 40-654

D042 Wiring connector 40-654
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

F011 2.8039.021.0/10 Rh high beam head- POSITION

-
light
GND

F011

F016 2.8039.022.0/10 LH high beam head- -

light

F016

H007 2.3729.719.0/10 Handbrake 40-586

H007

I005 0.015.0485.4 Starter switch 40-586

I005

40-366
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031a 2.7659.351.0 Battery disconnect 40-652
switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I040 2.7659.283.0/10 Top/Low work lights I040

40-586
switch
8 1 2 3
7 4 5 6

POS. +8 1 3 4 6
0 1
1

-7 2 5

I041 Lights switch I041

40-586

Jc001 Start relay (70A - 40-586

12V)
Je006 Trailer braking relay 40-586
Jf001 Sidelights relay 40-586
K010 2.7099.035.0/10 Fuel level sensor 40-606

K010

Pin C: Output

Pin A: +
Pin B: -

K016 Air filter pressure 40-583

sensor
K035 2.7099.960.0 Trailer hydraulic Normally closed 40-606
braking pressure (NC) contact
sensor Switching pressure:
11 bar

40-367
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-586
switch 15 Bar +- 1
Max. operating volt-
age: 24 V
Max. continuous K037

pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

K038 Transmission filter 40-606

sensor

K038

K043 0.020.0800.0 Clogged Pal filter K043

40-606
sensor

L002 Trailer parking brake 40-647

control solenoid
valve
M001 HLHP unit 40-586

M001

M003 ECU control unit 40-606

M005 Control unit USA 40-586

M005

P028 Services connector 40-606

P028

40-368
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
R002 Diagnostics socket 40-586
in cab
R002

40.3.16 - S009 - Radio

I005 Jc001 Jf001
30
50 15
C006
50 15 30 87 85 86 30 30 85 86 87
0.020.6707.4/20

Bd002 Bd001 Ba004 Bd004 Ba003 Bb014

7,5A
15A
15A

3A

5A

5A
D001
D043 10 11 16

10 11 16

B001
C0 11
150A

0.020.6706.4/20
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 1 2 1 2 4 3 6 5 6 7 4 8 1 2

C013
-
+
-
+

-31
+58

+15

+30
RIGHT F R ONT TWEETER
LEFT F R ONT TWEETER

RIGHT F R ONT TWEETER

LEFT F R ONT TWEETER

B ATTE RY

P0 11 P013 G007

P015

Fig. 2686
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D043 - Wiring connector for battery wiring loom

40-369
 Wiring diagrams
I005 Jc001 Jf001
30
50 15
C006
50 15 30 87 85 86 30 30 85 86 87
0.020.6707.4/20

Bd002 Bd001 Ba004 Bd004 Ba003 Bb014

7,5A
15A
15A

3A

5A

5A
D001
D043 10 11 16

10 11 16

B001
C0 11
150A

0.020.6706.4/20
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 1 2 1 2 4 3 6 5 6 7 4 8 1 2

C013
-
+
-
+

-31
+58

+15

+30
RIGHT F R ONT TWEETER
LEFT F R ONT TWEETER

RIGHT F R ONT TWEETER

LEFT F R ONT TWEETER

B ATTE RY

P0 11 P013 G007

P015

Fig. 2686
l D043 - Wiring connector to cab wiring loom
l G007 - Light in cab
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P011 - LH loudspeaker
l P013 - RH loudspeaker
l P015 - Radio

40-370
Wiring diagrams

Fig. 2688
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l G007 - Light in cab
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P011 - LH loudspeaker
l P013 - RH loudspeaker
l P015 - Radio

40-371
 Wiring diagrams

Fig. 2689
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l G007 - Light in cab
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P011 - LH loudspeaker
l P013 - RH loudspeaker

40-372
Wiring diagrams

Fig. 2689
l P015 - Radio

40-373
 Wiring diagrams

Fig. 2691
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb014 - Radio/amplifier fuse +15 (5A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l G007 - Light in cab
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P011 - LH loudspeaker
l P013 - RH loudspeaker
l P015 - Radio

40-374
Wiring diagrams
Table 325
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba003 Monitor fuse +30 40-586
(15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb014 Trailer braking fuse 40-586
+15 (7.5A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
C011 Battery earth C011
40-652

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
G007 Cab light 40-612

G007

40-375
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
P011 0.013.2161.0 LH loudspeaker 40-612

P011

P013 0.012.1725.0 RH loudspeaker 40-612

P013

P015 Radio 40-612

P015

40-376
Wiring diagrams
40.3.17 - S010 - Manual air conditioner (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
I005 Jc001 Jf001 J005 K015 K017
30
50 15
0.020.2857.4/10
C006 0.020.3229.4/30
50 15 30 87 85 86 30 87 86 85 30 85 30 87 86 1 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 Ba004 Bb0 11 Bd005

7,5A

7,5A
15A

15A

10A
3A

D023
Bc002 6 6
1 1

30A
D025A D024
A8 A8
D1 D1 1 1
A1 A1

0.019.3018.4/30
D001 D002
D043 10 15 13
1

1
10 15 13

C0 11

B001
150A

0.020.6706.4/20
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 1 2 10 11 1 18 5 8 9 6 7 15 16 14 1 2 3 4 6 3 2 4 87 85 86 30

C016 C017
BATTE RY
M

K046 N007 J007

N019
M012

Fig. 2692
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom

40-377
 Wiring diagrams
I005 Jc001 Jf001 J005 K015 K017
30
50 15
0.020.2857.4/10
C006 0.020.3229.4/30
50 15 30 87 85 86 30 87 86 85 30 85 30 87 86 1 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 Ba004 Bb0 11 Bd005

7,5A

7,5A
15A

15A

10A
3A

D023
Bc002 6 6
1 1

30A
D025A D024
A8 A8
D1 D1 1 1
A1 A1

0.019.3018.4/30
D001 D002
D043 10 15 13
1

1
10 15 13

C0 11

B001
150A

0.020.6706.4/20
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 1 2 10 11 1 18 5 8 9 6 7 15 16 14 1 2 3 4 6 3 2 4 87 85 86 30

C016 C017
BATTE RY
M

K046 N007 J007

N019
M012

Fig. 2692
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer

40-378
Wiring diagrams

Fig. 2694
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button

40-379
 Wiring diagrams

Fig. 2694
l I031b - Battery master switch button
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer

40-380
Wiring diagrams

Fig. 2696
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom

40-381
 Wiring diagrams

Fig. 2696
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer

40-382
Wiring diagrams

Fig. 2698
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button

40-383
 Wiring diagrams

Fig. 2698
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer
Table 326
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb011 Power fuse +15 (3A) 40-586
Bc002 Power outlet fuse 40-586
+30 (20A)

40-384
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd005 Steering fuse +30 40-586
(25A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

C016 Grounding point 40-612

C016

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D002 Wiring connector to D002

40-586
cab wiring loom

D002 Wiring connector for 40-612

roof wiring loom
D002

40-385
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D023 Wiring connector for 40-583
front wiring loom
D023

D023 Wiring connector for 40-596

rear wiring loom
D023

D024 Wiring connector for 40-583

front wiring loom D024

D024 Wiring connector for 40-596

rear wiring loom D024

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

40-386
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

J005 Air conditioning 40-586

compressor relay
J007 Right hand air condi- 40-612
tioning fan relay
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
K015 Air conditioning 40-583
pressure switch
K017 Air conditioning 40-583
compressor
M012 Air conditioning con- 40-612
M012

trol unit

N007 Air-conditioning fan 40-612

N007

N019 Temperature control 40-612

valve
N019

40-387
 Wiring diagrams
40.3.18 - S010 - Manual air conditioner (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
I005 Jc001 Jf001 J005 K015 K017
30
50 15
0.020.2857.4/10
C006 0.020.3229.4/30
50 15 30 87 85 86 30 87 86 85 30 85 30 87 86 1 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 Ba004 Bb0 11 Bd005

7,5A

7,5A
15A

15A

10A
3A

D023
Bc002 6 6
1 1

30A
D025A D024
A8 A8
D1 D1 1 1
A1 A1

0.019.3018.4/30
D001 D002
D043 10 15 13
1

1
10 15 13

C0 11

B001
150A

0.020.6706.4/20
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 1 2 10 11 1 18 5 8 9 6 7 15 16 14 1 2 3 4 6 3 2 4 87 85 86 30

C016 C017
BATTE RY
M

K046 N007 J007

N019
M012

Fig. 2700
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom

40-388
Wiring diagrams
I005 Jc001 Jf001 J005 K015 K017
30
50 15
0.020.2857.4/10
C006 0.020.3229.4/30
50 15 30 87 85 86 30 87 86 85 30 85 30 87 86 1 2 1
0.020.6707.4/20

Bd002 Bd001 Bb006 Ba004 Bb0 11 Bd005

7,5A

7,5A
15A

15A

10A
3A

D023
Bc002 6 6
1 1

30A
D025A D024
A8 A8
D1 D1 1 1
A1 A1

0.019.3018.4/30
D001 D002
D043 10 15 13
1

1
10 15 13

C0 11

B001
150A

0.020.6706.4/20
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 1 2 10 11 1 18 5 8 9 6 7 15 16 14 1 2 3 4 6 3 2 4 87 85 86 30

C016 C017
BATTE RY
M

K046 N007 J007

N019
M012

Fig. 2700
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer

40-389
 Wiring diagrams

Fig. 2702
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button

40-390
Wiring diagrams

Fig. 2702
l I031b - Battery master switch button
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer

40-391
 Wiring diagrams

Fig. 2704
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom

40-392
Wiring diagrams

Fig. 2704
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer

40-393
 Wiring diagrams

Fig. 2706
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb011 - AC system fuse +15 (7.5A)
l Bc002 - Fan fuse +30 (30A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l C006 - Grounding point
l C011 - Grounding point
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button

40-394
Wiring diagrams

Fig. 2706
l J005 - Air conditioning compressor relay
l J007 - AC system fan relay
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K015 - Air conditioning pressure switch
l K017 - Air conditioning compressor
l K046 - Evaporator sensor
l M012 - A/C control unit
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer
Table 327
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb011 Power fuse +15 (3A) 40-586
Bc002 Power outlet fuse 40-586
+30 (20A)

40-395
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd005 Steering fuse +30 40-586
(25A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

C016 Grounding point 40-612

C016

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D002 Wiring connector to D002

40-586
cab wiring loom

D002 Wiring connector for 40-612

roof wiring loom
D002

40-396
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D023 Wiring connector for 40-583
front wiring loom
D023

D023 Wiring connector for 40-606

rear wiring loom
D023

D024 Wiring connector for 40-583

front wiring loom D024

D024 Wiring connector for 40-606

rear wiring loom D024

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

40-397
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

J005 Air conditioning 40-586

compressor relay
J007 Right hand air condi- 40-612
tioning fan relay
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
K015 Air conditioning 40-583
pressure switch
K017 Air conditioning 40-583
compressor
M012 Air conditioning con- 40-612
M012

trol unit

N007 Air-conditioning fan 40-612

N007

N019 Temperature control 40-612

valve
N019

40-398
Wiring diagrams
40.3.19 - S011 - Transmission (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 E008 H001 I082

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1
0.020.6707.4/20

to S005 Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012

7,5A
7,5A

20A
15A

3A

5A

15A

D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B

C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002
0.020.3229.4/30
0.020.2857.4/20

1 2 3
0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 3 2 1 2 1
WHEE L SPEE D

+15

GNDCOM
GNDCOM

GESR OIL TEMP

3 1 4 2 2 4 1 3
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 1 2 1 2 1 2

A006 A003 I031a I031b I071 I070 K004
BATTE RY
L021 L022 L023

Fig. 2708
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D078 - Wiring connector for rear wiring loom

40-399
 Wiring diagrams
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 E008 H001 I082

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1
0.020.6707.4/20

to S005
Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012

7,5A
7,5A

20A
15A

3A

5A

15A

D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B

C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002
0.020.3229.4/30
0.020.2857.4/20

1 2 3
0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 3 2 1 2 1
WHEE L SPEE D

+15

GNDCOM
GNDCOM

GESR OIL TEMP

3 1 4 2 2 4 1 3
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 1 2 1 2 1 2

A006 A003 I031a I031b I071 I070 K004
BATTE RY
L021 L022 L023

Fig. 2708
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve

40-400
Wiring diagrams
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 E008 H001 I082

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1
0.020.6707.4/20

to S005
Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012

7,5A
7,5A

20A
15A

3A

5A

15A

D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B

C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002
0.020.3229.4/30
0.020.2857.4/20

1 2 3
0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 3 2 1 2 1
WHEE L SPEE D

+15

GNDCOM
GNDCOM

GESR OIL TEMP

3 1 4 2 2 4 1 3
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 1 2 1 2 1 2

A006 A003 I031a I031b I071 I070 K004
BATTE RY
L021 L022 L023

Fig. 2708
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-401
 Wiring diagrams

Fig. 2711
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom

40-402
Wiring diagrams

Fig. 2711
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve

40-403
 Wiring diagrams

Fig. 2711
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-404
Wiring diagrams

Fig. 2714
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever

40-405
 Wiring diagrams

Fig. 2714
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-406
Wiring diagrams
Table 328
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb007 Climate control fuse 40-586
+15 (20A)
Bb012 Lights Gen fuse +15 40-586
(5A)
Bc004 HLHP2 control unit 40-586
fuse +30 (20 A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP2 control unit 40-586
fuse +30 (20A)
C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

40-407
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector for 40-596
rear wiring loom D025

D026 Wiring connector to 40-586

cab wiring loom

D026

D026 Wiring connector for 40-596

rear wiring loom
D026

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D078 Wiring connector for 40-596
rear wiring loom
D078

D078 Wiring connector for 40-648

wiring loom 7/8

D078

D079 Wiring connector for 40-596

rear wiring loom
D079 Wiring connector for
wiring loom 100/110
HP
D080 Wiring connector for 40-596
rear wiring loom
D080 Wiring connector for
wiring loom 100/110
HP
E008 Instrument panel E008
40-586

H001 H/L selection lever 40-586

H001

40-408
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I070 Dual traction activa- 40-620

tion push button
I071 2.7659.416.0 Differential lock acti- 40-620
vation switch
I082 Distributor 7/8 switch 40-586
I082

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
K003 2.7099.999.0 HML speed sensor

K003

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-596

sor checked using an
ordinary tester; use
the ART. K004

K012 Gearbox output K012

40-596
shaft speed sensor

40-409
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K013 2.7099.690.0/10 Transmission oil Normally closed 40-596
temperature sensor (NC) contact
Switching pressure:
4 Bar
L007 Differential lock con- 40-596
trol solenoid valve

L007

L010 “High” range sole-

noid valve

L010

L011 “Medium” range so-

lenoid valve

L011

L012 “Low” range sole-

noid valve

L012

L013 Reverse proportion-

al solenoid valve
L013

L014 Forward drive sole-

noid valve
L014

L020 Four-wheel drive so- 40-596

lenoid valve
L020

L021 Solenoid valve SV 1 40-648

L021

L022 Solenoid valve SV 2 40-648

L022

40-410
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
L023 COM SV solenoid L023
40-648
valve

L024 R solenoid valve

L024

M001 HLHP2 ECU 40-586

M001

40-411
 Wiring diagrams
40.3.20 - S011 - Transmission (5100 C -> ZKDY480200TD10001)
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 E008 H001 I082

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1
0.020.6707.4/20

to S005
Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012

7,5A
7,5A

20A
15A

3A

5A

15A

D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B

C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002
0.020.3229.4/30
0.020.2857.4/20

1 2 3
0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 3 2 1 2 1
WHEE L SPEE D

+15

GNDCOM
GNDCOM

GESR OIL TEMP

3 1 4 2 2 4 1 3
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 1 2 1 2 1 2

A006 A003 I031a I031b I071 I070 K004
BATTE RY
L021 L022 L023

Fig. 2716
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8

40-412
Wiring diagrams
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 E008 H001 I082

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1
0.020.6707.4/20

to S005
Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012

7,5A
7,5A

20A
15A

3A

5A

15A

D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B

C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002
0.020.3229.4/30
0.020.2857.4/20

1 2 3
0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 3 2 1 2 1
WHEE L SPEE D

+15

GNDCOM
GNDCOM

GESR OIL TEMP

3 1 4 2 2 4 1 3
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 1 2 1 2 1 2

A006 A003 I031a I031b I071 I070 K004
BATTE RY
L021 L022 L023

Fig. 2716
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve

40-413
 Wiring diagrams
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 E008 H001 I082

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1
0.020.6707.4/20

to S005
Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012

7,5A
7,5A

20A
15A

3A

5A

15A

D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B

C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002
0.020.3229.4/30
0.020.2857.4/20

1 2 3
0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 3 2 1 2 1
WHEE L SPEE D

+15

GNDCOM
GNDCOM

GESR OIL TEMP

3 1 4 2 2 4 1 3
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 1 2 1 2 1 2

A006 A003 I031a I031b I071 I070 K004
BATTE RY
L021 L022 L023

Fig. 2716
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-414
Wiring diagrams

Fig. 2719
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom

40-415
 Wiring diagrams

Fig. 2719
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve

40-416
Wiring diagrams

Fig. 2719
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-417
 Wiring diagrams

Fig. 2722
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever

40-418
Wiring diagrams

Fig. 2722
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-419
 Wiring diagrams
Table 329
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb007 Climate control fuse 40-586
+15 (20A)
Bb012 Lights Gen fuse +15 40-586
(5A)
Bc004 HLHP2 control unit 40-586
fuse +30 (20 A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP2 control unit 40-586
fuse +30 (20A)
C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

40-420
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector for 40-606
rear wiring loom D025

D026 Wiring connector to 40-586

cab wiring loom

D026

D026 Wiring connector for 40-606

rear wiring loom
D026

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D078 Wiring connector for 40-606
rear wiring loom
D078

D078 Wiring connector for 40-648

wiring loom 7/8

D078

D079 Wiring connector for 40-606

rear wiring loom
D079 Wiring connector for
wiring loom 100/110
HP
D080 Wiring connector for 40-606
rear wiring loom
D080 Wiring connector for
wiring loom 100/110
HP
E008 Instrument panel E008
40-586

H001 H/L selection lever 40-586

H001

40-421
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I070 Dual traction activa- 40-620

tion push button
I071 2.7659.416.0 Differential lock acti- 40-620
vation switch
I082 Distributor 7/8 switch 40-586
I082

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
K003 2.7099.999.0 HML speed sensor

K003

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-606

sor checked using an
ordinary tester; use
the ART. K004

K012 Gearbox output K012

40-606
shaft speed sensor

40-422
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K013 2.7099.690.0/10 Transmission oil Normally closed 40-606
temperature sensor (NC) contact
Switching pressure:
4 Bar
L007 Differential lock con- 40-606
trol solenoid valve

L007

L010 “High” range sole-

noid valve

L010

L011 “Medium” range so-

lenoid valve

L011

L012 “Low” range sole-

noid valve

L012

L013 Reverse proportion-

al solenoid valve
L013

L014 Forward drive sole-

noid valve
L014

L020 Four-wheel drive so- 40-606

lenoid valve
L020

L021 Solenoid valve SV 1 40-648

L021

L022 Solenoid valve SV 2 40-648

L022

40-423
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
L023 COM SV solenoid L023
40-648
valve

L024 R solenoid valve

L024

M001 HLHP2 ECU 40-586

M001

40-424
Wiring diagrams
40.3.21 - S011 - Transmission (5110 C -> ZKDY520200TD10001, 5120 C -> ZK-
DY560200TD10001)
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 H001 I082 L010 L0 11 L012
E008

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1 2 1 2 1 2 1
0.020.6707.4/20

to S005

Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012 D026

7,5A

B4 B2 A2 A3 A4 A5 A6 B3 B7 B8
B4 B2 A2 A3 A4 A5 A6 B3 B7 B8
7,5A

20A
15A

3A

5A

15A

N.C.
D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B
C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002 D079 2 1 1 2 D080

0.020.3229.4/30
0.020.2857.4/20

1 2 3 2 1 1 2
0.020.7971.4/10

0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 1 2 3 3 2 1 2 1 2 1
WHEE L SPEE D

GESR OI L TEM P
+15

+15
R

GNDCOM

GNDCOM

GNDCOM

GS 110C V
120CV
3 1 4 2 2 4 1 3
HM L SPEED SENSO
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 K012 1 2 1 2 1 2 2 1 1 2

A006 A003 I031a I031b I071 I070 K003 K004
BATTE RY
L021 L022 L023 L014 L024

Fig. 2724
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D078 - Wiring connector for rear wiring loom

40-425
 Wiring diagrams
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 H001 I082 L010 L0 11 L012
E008

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1 2 1 2 1 2 1
0.020.6707.4/20

to S005 Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012 D026

7,5A

B4 B2 A2 A3 A4 A5 A6 B3 B7 B8
B4 B2 A2 A3 A4 A5 A6 B3 B7 B8
7,5A

20A
15A

3A

5A

15A

N.C.
D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B
C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002 D079 2 1 1 2 D080

0.020.3229.4/30
0.020.2857.4/20

1 2 3 2 1 1 2
0.020.7971.4/10

0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 1 2 3 3 2 1 2 1 2 1
WHEE L SPEE D

GESR OI L TEM P
+15

+15
R

GNDCOM

GNDCOM

GNDCOM

GS 110C V
120CV
3 1 4 2 2 4 1 3
HM L SPEED SENSO
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 K012 1 2 1 2 1 2 2 1 1 2

A006 A003 I031a I031b I071 I070 K003 K004
BATTE RY
L021 L022 L023 L014 L024

Fig. 2724
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve

40-426
Wiring diagrams
M001

INCREMENT/CRUISE CONTROL

L HS
I005

DECREMENT/TC-MODE SW
Jc001 Jf001 H001 I082 L010 L0 11 L012
E008

EPYC. SPEED/WHEE
GESR OI L TEM P
30

+15V HLHP

GND COM

GND COM

GND COM
15 50

DT S W
C006 C005 C009

DF SW

EV DT

EV DF
+30

+30

+30
-31

-31

-31
30 15 50 87 85 86 30 87 86 85 30 16 25 1 3 4 2 2 4 6 1 3 5 67 68 8 93 94 10 9 31 53 19 7 9 8 10 2 3 1 2 1 2 1 2 1
0.020.6707.4/20

to S005 Bb007

7,5A
Bd002 Bd001 Bb015 Bd004 Ba004 Bc004 Bb012 D026

7,5A

B4 B2 A2 A3 A4 A5 A6 B3 B7 B8
B4 B2 A2 A3 A4 A5 A6 B3 B7 B8
7,5A

20A
15A

3A

5A

15A

N.C.
D043 D015 14-4 12-1 18-17 14-13 14-6 D025A D025B
C8 D2 B3 B2 B3 A2 B1 D5 D6

C8 D2 B3 B2 B3 A2 B1 D5 D6
14-4 12-1 18-17 14-13 14-6

C0 11
B001
150A

D078 1 2 3 C002 D079 2 1 1 2 D080

0.020.3229.4/30
0.020.2857.4/20

1 2 3 2 1 1 2
0.020.7971.4/10

0.020.7971.4/10

0.020.7971.4/10
0.020.6714.4
0.021.1202.4

2 1 1 2 1 2 3 3 2 1 2 1 2 1
WHEE L SPEE D

GESR OI L TEM P
+15

+15
R

GNDCOM

GNDCOM

GNDCOM

GS 110C V
120CV
3 1 4 2 2 4 1 3
HM L SPEED SENSO
-31

-31
+58

+58
DF SW

DF SW
+15 HLHP1

+15 HLHP1

L020 L007 K013 K012 1 2 1 2 1 2 2 1 1 2

A006 A003 I031a I031b I071 I070 K003 K004
BATTE RY
L021 L022 L023 L014 L024

Fig. 2724
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-427
 Wiring diagrams

Fig. 2727
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom

40-428
Wiring diagrams

Fig. 2727
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve

40-429
 Wiring diagrams

Fig. 2727
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-430
Wiring diagrams

Fig. 2730
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D078 - Wiring connector for rear wiring loom
l D078 - Wiring connector for wiring loom 7/8
l D079 - Wiring connector for rear wiring loom
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for rear wiring loom
l D080 - Wiring connector for wiring loom, 100/110 HP
l E008 - Instrument panel
l H001 - H/L selection lever

40-431
 Wiring diagrams

Fig. 2730
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
l I082 - Distributor 7/8 switch
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l L007 - Differential lock control solenoid valve
l L010 - “High” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L021 - Solenoid valve SV1
l L022 - Solenoid valve SV2
l L023 - COM SV solenoid valve
l L024 - R solenoid valve
l M001 – HLHP2 ECU

40-432
Wiring diagrams
Table 330
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb007 Climate control fuse 40-586
+15 (20A)
Bb012 Lights Gen fuse +15 40-586
(5A)
Bc004 HLHP2 control unit 40-586
fuse +30 (20 A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP2 control unit 40-586
fuse +30 (20A)
C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

40-433
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector for 40-606
rear wiring loom D025

D026 Wiring connector to 40-586

cab wiring loom

D026

D026 Wiring connector for 40-606

rear wiring loom
D026

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D078 Wiring connector for 40-606
rear wiring loom
D078

D078 Wiring connector for 40-648

wiring loom 7/8

D078

D079 Wiring connector for 40-606

rear wiring loom
D079 Wiring connector for
wiring loom 100/110
HP
D080 Wiring connector for 40-606
rear wiring loom
D080 Wiring connector for
wiring loom 100/110
HP
E008 Instrument panel E008
40-586

H001 H/L selection lever 40-586

H001

40-434
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I070 Dual traction activa- 40-620

tion push button
I071 2.7659.416.0 Differential lock acti- 40-620
vation switch
I082 Distributor 7/8 switch 40-586
I082

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
K003 2.7099.999.0 HML speed sensor

K003

1: SIGNAL 2: SUPPLY VOLTAGE

K004 2.7099.996.0 Wheels speed sen- This cannot be 40-606

sor checked using an
ordinary tester; use
the ART. K004

K012 Gearbox output K012

40-606
shaft speed sensor

40-435
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K013 2.7099.690.0/10 Transmission oil Normally closed 40-606
temperature sensor (NC) contact
Switching pressure:
4 Bar
L007 Differential lock con- 40-606
trol solenoid valve

L007

L010 “High” range sole-

noid valve

L010

L011 “Medium” range so-

lenoid valve

L011

L012 “Low” range sole-

noid valve

L012

L013 Reverse proportion-

al solenoid valve
L013

L014 Forward drive sole-

noid valve
L014

L020 Four-wheel drive so- 40-606

lenoid valve
L020

L021 Solenoid valve SV 1 40-648

L021

L022 Solenoid valve SV 2 40-648

L022

40-436
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
L023 COM SV solenoid L023
40-648
valve

L024 R solenoid valve

L024

M001 HLHP2 ECU 40-586

M001

40-437
 Wiring diagrams
40.3.22 - S012 - PTO (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001)
M001
I005 H006 E008

P T O FRON T BUT T ON 1

P T O FRON T BUT T ON 2
Jc001 Jf001

T ON 1

T ON 2
P T O AU T O BUT T O N
TO S W

EV P T O FRON T
30

TO

O
P T O REAR BUT

P T O REAR BUT

P T O SPEE D

COMUNE SW

P T O SYNCR
P T O 100 0
+15V HLHP

EV REAR P

P T O EC O
FENDER P

GND COM

GND COM

GND COM
50 15

P T O 54 0
EV HI/LO
C006 C005 C007

1000
+30

+30

+30

540
-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 89 9 31 53 8 65 35 36 37 38 18 78 81 76 2 4 6 3 1 2 10 11 24 9
0.020.6707.4/20

1 2

1 2
Bd002 Bd001 Bb007 Bb010 Bd004 Ba004 Bc004
7,5A

7,5A

20A
15A

3A
3A

15A

D015 D025B D025A

D043 14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 D3 C2 D4

2 1 3 1 2 3

14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 C002 D3 C2 D4

0.020.2857.4/20
0.020.3229.4/30
I026 I029
0.020.7971.4/10

D023 5 3

B001
C0 11 2 3 4 1 1 6 4 5 3 1 6 4 5 3 1 2 3 2 3 3 2 1 2 2 1

L EC O
150A

5 3

GND COM

GND COM
SELECTION SYNCRO

P T O NORMA
R1000E
R1000
RDIAG

R540E
R540

I061 I062 I063 K006 L003 L025

0.019.3018.4/30
H005 H004

D032 2 1

2 1
0.021.1202.4

0.020.6714.4

0.012.2756.3
A006 A003 I031a I031b
1 2

B ATTE RY

L001

Fig. 2732
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D032 - Wiring connector for front wiring loom

40-438
Wiring diagrams
M001
I005 H006 E008

P T O FRON T BUT T ON 1

P T O FRON T BUT T ON 2
Jc001 Jf001

T ON 1

T ON 2
P T O AU T O BUT T O N
TO S W

EV P T O FRON T
30

TO

O
P T O REAR BUT

P T O REAR BUT

P T O SPEE D

COMUNE SW

P T O SYNCR
P T O 100 0
+15V HLHP

EV REAR P

P T O EC O
FENDER P

GND COM

GND COM

GND COM
50 15

P T O 54 0
EV HI/LO
C006 C005 C007

1000
+30

+30

+30

540
-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 89 9 31 53 8 65 35 36 37 38 18 78 81 76 2 4 6 3 1 2 10 11 24 9
0.020.6707.4/20

1 2

1 2
Bd002 Bd001 Bb007 Bb010 Bd004 Ba004 Bc004
7,5A

7,5A

20A
15A

3A
3A

15A

D015 D025B D025A

D043 14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 D3 C2 D4

2 1 3 1 2 3

14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 C002 D3 C2 D4

0.020.2857.4/20
0.020.3229.4/30
I026 I029
0.020.7971.4/10

D023 5 3

B001
C0 11 2 3 4 1 1 6 4 5 3 1 6 4 5 3 1 2 3 2 3 3 2 1 2 2 1

L EC O
150A

5 3

GND COM

GND COM
SELECTION SYNCRO

P T O NORMA
R1000E
R1000
RDIAG

R540E
R540

I061 I062 I063 K006 L003 L025

0.019.3018.4/30
H005 H004

D032 2 1

2 1
0.021.1202.4

0.020.6714.4

0.012.2756.3
A006 A003 I031a I031b
1 2

B ATTE RY

L001

Fig. 2732
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E008 - Instrument panel
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l H006 - Rear PTO rotation speed selection lever
l I005 - Ignition switch
l I026 - Rear PTO control button
l I029 - Rear PTO control button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I061 - Auto PTO switch
l I062 - Front PTO clutch button
l I063 - Rear PTO clutch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K006 - PTO speed sensor
l L001 - Front PTO control solenoid valve
l L003 - Rear PTO control solenoid valve
l L025 - HI/LO solenoid valve
l M001 - HLHP control unit

40-439
 Wiring diagrams

Fig. 2734
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D032 - Wiring connector for front wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E008 - Instrument panel
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l H006 - Rear PTO rotation speed selection lever

40-440
Wiring diagrams

Fig. 2734
l I005 - Ignition switch
l I026 - Rear PTO control button
l I029 - Rear PTO control button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I061 - Auto PTO switch
l I062 - Front PTO clutch button
l I063 - Rear PTO clutch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K006 - PTO speed sensor
l L001 - Front PTO control solenoid valve
l L003 - Rear PTO control solenoid valve
l L025 - HI/LO solenoid valve
l M001 - HLHP control unit

40-441
 Wiring diagrams

Fig. 2736
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom

40-442
Wiring diagrams

Fig. 2736
l D032 - Wiring connector for front wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E008 - Instrument panel
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l H006 - Rear PTO rotation speed selection lever
l I005 - Ignition switch
l I026 - Rear PTO control button
l I029 - Rear PTO control button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I061 - Auto PTO switch
l I062 - Front PTO clutch button
l I063 - Rear PTO clutch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K006 - PTO speed sensor
l L001 - Front PTO control solenoid valve
l L003 - Rear PTO control solenoid valve

40-443
 Wiring diagrams

Fig. 2736
l L025 - HI/LO solenoid valve
l M001 - HLHP control unit
Table 331
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb007 Climate control fuse 40-586
+15 (20A)

40-444
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
C002 Grounding point 40-596

C002

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D023 Wiring connector for 40-583

front wiring loom
D023

40-445
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D023 Wiring connector for 40-596
rear wiring loom
D023

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D032 Wiring connector for 40-583

front wiring loom
D032

D032 Wiring connector for 40-640

PTO solenoid valve
wiring loom D032

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E008 Instrument panel E008
40-586

H004 Rear PTO rotation 40-596

mode selection lever
(Standard-Econom- H004

ic)

H005 Synchronised rear 40-596

PTO selection lever
H005

H006 Rear PTO rotation 40-586

speed selection le-
ver

H006

40-446
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I026 Rear PTO control I026

40-586
pushbutton

I029 Rear PTO control 40-586

pushbutton
I029

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I061 Automatic PTO con- 40-620

trol switch
I062 0.019.5354.0/10 Front PTO clutch 1 3 40-620
control push button
4 6

4 5

I063 0.019.8573.0/10 Rear PTO clutch 40-620

control push button
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586

40-447
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K006 2.7099.996.0 PTO speed sensor This cannot be 40-596
checked using an
ordinary tester; use
the ART. K006

L001 Front PTO control L001 40-640

solenoid valve

L003 Rear PTO control 40-596

solenoid valve

L003

L025 HI/LO solenoid valve 40-596

L025

M001 HLHP unit 40-586

M001

40-448
Wiring diagrams
40.3.23 - S012 - PTO (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
M001
I005 H006 E008

P T O FRON T BUT T ON 1

P T O FRON T BUT T ON 2
Jc001 Jf001

T ON 1

T ON 2
P T O AU T O BUT T O N
TO S W

EV P T O FRON T
30

TO

O
P T O REAR BUT

P T O REAR BUT

P T O SPEE D

COMUNE SW

P T O SYNCR
P T O 100 0
+15V HLHP

EV REAR P

P T O EC O
FENDER P

GND COM

GND COM

GND COM
50 15

P T O 54 0
EV HI/LO
C006 C005 C007

1000
+30

+30

+30

540
-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 89 9 31 53 8 65 35 36 37 38 18 78 81 76 2 4 6 3 1 2 10 11 24 9
0.020.6707.4/20

1 2

1 2
Bd002 Bd001 Bb007 Bb010 Bd004 Ba004 Bc004
7,5A

7,5A

20A
15A

3A
3A

15A

D015 D025B D025A

D043 14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 D3 C2 D4

2 1 3 1 2 3

14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 C002 D3 C2 D4

0.020.2857.4/20
0.020.3229.4/30
I026 I029
0.020.7971.4/10

D023 5 3

B001
C0 11 2 3 4 1 1 6 4 5 3 1 6 4 5 3 1 2 3 2 3 3 2 1 2 2 1

L EC O
150A

5 3

GND COM

GND COM
SELECTION SYNCRO

P T O NORMA
R1000E
R1000
RDIAG

R540E
R540

I061 I062 I063 K006 L003 L025

0.019.3018.4/30
H005 H004

D032 2 1

2 1
0.021.1202.4

0.020.6714.4

0.012.2756.3
A006 A003 I031a I031b
1 2

B ATTE RY

L001

Fig. 2739
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D032 - Wiring connector for front wiring loom

40-449
 Wiring diagrams
M001
I005 H006 E008

P T O FRON T BUT T ON 1

P T O FRON T BUT T ON 2
Jc001 Jf001

T ON 1

T ON 2
P T O AU T O BUT T O N
TO S W

EV P T O FRON T
30

TO

O
P T O REAR BUT

P T O REAR BUT

P T O SPEE D

COMUNE SW

P T O SYNCR
P T O 100 0
+15V HLHP

EV REAR P

P T O EC O
FENDER P

GND COM

GND COM

GND COM
50 15

P T O 54 0
EV HI/LO
C006 C005 C007

1000
+30

+30

+30

540
-31

-31

-31
50 15 30 87 85 86 30 87 86 85 30 1 3 5 89 9 31 53 8 65 35 36 37 38 18 78 81 76 2 4 6 3 1 2 10 11 24 9
0.020.6707.4/20

1 2

1 2
Bd002 Bd001 Bb007 Bb010 Bd004 Ba004 Bc004
7,5A

7,5A

20A
15A

3A
3A

15A

D015 D025B D025A

D043 14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 D3 C2 D4

2 1 3 1 2 3

14-13 14-3 14-14 12-6 12-7 12-8 12-9 12-1 B1 A4 B3 C3 C2 C002 D3 C2 D4

0.020.2857.4/20
0.020.3229.4/30
I026 I029
0.020.7971.4/10

D023 5 3

B001
C0 11 2 3 4 1 1 6 4 5 3 1 6 4 5 3 1 2 3 2 3 3 2 1 2 2 1

L EC O
150A

5 3

GND COM

GND COM
SELECTION SYNCRO

P T O NORMA
R1000E
R1000
RDIAG

R540E
R540

I061 I062 I063 K006 L003 L025

0.019.3018.4/30
H005 H004

D032 2 1

2 1
0.021.1202.4

0.020.6714.4

0.012.2756.3
A006 A003 I031a I031b
1 2

B ATTE RY

L001

Fig. 2739
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E008 - Instrument panel
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l H006 - Rear PTO rotation speed selection lever
l I005 - Ignition switch
l I026 - Rear PTO control button
l I029 - Rear PTO control button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I061 - Auto PTO switch
l I062 - Front PTO clutch button
l I063 - Rear PTO clutch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K006 - PTO speed sensor
l L001 - Front PTO control solenoid valve
l L003 - Rear PTO control solenoid valve
l L025 - HI/LO solenoid valve
l M001 - HLHP control unit

40-450
Wiring diagrams

Fig. 2741
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D032 - Wiring connector for front wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E008 - Instrument panel
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l H006 - Rear PTO rotation speed selection lever

40-451
 Wiring diagrams

Fig. 2741
l I005 - Ignition switch
l I026 - Rear PTO control button
l I029 - Rear PTO control button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I061 - Auto PTO switch
l I062 - Front PTO clutch button
l I063 - Rear PTO clutch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K006 - PTO speed sensor
l L001 - Front PTO control solenoid valve
l L003 - Rear PTO control solenoid valve
l L025 - HI/LO solenoid valve
l M001 - HLHP control unit

40-452
Wiring diagrams

Fig. 2743
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom

40-453
 Wiring diagrams

Fig. 2743
l D032 - Wiring connector for front wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E008 - Instrument panel
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l H006 - Rear PTO rotation speed selection lever
l I005 - Ignition switch
l I026 - Rear PTO control button
l I029 - Rear PTO control button
l I031a - Battery master switch button
l I031b - Battery master switch button
l I061 - Auto PTO switch
l I062 - Front PTO clutch button
l I063 - Rear PTO clutch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l K006 - PTO speed sensor
l L001 - Front PTO control solenoid valve
l L003 - Rear PTO control solenoid valve

40-454
Wiring diagrams

Fig. 2743
l L025 - HI/LO solenoid valve
l M001 - HLHP control unit
Table 332
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb007 Climate control fuse 40-586
+15 (20A)

40-455
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
C002 Grounding point 40-606

C002

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D023 Wiring connector for 40-583

front wiring loom
D023

40-456
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D023 Wiring connector for 40-606
rear wiring loom
D023

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D032 Wiring connector for 40-583

front wiring loom
D032

D032 Wiring connector for 40-640

PTO solenoid valve
wiring loom D032

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E008 Instrument panel E008
40-586

H004 Rear PTO rotation 40-606

mode selection lever
(Standard-Econom- H004

ic)

H005 Synchronised rear 40-606

PTO selection lever
H005

H006 Rear PTO rotation 40-586

speed selection le-
ver

H006

40-457
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I026 Rear PTO control I026

40-586
pushbutton

I029 Rear PTO control 40-586

pushbutton
I029

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I061 Automatic PTO con- 40-620

trol switch
I062 0.019.5354.0/10 Front PTO clutch 1 3 40-620
control push button
4 6

4 5

I063 0.019.8573.0/10 Rear PTO clutch 40-620

control push button
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586

40-458
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
K006 2.7099.996.0 PTO speed sensor This cannot be 40-606
checked using an
ordinary tester; use
the ART. K006

L001 Front PTO control L001 40-640

solenoid valve

L003 Rear PTO control 40-606

solenoid valve

L003

L025 HI/LO solenoid valve 40-606

L025

M001 HLHP unit 40-586

M001

40-459
 Wiring diagrams
40.3.24 - S013 - Accessories (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
I005 H023 Jc001 P006 P010 Jf001 P029 P007
30

+30 LIGHTER
50 15
C009 C006 C007

+12V
+58
-31

-31
50 15 30 2 6 1 87 85 86 30 1 2 1 1 2 87 85 86 30 1 2 2 1 3
0.020.6707.4/20

Bd002 Ba006 Bd001 Bb013 Ba009 Bd004 Bd006 Ba004 Bb005 Bc008

15A
7,5A

7,5A
7,5A

7,5A
5A
15A

15A

15A
3A

D043 D025B B5 10
D001

B5 10

B001

D028
150A

16 1

C0 11 16 1
C002 0.020.2857.4/10
0.020.3229.4/30
0.019.5702.4/10

0.020.6706.4/20
0.019.9803.4
0.021.1202.4

0.020.6714.4

1 2 2 1 2 1 2 1

C013

A006 A003 I031a I031b

E004 F025 F026 F027
B ATTE R Y

Fig. 2746
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom

40-460
Wiring diagrams
I005 H023 Jc001 P006 P010 Jf001 P029 P007
30

+30 LIGHTER
50 15
C009 C006 C007

+12V
+58
-31

-31
50 15 30 2 6 1 87 85 86 30 1 2 1 1 2 87 85 86 30 1 2 2 1 3
0.020.6707.4/20

Bd002 Ba006 Bd001 Bb013 Ba009 Bd004 Bd006 Ba004 Bb005 Bc008

15A
7,5A

7,5A
7,5A

7,5A
5A
15A

15A

15A
3A

D043 D025B B5 10
D001

B5 10

B001

D028
150A

16 1

C0 11 16 1
C002 0.020.2857.4/10
0.020.3229.4/30
0.019.5702.4/10

0.020.6706.4/20
0.019.9803.4
0.021.1202.4

0.020.6714.4

1 2 2 1 2 1 2 1

C013

A006 A003 I031a I031b

E004 F025 F026 F027
B ATTE R Y

Fig. 2746
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay

40-461
 Wiring diagrams
I005 H023 Jc001 P006 P010 Jf001 P029 P007
30

+30 LIGHTER
50 15
C009 C006 C007

+12V
+58
-31

-31
50 15 30 2 6 1 87 85 86 30 1 2 1 1 2 87 85 86 30 1 2 2 1 3
0.020.6707.4/20

Bd002 Ba006 Bd001 Bb013 Ba009 Bd004 Bd006 Ba004 Bb005 Bc008

15A
7,5A

7,5A
7,5A

7,5A
5A
15A

15A

15A
3A

D043 D025B B5 10
D001

B5 10

B001

D028
150A

16 1

C0 11 16 1
C002 0.020.2857.4/10
0.020.3229.4/30
0.019.5702.4/10

0.020.6706.4/20
0.019.9803.4
0.021.1202.4

0.020.6714.4

1 2 2 1 2 1 2 1

C013

A006 A003 I031a I031b

E004 F025 F026 F027
B ATTE R Y

Fig. 2746
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket

40-462
Wiring diagrams

Fig. 2749
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn

40-463
 Wiring diagrams

Fig. 2749
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P006 - Cigar lighter
l P007 - 25 A socket

40-464
Wiring diagrams

Fig. 2749
l P010 - Socket in cab +12 V
l P029 - Seat socket

40-465
 Wiring diagrams

Fig. 2752
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom

40-466
Wiring diagrams

Fig. 2752
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket

40-467
 Wiring diagrams

Fig. 2754
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom

40-468
Wiring diagrams

Fig. 2754
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay

40-469
 Wiring diagrams

Fig. 2754
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket

Table 333
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Ba006 Radio fuse +30 (5A) 40-586
Ba009 Wolp fuse +30 (10A) 40-586

40-470
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb004 Russia Kit/25A fuse 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-586
Bb013 Wolp fuse +15 (3A) 40-586
Bc008 Not used 40-586
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-596

C002

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D025 Wiring connector to 40-586

cab wiring loom

D025

40-471
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector for 40-596
rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-596

rear wiring loom D028

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D081 Wiring connector for D081
40-596
rear wiring loom

D081 Wiring connector for D081

STOLL wiring loom

D082 Wiring connector to

STOLL wiring loom
D082 Wiring connector for
STOLL wiring loom
E004 2.8419.007.0 Horn -

E004

F025 Left hand ambient F025

40-612
light

F026 Spot light 40-612

F026

F027 Right hand ambient 40-612

F027

light

40-472
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
H023 Lights selector H023
40-586
switch

H024 Single lever Stoll

controller
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I083 Comfort Drive switch -

I084 Hydro Lock switch -
I085 Return to level / 3rd -
function switch
I086 Quick empty / 4th -
function switch
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
P006 Cigarette lighter 40-586

P006

P007 25 A socket 40-586

P007

P010 Socket in cab +12 V 40-586

P010

40-473
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
P029 Seat socket 40-586

P029

40.3.25 - S013 - Accessories (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-

DY520200TD10001, 5120 C -> ZKDY560200TD10001)
I005 H023 Jc001 P006 P010 Jf001 P029 P007
30

+30 LIGHTER
50 15
C009 C006 C007

+12V
+58
-31

-31
50 15 30 2 6 1 87 85 86 30 1 2 1 1 2 87 85 86 30 1 2 2 1 3
0.020.6707.4/20

Bd002 Ba006 Bd001 Bb004 Bb013 Ba009 Bd004 Bd006 Ba004 Bb005 Bc008

15A
7,5A

7,5A

7,5A
7,5A

7,5A
5A
15A

15A

15A
3A

D043 D025B B5 B6 10
D001

B5 B6 10
0.020.2857.4/10
0.020.3229.4/30

B001

D028 D081
150A

16 1 2 1

C0 11 16 1
C002 2 1
0.019.5702.4/10
0.019.9803.4

2 1 D082
2 1
0.017.93 11.4/3 0

1 2
0.020.6706.4/20

E004
0.021.1202.4

0.020.6714.4

1 2 3 3 1 2 6 5 4 1 3 2 2 3 1 4 4 2 3 1 2 1 2 1 2 1

C013

A006 A003 I031a I031b I084 I083 H024 I085 I086

F025 F026 F027
B ATTE R Y

Fig. 2757
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)

40-474
Wiring diagrams
I005 H023 Jc001 P006 P010 Jf001 P029 P007
30

+30 LIGHTER
50 15
C009 C006 C007

+12V
+58
-31

-31
50 15 30 2 6 1 87 85 86 30 1 2 1 1 2 87 85 86 30 1 2 2 1 3
0.020.6707.4/20

Bd002 Ba006 Bd001 Bb004 Bb013 Ba009 Bd004 Bd006 Ba004 Bb005 Bc008

15A
7,5A

7,5A

7,5A
7,5A

7,5A
5A
15A

15A

15A
3A

D043 D025B B5 B6 10
D001

B5 B6 10

0.020.2857.4/10
0.020.3229.4/30
B001

D028 D081
150A

16 1 2 1

C0 11 16 1
C002 2 1
0.019.5702.4/10
0.019.9803.4

2 1 D082
2 1
0.017.93 11.4/3 0

0.020.6706.4/20
1 2

E004
0.021.1202.4

0.020.6714.4

1 2 3 3 1 2 6 5 4 1 3 2 2 3 1 4 4 2 3 1 2 1 2 1 2 1

C013

A006 A003 I031a I031b I084 I083 H024 I085 I086

F025 F026 F027
B ATTE R Y

Fig. 2757
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller

40-475
 Wiring diagrams
I005 H023 Jc001 P006 P010 Jf001 P029 P007
30

+30 LIGHTER
50 15
C009 C006 C007

+12V
+58
-31

-31
50 15 30 2 6 1 87 85 86 30 1 2 1 1 2 87 85 86 30 1 2 2 1 3
0.020.6707.4/20

Bd002 Ba006 Bd001 Bb004 Bb013 Ba009 Bd004 Bd006 Ba004 Bb005 Bc008

15A
7,5A

7,5A

7,5A
7,5A

7,5A
5A
15A

15A

15A
3A

D043 D025B B5 B6 10
D001

B5 B6 10

0.020.2857.4/10
0.020.3229.4/30
B001

D028 D081
150A

16 1 2 1

C0 11 16 1
C002 2 1
0.019.5702.4/10
0.019.9803.4

2 1 D082
2 1
0.017.93 11.4/3 0

0.020.6706.4/20
1 2

E004
0.021.1202.4

0.020.6714.4

1 2 3 3 1 2 6 5 4 1 3 2 2 3 1 4 4 2 3 1 2 1 2 1 2 1

C013

A006 A003 I031a I031b I084 I083 H024 I085 I086

F025 F026 F027
B ATTE R Y

Fig. 2757
l I005 - Ignition switch
l I031a - Battery disconnect switch
l I031b - Battery disconnect switch
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket

40-476
Wiring diagrams

Fig. 2760
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn

40-477
 Wiring diagrams

Fig. 2760
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery disconnect switch
l I031b - Battery disconnect switch
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P006 - Cigar lighter
l P007 - 25 A socket

40-478
Wiring diagrams

Fig. 2760
l P010 - Socket in cab +12 V
l P029 - Seat socket

40-479
 Wiring diagrams

Fig. 2763
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom

40-480
Wiring diagrams

Fig. 2763
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery disconnect switch
l I031b - Battery disconnect switch
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket

40-481
 Wiring diagrams

Fig. 2765
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba006 - High beam headlights fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bc008 - Power socket fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom

40-482
Wiring diagrams

Fig. 2765
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D081 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l E004 - Horn
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l H023 - Lights selector switch
l H024 - Single lever Stoll controller
l I005 - Ignition switch
l I031a - Battery disconnect switch
l I031b - Battery disconnect switch
l I083 - “Comfort Drive” switch
l I084 - “Hydro Lock” switch
l I085 - “Return to level / 3rd function switch”
l I086 - “Quick empty / 4th function switch”
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay

40-483
 Wiring diagrams

Fig. 2765
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket

Table 334
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba004 Front suspension 40-586
fuse +30 (7.5A)
Ba006 Radio fuse +30 (5A) 40-586
Ba009 Wolp fuse +30 (10A) 40-586

40-484
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bb004 Russia Kit/25A fuse 40-586
+15 (7.5A)
Bb005 Seat fuse +15 (15A) 40-586
Bb013 Wolp fuse +15 (3A) 40-586
Bc008 Not used 40-586
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-606

C002

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

C017 Grounding point 40-612

C017

D001 Wiring connector to D001

40-586
cab wiring loom

D001 Wiring connector for 40-612

roof wiring loom

D001

D025 Wiring connector to 40-586

cab wiring loom

D025

40-485
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector for 40-606
rear wiring loom D025

D028 Wiring connector -

for front light wiring D028

loom-horn

D028 Wiring connector for 40-606

rear wiring loom D028

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D081 Wiring connector for D081
40-606
rear wiring loom

D081 Wiring connector for D081

STOLL wiring loom

D082 Wiring connector to

STOLL wiring loom
D082 Wiring connector for
STOLL wiring loom
E004 2.8419.007.0 Horn -

E004

F025 Left hand ambient F025

40-612
light

F026 Spot light 40-612

F026

F027 Right hand ambient 40-612

F027

light

40-486
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
H023 Lights selector H023
40-586
switch

H024 Single lever Stoll

controller
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

I083 Comfort Drive switch 40-642

I084 Hydro Lock switch 40-642
I085 Return to level / 3rd 40-642
function switch
I086 Quick empty / 4th 40-642
function switch
Jc001 Start relay (70A - 40-586
12V)
Jf001 Sidelights relay 40-586
P006 Cigarette lighter 40-586

P006

P007 25 A socket 40-586

P007

P010 Socket in cab +12 V 40-586

P010

40-487
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
P029 Seat socket 40-586

P029

40.3.26 - S014 - CAN BUS (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,
5110 C -> ZKDY440200TD10001)
E007 E008

R001 M001
I005 Jc001

CAN L VEHICL E

CAN L VEHICL E
CAN L VEHICL E

30

CAN H VEHICLE
CAN H VEHICLE

CAN H VEHICLE
CAN L VEHICLE

50 15
C006 C005 C004

+15
+15

+30

+30

+30

-31

-31
-31

-31

-31

-31

50 15 30 30 86 85 87 U V C D 1 3 5 49 50 2 4 6 3 4 2 13 8 14
0.020.6707.4/20

Bd002 Bd001 Bb010 Bc004

15A

20A
3A

3A

Bd009
10A

D015 D0 11 D025A
D043 14-5 14-14 12- 11 12-12
1 2 3 4 A5 A4

1 2 3 4 A5 A4
14-5 14-14 12- 11 12-12

B001
C0 11
150A

0.019.5702.4/10

0.020.2857.4/10
0.020.3229.4/30
0.020.7971.4/10
0.020.6714.4
0.021.1202.4

6 9 11 10 8B 8C 2C 2B 3B 4B 5B 6B 7B 6 2 3 4 5 1 54 76 3 2
-31

-31
+15

+15
CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E
CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE

A006 A003 I031a I031b

M008 P014 120 Ohm

BATTE RY H009 M003 R005 O003

Fig. 2768
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point

40-488
Wiring diagrams
E007 E008

R001 M001
I005 Jc001

CAN L VEHICL E

CAN L VEHICL E
CAN L VEHICL E
30

CAN H VEHICLE
CAN H VEHICLE

CAN H VEHICLE
CAN L VEHICLE
50 15
C006 C005 C004

+15
+15

+30

+30

+30

-31

-31
-31

-31

-31

-31
50 15 30 30 86 85 87 U V C D 1 3 5 49 50 2 4 6 3 4 2 13 8 14
0.020.6707.4/20

Bd002 Bd001 Bb010 Bc004

15A

20A
3A

3A

Bd009

10A
D015 D0 11 D025A
D043 14-5 14-14 12- 11 12-12
1 2 3 4 A5 A4

1 2 3 4 A5 A4
14-5 14-14 12- 11 12-12

B001
C0 11
150A

0.019.5702.4/10

0.020.2857.4/10
0.020.3229.4/30
0.020.7971.4/10
0.020.6714.4
0.021.1202.4

6 9 11 10 8B 8C 2C 2B 3B 4B 5B 6B 7B 6 2 3 4 5 1 54 76 3 2
-31

-31
+15

+15
CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E
CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE
A006 A003 I031a I031b
M008 P014 120 Ohm

BATTE RY H009 M003 R005 O003

Fig. 2768
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H009 - Hitch control console
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 – ECU
l M003 - Deutz-AG engine control unit
l M008 – ISO 11786 socket control unit
l O003 - Resistor, 120 ohm
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostics port

40-489
 Wiring diagrams

Fig. 2770
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H009 - Hitch control console
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 – HLHP2 ECU
l M003 - Deutz-AG engine control unit
l M008 – ISO 11786 socket control unit

40-490
Wiring diagrams

Fig. 2770
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostics port

40-491
 Wiring diagrams

Fig. 2772
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H009 - Hitch control console
l I005 - Ignition switch

40-492
Wiring diagrams

Fig. 2772
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 – HLHP2 ECU
l M003 - Deutz-AG engine control unit
l M008 – ISO 11786 socket control unit
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostics port

40-493
 Wiring diagrams

Fig. 2774
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel

40-494
Wiring diagrams

Fig. 2774
l E008 - Instrument panel
l H009 - Hitch control console
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 – HLHP2 ECU
l M003 - Deutz-AG engine control unit
l M008 – ISO 11786 socket control unit
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostics port

Table 335
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

40-495
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Bb009 Rear hitch fuse +15 40-586
(3A)
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bc004 HLHP2 control unit 40-586
fuse +30 (20 A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
C004 Grounding point C004
40-586

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D011 Wiring connector to 40-586

cab wiring loom
D011

D011 Wiring connector to 40-658

ISO 11786 wiring
loom D011

D015 Wiring connector to 40-586

cab wiring loom
D015

40-496
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D015 Wiring connector for 40-620
console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

H009 Hitch control instru- 40-620

ment panel
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

40-497
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

Jc001 Start relay (70A - 40-586

12V)
M001 HLHP2 ECU 40-586

M001

M003 DEUTZ-AG engine 40-596

control unit
M008 2.8519.148.0 ISO 11786 socket 40-658
control unit

FUSE
15 C8

10A MAX

31 B8

P014 Outlet power and 40-658

signals ISO 11786
R001 CAN Diagnostics R001
40-586
socket

R005 Diagnostics socket 40-596

40-498
Wiring diagrams
40.3.27 - S014 - CAN BUS (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
E007 E008

R001 M001
I005 Jc001

CAN L VEHICL E

CAN L VEHICL E
CAN L VEHICL E
30

CAN H VEHICLE
CAN H VEHICLE

CAN H VEHICLE
CAN L VEHICLE
50 15
C006 C005 C004

+15
+15

+30

+30

+30

-31

-31
-31

-31

-31

-31
50 15 30 30 86 85 87 U V C D 1 3 5 49 50 2 4 6 3 4 2 13 8 14
0.020.6707.4/20

Bd002 Bd001 Bb010 Bc004

15A

20A
3A

3A

Bd009

10A
D015 D0 11 D025A
D043 14-5 14-14 12- 11 12-12
1 2 3 4 A5 A4

1 2 3 4 A5 A4
14-5 14-14 12- 11 12-12

B001
C0 11
150A

0.019.5702.4/10

0.020.2857.4/10
0.020.3229.4/30
0.020.7971.4/10
0.020.6714.4
0.021.1202.4

6 9 11 10 8B 8C 2C 2B 3B 4B 5B 6B 7B 6 2 3 4 5 1 54 76 3 2
-31

-31
+15

+15
CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E
CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE

A006 A003 I031a I031b

M008 P014 120 Ohm

BATTE RY H009 M003 R005 O003

Fig. 2776
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel

40-499
 Wiring diagrams
E007 E008

R001 M001
I005 Jc001

CAN L VEHICL E

CAN L VEHICL E
CAN L VEHICL E
30

CAN H VEHICLE
CAN H VEHICLE

CAN H VEHICLE
CAN L VEHICLE
50 15
C006 C005 C004

+15
+15

+30

+30

+30

-31

-31
-31

-31

-31

-31
50 15 30 30 86 85 87 U V C D 1 3 5 49 50 2 4 6 3 4 2 13 8 14
0.020.6707.4/20

Bd002 Bd001 Bb010 Bc004

15A

20A
3A

3A

Bd009

10A
D015 D0 11 D025A
D043 14-5 14-14 12- 11 12-12
1 2 3 4 A5 A4

1 2 3 4 A5 A4
14-5 14-14 12- 11 12-12

B001
C0 11
150A

0.019.5702.4/10

0.020.2857.4/10
0.020.3229.4/30
0.020.7971.4/10
0.020.6714.4
0.021.1202.4

6 9 11 10 8B 8C 2C 2B 3B 4B 5B 6B 7B 6 2 3 4 5 1 54 76 3 2
-31

-31
+15

+15
CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E

CAN L VEHICL E
CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE

CAN H VEHICLE
A006 A003 I031a I031b
M008 P014 120 Ohm

BATTE RY H009 M003 R005 O003

Fig. 2776
l H009 - Lift control console
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 – HLHP2 ECU
l M003 - Deutz-AG engine control unit
l M008 – ISO 11786 socket control unit
l O003 - Resistor, 120 ohm
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostic socket

40-500
Wiring diagrams

Fig. 2778
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H009 - Lift control console
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 - HLHP control unit
l M003 - ECU control unit
l M008 - ECU ISO 11786 control unit

40-501
 Wiring diagrams

Fig. 2778
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostic socket

40-502
Wiring diagrams

Fig. 2780
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l H009 - Lift control console
l I005 - Ignition switch

40-503
 Wiring diagrams

Fig. 2780
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 - HLHP control unit
l M003 - ECU control unit
l M008 - ECU ISO 11786 control unit
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostic socket

40-504
Wiring diagrams

Fig. 2782
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 – HLHP2 control unit fuse +30 (20 A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel

40-505
 Wiring diagrams

Fig. 2782
l E008 - Instrument panel
l H009 - Lift control console
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 - HLHP control unit
l M003 - ECU control unit
l M008 - ECU ISO 11786 control unit
l P014 - Outlet power and signals ISO 11786
l R001 - CAN diagnostics socket
l R005 - Diagnostic socket

Table 336
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

40-506
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Bb009 Rear lift fuse +15 40-586
(3A)
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bc004 HLHP2 control unit 40-586
fuse +30 (20 A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
C004 Grounding point C004
40-586

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D011 Wiring connector to 40-586

cab wiring loom
D011

D011 Wiring connector to 40-658

ISO 11786 wiring
loom D011

D015 Wiring connector to 40-586

cab wiring loom
D015

40-507
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D015 Wiring connector for 40-620
console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

H009 Lift control instru- 40-620

ment panel
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

40-508
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

Jc001 Start relay (70A - 40-586

12V)
M001 HLHP2 ECU 40-586

M001

M003 DEUTZ-AG engine 40-606

control unit
M008 2.8519.148.0 ISO 11786 socket 40-658
control unit

FUSE
15 C8

10A MAX

31 B8

P014 Outlet power and 40-658

signals ISO 11786
R001 CAN Diagnostics R001
40-586
socket

R005 Diagnostics socket 40-606

40-509
 Wiring diagrams
40.3.28 - S015 – CAN BUS (Engine line) (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
I005 Jc001 R001 O009

CAN L ENGIN E
30 120OHM

CAN H ENGINE
50 15
C006

+15
-31
50 15 30 30 86 85 87 U V L M 3 2
0.020.6707.4/20

Bb008

3A
Bd002 Bd001
15A

3A

D043 A2 A3 D025A
A2 A3

B001
C0 11
150A

C004

0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

2 4 6 1 3 5 75 53
A006 A003 I031a I031b
-31

-31

-31

+30

+30

+30

CAN L ENGIN E
CAN H ENGINE

BATTE RY
M003

Fig. 2784
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M003 - Deutz-AG engine control unit
l O003 - Wiring connector for resistor (120 Ohm)
l O009 - Wiring connector for resistor (120 Ohm)
l R001 - CAN diagnostics socket

40-510
Wiring diagrams

Fig. 2785
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M003 - Deutz-AG engine control unit
l O003 - Wiring connector for resistor (120 Ohm)
l O009 - Wiring connector for resistor (120 Ohm)
l R001 - CAN diagnostics socket

40-511
 Wiring diagrams

Fig. 2786
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M003 - Deutz-AG engine control unit
l O003 - Wiring connector for resistor (120 Ohm)
l O009 - Wiring connector for resistor (120 Ohm)

40-512
Wiring diagrams

Fig. 2786
l R001 - CAN diagnostics socket
Table 337
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

B002 Outlet power fuse 40-596
ISO 11783 (60A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)

40-513
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
C004 Grounding point 40-586
C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)

40-514
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
M003 DEUTZ-AG engine 40-596
control unit
O003 Wiring connector for 40-596
resistor (120 Ohm)
O009 Resistance: 120 40-586
ohm
R001 CAN Diagnostics R001
40-586
socket

40.3.29 - S015 – CAN BUS (Engine line) (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
I005 Jc001 R001 O009

CAN L ENGIN E
30 120OHM

CAN H ENGINE
50 15
C006

+15
-31
50 15 30 30 86 85 87 U V L M 3 2
0.020.6707.4/20

Bb008

3A
Bd002 Bd001
15A

3A

D043 A2 A3 D025A
A2 A3

B001
C0 11
150A

C004
0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

2 4 6 1 3 5 75 53
A006 A003 I031a I031b
-31

-31

-31

+30

+30

+30

CAN L ENGIN E
CAN H ENGINE

BATTE RY
M003

Fig. 2788
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)

40-515
 Wiring diagrams
I005 Jc001 R001 O009

CAN L ENGIN E
30 120OHM

CAN H ENGINE
50 15
C006

+15
-31
50 15 30 30 86 85 87 U V L M 3 2
0.020.6707.4/20

Bb008

3A
Bd002 Bd001
15A

3A

D043 A2 A3 D025A
A2 A3

B001
C0 11
150A

C004

0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

2 4 6 1 3 5 75 53
A006 A003 I031a I031b
-31

-31

-31

+30

+30

+30

CAN L ENGIN E
CAN H ENGINE

BATTE RY
M003

Fig. 2788
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M003 - Deutz-AG engine control unit
l O003 - Wiring connector for resistor (120 Ohm)
l O009 - Wiring connector for resistor (120 Ohm)
l R001 - CAN diagnostics socket

40-516
Wiring diagrams

Fig. 2790
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M003 - Deutz-AG engine control unit
l O003 - Wiring connector for resistor (120 Ohm)
l O009 - Wiring connector for resistor (120 Ohm)
l R001 - CAN diagnostics socket

40-517
 Wiring diagrams

Fig. 2791
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 1 fuse (30 A)
l Bb008 - Cluster fuse +15 (3A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M003 - Deutz-AG engine control unit
l O003 - Wiring connector for resistor (120 Ohm)
l O009 - Wiring connector for resistor (120 Ohm)

40-518
Wiring diagrams

Fig. 2791
l R001 - CAN diagnostics socket
Table 338
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

B002 Outlet power fuse 40-606
ISO 11783 (60A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)

40-519
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
C004 Grounding point 40-586
C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)

40-520
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
M003 DEUTZ-AG engine 40-606
control unit
O003 Wiring connector for 40-606
resistor (120 Ohm)
O009 Resistance: 120 40-586
ohm
R001 CAN Diagnostics R001
40-586
socket

40.3.30 - S016 - Brakes (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001,

5110 C -> ZKDY440200TD10001)
M001
I004 H007 K037

W
I005 Jc001 F008 F010

PARK BRAKE PRESS. S

30

BRAKE SENSOR
50 15
C006 C007 C003 C005

+30

+30

+30

-31
-31

-31
50 15 30 30 86 85 87 2 3 2 1 2 3 2 3 1 58 40 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bb003 Bc004

15A

15A

20A
3A

D045
6
3

Bb008 Ba001
3A

3A

D043 D025B C1
14 15 21 22 26 7 8

C004 C1
-31
P.B.SIGNA L
+15

L LEVE L
+12V(+30)

+12V(+30)

HAND BRAKE

BRAKES OI

E008

B001
C0 11
150A

C002
0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

1 1

A006 A003 I031a I031b

BATTE RY K007

Fig. 2793
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)

40-521
 Wiring diagrams
M001
I004 H007 K037

W
I005 Jc001 F008 F010

PARK BRAKE PRESS. S

30

BRAKE SENSOR
50 15
C006 C007 C003 C005

+30

+30

+30

-31
-31

-31
50 15 30 30 86 85 87 2 3 2 1 2 3 2 3 1 58 40 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bb003 Bc004

15A

15A

20A
3A

D045
6
3

Bb008 Ba001
3A

3A
D043 D025B C1
14 15 21 22 26 7 8

C004 C1

-31
P.B.SIGNA L
+15

L LEVE L
+12V(+30)

+12V(+30)

HAND BRAKE

BRAKES OI
E008

B001
C0 11
150A

C002
0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

1 1

A006 A003 I031a I031b

BATTE RY K007

Fig. 2793
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C003 - Grounding point
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D045 - Wiring connector for trailer wiring loom
l E008 - Instrument panel
l F008 - Sidelight/rear right brake light
l F010 - Sidelight/rear right brake light
l H007 - Handbrake
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K007 - Brake fluid sensor

40-522
Wiring diagrams
M001
I004 H007 K037

W
I005 Jc001 F008 F010

PARK BRAKE PRESS. S

30

BRAKE SENSOR
50 15
C006 C007 C003 C005

+30

+30

+30

-31
-31

-31
50 15 30 30 86 85 87 2 3 2 1 2 3 2 3 1 58 40 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bb003 Bc004

15A

15A

20A
3A

D045
6
3

Bb008 Ba001
3A

3A
D043 D025B C1
14 15 21 22 26 7 8

C004 C1

-31
P.B.SIGNA L
+15

L LEVE L
+12V(+30)

+12V(+30)

HAND BRAKE

BRAKES OI
E008

B001
C0 11
150A

C002
0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

1 1

A006 A003 I031a I031b

BATTE RY K007

Fig. 2793
l K037 - Handbrake pressure switch
l M001 - HLHP control unit

40-523
 Wiring diagrams

Fig. 2796
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C003 - Grounding point
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D045 - Wiring connector for trailer wiring loom
l E008 - Instrument panel
l F008 - Sidelight/rear right brake light
l F010 - Sidelight/rear right brake light
l H007 - Handbrake
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)

40-524
Wiring diagrams

Fig. 2796
l K007 - Brake fluid sensor
l K037 - Handbrake pressure switch
l M001 - HLHP control unit

40-525
 Wiring diagrams

Fig. 2798
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C003 - Grounding point
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D045 - Wiring connector for trailer wiring loom

40-526
Wiring diagrams

Fig. 2798
l E008 - Instrument panel
l F008 - Sidelight/rear right brake light
l F010 - Sidelight/rear right brake light
l H007 - Handbrake
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K007 - Brake fluid sensor
l K037 - Handbrake pressure switch
l M001 - HLHP control unit

Table 339
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

40-527
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Bb003 Stoll fuse +15 (7.5A) 40-586
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
C002 Grounding point 40-596

C002

C003 Grounding point 40-586

C003

C004 Grounding point C004

40-586

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

C011 Battery earth C011

40-652

40-528
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector to 40-586
cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D045 Wiring connector for 40-586
trailer wiring loom
E008 Instrument panel E008
40-586

F008 2.8059.500.0/10 Sidelight/rear right F008

40-586
brake light

F010 2.8059.510.0/10 Sidelight/rear left 40-586

brake light R5W
GND

P21W F010

GND

H007 2.3729.719.0/10 Handbrake 40-586

H007

I004 2.7659.281.0 LH brake pedal 40-586

switch
I004

4 3 2 1

4 1

3 2

NC
NO

40-529
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
K007 2.7099.034.0 Brake fluid sensor 40-596
K007

Pin C: Output

Pin A: +
Pin B: -

K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-586

switch 15 Bar +- 1
Max. operating volt-
age: 24 V
Max. continuous K037

pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

40-530
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
M001 HLHP unit 40-586

M001

40.3.31 - S017 - Trailer brake (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
E007 E008
E002
I005 Jc001 Jf001 Je006

TRAILER PRESS.
30

HPB PREX
50 15

+12V(+30)

+12V(+30)
C006 C009 C004

+15
+58

-31

-31
50 15 30 87 85 86 30 87 86 85 30 87a 87 86 85 30 + G T 1 2 8 13 26 8 14 15 21 12
0.020.6707.4/20

Bd002 Bd001 Bb008 Bb017 Bd006 Ba004 Ba001

15A
7,5A

7,5A
15A

3A

3A

3A
D043 D025B B8 B7 C5

B8 B7 C5

C002
0.020.2857.4/10
0.020.3229.4/30

B001
C0 11
150A

2 1 D040 D041 1
1

2 1 1

K035
0.016.1001.4/20

0.014.1645.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 2 1 1

BATTE RY
L002 K002

Fig. 2800
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point

40-531
 Wiring diagrams
E007 E008
E002
I005 Jc001 Jf001 Je006

TRAILER PRESS.
30

HPB PREX
50 15

+12V(+30)

+12V(+30)
C006 C009 C004

+15
+58

-31

-31
50 15 30 87 85 86 30 87 86 85 30 87a 87 86 85 30 + G T 1 2 8 13 26 8 14 15 21 12
0.020.6707.4/20

Bd002 Bd001 Bb008 Bb017 Bd006 Ba004 Ba001

15A
7,5A

7,5A
15A

3A

3A

3A
D043 D025B B8 B7 C5

B8 B7 C5

C002
0.020.2857.4/10
0.020.3229.4/30

B001
C0 11
150A

2 1 D040 D041 1
1

2 1 1

K035
0.016.1001.4/20

0.014.1645.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 2 1 1

BATTE RY
L002 K002

Fig. 2800
l C009 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E002 - Trailer braking system air pressure gauge
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K002 - Trailer braking low pressure switch
l K035 - Trailer hydraulic braking pressure sensor
l L002 - Trailer parking brake control solenoid valve

40-532
Wiring diagrams

Fig. 2802
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E002 - Trailer braking system air pressure gauge
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)

40-533
 Wiring diagrams

Fig. 2802
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K002 - Trailer braking low pressure switch
l K035 - Trailer hydraulic braking pressure sensor
l L002 - Trailer parking brake control solenoid valve

40-534
Wiring diagrams

Fig. 2804
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E002 - Trailer braking system air pressure gauge

40-535
 Wiring diagrams

Fig. 2804
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K002 - Trailer braking low pressure switch
l K035 - Trailer hydraulic braking pressure sensor
l L002 - Trailer parking brake control solenoid valve
Table 340
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

40-536
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb001 Turn indicator lights 40-586
fuse +15 (15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bb017 Engine fuse +15 40-586
(7.5A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-596

C002

C004 Grounding point C004

40-586

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

40-537
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D040 Wiring connector 40-647
for hydraulic trailer
braking solenoid
valve wiring loom
D040 Wiring connector for 40-596
rear wiring loom D040

D041 Wiring connector for 40-596

rear wiring loom
D041

D041 Wiring connector for 40-644

Air braking pressure
switch wiring loom
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E002 Trailer braking sys- E002 40-586
tem air pressure
gauge

E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

40-538
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Je006 Trailer braking relay 40-586
Jf001 Sidelights relay 40-586
K002 0.011.9428.0 Trailer braking low Power 12V DC 40-644
pressure switch Resistance at 0 bar
10-13 Ohm
Resistance at 6 Bar
119-129 Ohm

K035 2.7099.960.0 Trailer hydraulic Normally closed 40-596

braking pressure (NC) contact
sensor Switching pressure:
11 bar
L002 Trailer parking brake 40-647
control solenoid
valve

40-539
 Wiring diagrams
40.3.32 - S018 - Diagnostics

E007 E008
R002
Jc001 M001
I005

S.
INST R UMENT CLU

ISO(Dig)-RX(Preh)
30

ISO K HLHP1

ISO K HLHP1

+12V(+30)

+12V(+30)
15 50

+15 HLHP
C006 C005 C004

+15
-31

-31
+30

+30

+30
-31

-31

-31

-31
30 15 50 30 86 85 87 2 10 1 13 21 1 3 5 2 4 6 1 13 8 14 15 21
0.020.6707.4/20

Bd002 Bd001 Bb008 Bc004 Ba001

15A

15A

3A

3A

3A
D043

B001
C0 11
150A

0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b

B ATTE RY

Fig. 2806
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 - HLHP control unit
l R002 - Diagnostics socket in cab

40-540
Wiring diagrams

Fig. 2807
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 - HLHP control unit
l R002 - Diagnostics socket in cab

40-541
 Wiring diagrams

Fig. 2808
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l M001 - HLHP control unit
l R002 - Diagnostics socket in cab

40-542
Wiring diagrams
Table 341
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
C004 Grounding point C004
40-586

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E007 2.8339.278.0/10 Instrument panel E007

40-586

40-543
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
E008 Instrument panel E008
40-586

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
M001 HLHP unit 40-586

M001

R002 Diagnostics socket 40-586

in cab
R002

40-544
Wiring diagrams
40.3.33 - S019 - Distributors (5090 C -> ZKDY360200TD10001, 5100 C -> ZK-
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
M001

I005 Jc001 Jf001

ENERG Y S AVING E V
30

ECO S AVIN G
50 15
C006 C005

+30

+30

+30
-31

-31

-31
50 15 30 87 85 86 30 30 85 86 87 88 59 2 4 6 1 3 5 85 79
0.020.6707.4/20

Bd002 Bd001 Bb010 Ba004 Bd004 Bc004

15A

7,5A

20A
15A

5A
3A

D015 D026B
D043 14-14 14-13 12-1 14-2 14-1
D4 D3

D4 D3
14-14 14-13 12-1 14-2 14-1

B001
C0 11
150A

C002

0.020.2857.4/10
0.020.2857.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 10 9 2 3 7 8 1 2 1 2

B ATTE RY

I002 L008 L009

Fig. 2809
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I002 - ECO Saving switch 60 l/min
l I005 - Ignition switch
l I031a - Battery master switch button

40-545
 Wiring diagrams
M001

I005 Jc001 Jf001

ENERG Y S AVING E V
30

ECO S AVIN G
50 15
C006 C005

+30

+30

+30
-31

-31

-31
50 15 30 87 85 86 30 30 85 86 87 88 59 2 4 6 1 3 5 85 79
0.020.6707.4/20

Bd002 Bd001 Bb010 Ba004 Bd004 Bc004

15A

7,5A

20A
15A

5A
3A

D015 D026B
D043 14-14 14-13 12-1 14-2 14-1
D4 D3

D4 D3
14-14 14-13 12-1 14-2 14-1

B001
C0 11
150A

C002

0.020.2857.4/10
0.020.2857.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 10 9 2 3 7 8 1 2 1 2

B ATTE RY

I002 L008 L009

Fig. 2809
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l L008 - Eco saving solenoid valve 60 l/min
l L009 - ECO Solenoid valve
l M001 - HLHP control unit

40-546
Wiring diagrams

Fig. 2811
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I002 - ECO Saving switch 60 l/min
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l L008 - Eco saving solenoid valve 60 l/min
l L009 - ECO Solenoid valve
l M001 - HLHP control unit

40-547
 Wiring diagrams

Fig. 2812
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I002 - ECO Saving switch 60 l/min
l I005 - Ignition switch

40-548
Wiring diagrams

Fig. 2812
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l L008 - Eco saving solenoid valve 60 l/min
l L009 - ECO Solenoid valve
l M001 - HLHP control unit
Table 342
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

40-549
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bc004 HLHP control unit 40-586
fuse, +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse, +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-596

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I002 2.7659.429.0 ECO Saving switch 40-620
60 l/min

40-550
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
L008 Eco saving solenoid 40-596
valve 60 l/min
L008

L009 ECO solenoid valve 40-596

L009

M001 HLHP unit 40-586

M001

40-551
 Wiring diagrams
40.3.34 - S003 - Starter (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
M001
I005 Jc001 K023
30

+5 V HLHP

GND COM

GND COM

GND COM
15 50
C006 C005

SE AT

+30

+30

+30

-31

-31

-31
30 15 50 87 85 86 30 3 1 2 39 71 9 53 31 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bc004

20A
15A

3A

D025A
D043 B2 A6

B2 A6

B001
150A

C002 B002 Bb006

7,5A
30A

0.020.2857.4/10
C0 11

D044 2 3

2 1 31 2 4 6 1 3 5 35 88 73 28 64 57 2 1
0.020.6714.4

-31

-31

-31

+50

E
T

S TA RT REL AY

S TA RT REL AY
0.021.1202.4

L SENSO R

2 3
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT CONSEN

FUE L LOW PRESSUR

t
W ATER IN FUE

I001 K018

A006 A003 I031a I031b M003

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2814
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l Bb006 - Engine fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button

40-552
Wiring diagrams
M001
I005 Jc001 K023
30

+5 V HLHP

GND COM

GND COM

GND COM
15 50
C006 C005

SE AT

+30

+30

+30

-31

-31

-31
30 15 50 87 85 86 30 3 1 2 39 71 9 53 31 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bc004

20A
15A

3A

D025A
D043 B2 A6

B2 A6

B001
150A

C002 B002 Bb006

7,5A
30A

0.020.2857.4/10
C0 11

D044 2 3

2 1 31 2 4 6 1 3 5 35 88 73 28 64 57 2 1
0.020.6714.4

-31

-31

-31

+50

E
T

S TA RT REL AY

S TA RT REL AY
0.021.1202.4

L SENSO R

2 3
+30 ENGINE ECU

+30 ENGINE ECU

+30 ENGINE ECU

+15 ENGINE ECU

S TA RT CONSEN

FUE L LOW PRESSUR

t
W ATER IN FUE

I001 K018

A006 A003 I031a I031b M003

+30 GND +30 50 4 3 1 2

50

B ATTE R Y 30
M

Fig. 2814
l Jc001 - Start relay (70A - 12V)
l K018 - Water in fuel sensor
l K023 - Start enable seat sensor
l M001 - HLHP control unit
l M003 - HLHP control unit

40-553
 Wiring diagrams

Fig. 2816
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l Bb006 - Engine fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K018 - Water in fuel sensor
l K023 - Start enable seat sensor
l M001 - HLHP control unit
l M003 - HLHP control unit

40-554
Wiring diagrams

Fig. 2817
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l B002 – FBAT 2 fuse (20 A)
l Bb006 - Engine fuse +15 (7.5A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D043 - Wiring connector to cab wiring loom
l D043 - Wiring connector for battery wiring loom
l D044 - Wiring connector for engine wiring loom
l D044 - Wiring connector for rear wiring loom
l I001 - Start enable switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K018 - Water in fuel sensor
l K023 - Start enable seat sensor
l M001 - HLHP control unit
l M003 - HLHP control unit

40-555
 Wiring diagrams
Table 343
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

B002 Outlet power fuse 40-606
ISO 11783 (60A)
Bb006 Brake lights fuse +15 40-586
(15A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
C002 Grounding point 40-606

C002

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D044 Wiring connector for 40-606
engine wiring loom

40-556
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I001 2.7659.343.0/10 Starter enable switch 40-606

I001

3,9 Ohm
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
K018 Water in fuel sensor 40-606
K023 Start enable seat 40-586
sensor

K023

M001 HLHP unit 40-586

M001

M003 ECU control unit 40-606

40-557
 Wiring diagrams
40.3.35 - S016 - Brakes (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001,
5120 C -> ZKDY560200TD10001)
M001
I004 H007 K037

W
I005 Jc001 F008 F010

PARK BRAKE PRESS. S

30

BRAKE SENSOR
50 15
C006 C007 C003 C005

+30

+30

+30

-31
-31

-31
50 15 30 30 86 85 87 2 3 2 1 2 3 2 3 1 58 40 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bb003 Bc004

15A

15A

20A
3A

D045
6
3

Bb008 Ba001
3A

3A
D043 D025B C1
14 15 21 22 26 7 8

C004 C1

-31
P.B.SIGNA L
+15

L LEVE L
+12V(+30)

+12V(+30)

HAND BRAKE

BRAKES OI
E008

B001
C0 11
150A

C002
0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

1 1

A006 A003 I031a I031b

BATTE RY K007

Fig. 2818
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C003 - Grounding point
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D045 - Wiring connector for trailer wiring loom
l E008 - Instrument panel

40-558
Wiring diagrams
M001
I004 H007 K037

W
I005 Jc001 F008 F010

PARK BRAKE PRESS. S

30

BRAKE SENSOR
50 15
C006 C007 C003 C005

+30

+30

+30

-31
-31

-31
50 15 30 30 86 85 87 2 3 2 1 2 3 2 3 1 58 40 1 3 5 2 4 6
0.020.6707.4/20

Bd002 Bd001 Bb003 Bc004

15A

15A

20A
3A

D045
6
3

Bb008 Ba001
3A

3A
D043 D025B C1
14 15 21 22 26 7 8

C004 C1

-31
P.B.SIGNA L
+15

L LEVE L
+12V(+30)

+12V(+30)

HAND BRAKE

BRAKES OI
E008

B001
C0 11
150A

C002
0.020.2857.4/10
0.020.3229.4/30
0.020.6714.4
0.021.1202.4

1 1

A006 A003 I031a I031b

BATTE RY K007

Fig. 2818
l F008 - Sidelight/rear right brake light
l F010 - Sidelight/rear right brake light
l H007 - Handbrake
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K007 - Brake fluid sensor
l K037 - Handbrake pressure switch
l M001 - HLHP control unit

40-559
 Wiring diagrams

Fig. 2820
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C003 - Grounding point
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D045 - Wiring connector for trailer wiring loom
l E008 - Instrument panel
l F008 - Sidelight/rear right brake light
l F010 - Sidelight/rear right brake light
l H007 - Handbrake
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)

40-560
Wiring diagrams

Fig. 2820
l K007 - Brake fluid sensor
l K037 - Handbrake pressure switch
l M001 - HLHP control unit

40-561
 Wiring diagrams

Fig. 2822
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb008 - Cluster fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l C002 - Grounding point
l C003 - Grounding point
l C004 - Grounding point
l C005 - Grounding point
l C006 - Grounding point
l C007 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l D045 - Wiring connector for trailer wiring loom

40-562
Wiring diagrams

Fig. 2822
l E008 - Instrument panel
l F008 - Sidelight/rear right brake light
l F010 - Sidelight/rear right brake light
l H007 - Handbrake
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l K007 - Brake fluid sensor
l K037 - Handbrake pressure switch
l M001 - HLHP control unit

Table 344
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

40-563
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Bb003 Stoll fuse +15 (7.5A) 40-586
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
C002 Grounding point 40-606

C002

C003 Grounding point 40-586

C003

C004 Grounding point C004

40-586

C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C007 Grounding point 40-586

C007

C011 Battery earth C011

40-652

40-564
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D025 Wiring connector to 40-586
cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
D045 Wiring connector for 40-586
trailer wiring loom
E008 Instrument panel E008
40-586

F008 2.8059.500.0/10 Sidelight/rear right F008

40-586
brake light

F010 2.8059.510.0/10 Sidelight/rear left 40-586

brake light R5W
GND

P21W F010

GND

H007 2.3729.719.0/10 Handbrake 40-586

H007

I004 2.7659.281.0 LH brake pedal 40-586

switch
I004

4 3 2 1

4 1

3 2

NC
NO

40-565
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
K007 2.7099.034.0 Brake fluid sensor 40-606
K007

Pin C: Output

Pin A: +
Pin B: -

K037 2.7099.670.0/10 Handbrake pressure Switching pressure: 40-586

switch 15 Bar +- 1
Max. operating volt-
age: 24 V
Max. continuous K037

pressure: 50 Bar
Max. current: 1 A
Operating tempera-
ture: -30 +140 °C
Max. vibration: 30 g
Max peak pressure:
65 Bar

40-566
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
M001 HLHP unit 40-586

M001

40.3.36 - S017 - Trailer brake (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
E007 E008
E002
I005 Jc001 Jf001 Je006

TRAILER PRESS.
30

HPB PREX
50 15

+12V(+30)

+12V(+30)
C006 C009 C004

+15
+58

-31

-31
50 15 30 87 85 86 30 87 86 85 30 87a 87 86 85 30 + G T 1 2 8 13 26 8 14 15 21 12
0.020.6707.4/20

Bd002 Bd001 Bb008 Bb017 Bd006 Ba004 Ba001

15A
7,5A

7,5A
15A

3A

3A

3A
D043 D025B B8 B7 C5

B8 B7 C5

C002
0.020.2857.4/10
0.020.3229.4/30

B001
C0 11
150A

2 1 D040 D041 1
1

2 1 1

K035
0.016.1001.4/20

0.014.1645.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 2 1 1

BATTE RY
L002 K002

Fig. 2824
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point

40-567
 Wiring diagrams
E007 E008
E002
I005 Jc001 Jf001 Je006

TRAILER PRESS.
30

HPB PREX
50 15

+12V(+30)

+12V(+30)
C006 C009 C004

+15
+58

-31

-31
50 15 30 87 85 86 30 87 86 85 30 87a 87 86 85 30 + G T 1 2 8 13 26 8 14 15 21 12
0.020.6707.4/20

Bd002 Bd001 Bb008 Bb017 Bd006 Ba004 Ba001

15A
7,5A

7,5A
15A

3A

3A

3A
D043 D025B B8 B7 C5

B8 B7 C5

C002
0.020.2857.4/10
0.020.3229.4/30

B001
C0 11
150A

2 1 D040 D041 1
1

2 1 1

K035
0.016.1001.4/20

0.014.1645.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 2 1 1

BATTE RY
L002 K002

Fig. 2824
l C009 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E002 - Trailer braking system air pressure gauge
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K002 - Trailer braking low pressure switch
l K035 - Trailer hydraulic braking pressure sensor
l L002 - Trailer parking brake control solenoid valve

40-568
Wiring diagrams

Fig. 2826
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E002 - Trailer braking system air pressure gauge
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)

40-569
 Wiring diagrams

Fig. 2826
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K002 - Trailer braking low pressure switch
l K035 - Trailer hydraulic braking pressure sensor
l L002 - Trailer parking brake control solenoid valve

40-570
Wiring diagrams

Fig. 2828
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb008 - Cluster fuse +15 (3A)
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bd002 - Power fuse +30 (3A)
l Bd006 - Front sidelights fuse (7.5A)
l C002 - Grounding point
l C004 - Grounding point
l C006 - Grounding point
l C009 - Grounding point
l C011 - Grounding point
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D040 - Wiring connector for hydraulic trailer braking solenoid valve wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l E002 - Trailer braking system air pressure gauge

40-571
 Wiring diagrams

Fig. 2828
l E007 - Instrument panel
l E008 - Instrument panel
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l K002 - Trailer braking low pressure switch
l K035 - Trailer hydraulic braking pressure sensor
l L002 - Trailer parking brake control solenoid valve
Table 345
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

40-572
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

Ba001 Line fuse ISO 11783 40-586
+30 (15A)
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb001 Turn indicator lights 40-586
fuse +15 (15A)
Bb008 Shuttle lever fuse 40-586
+15 (3A)
Bb017 Engine fuse +15 40-586
(7.5A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C002 Grounding point 40-606

C002

C004 Grounding point C004

40-586

C006 Grounding point 40-586

C006

C009 Grounding point C009

40-586

C011 Battery earth C011

40-652

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

40-573
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
D040 Wiring connector 40-647
for hydraulic trailer
braking solenoid
valve wiring loom
D040 Wiring connector for 40-606
rear wiring loom D040

D041 Wiring connector for 40-606

rear wiring loom
D041

D041 Wiring connector for 40-644

Air braking pressure
switch wiring loom
D043 Wiring connector for 40-654
battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
E002 Trailer braking sys- E002 40-586
tem air pressure
gauge

E007 2.8339.278.0/10 Instrument panel E007

40-586

E008 Instrument panel E008

40-586

I005 0.015.0485.4 Starter switch 40-586

I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

40-574
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I031b 2.7659.351.0 Battery disconnect 40-652
switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Je006 Trailer braking relay 40-586
Jf001 Sidelights relay 40-586
K002 0.011.9428.0 Trailer braking low Power 12V DC 40-644
pressure switch Resistance at 0 bar
10-13 Ohm
Resistance at 6 Bar
119-129 Ohm

K035 2.7099.960.0 Trailer hydraulic Normally closed 40-606

braking pressure (NC) contact
sensor Switching pressure:
11 bar
L002 Trailer parking brake 40-647
control solenoid
valve

40-575
 Wiring diagrams
40.3.37 - S019 - Distributors (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
M001

I005 Jc001 Jf001

ENERG Y S AVING E V
30

ECO S AVIN G
50 15
C006 C005

+30

+30

+30
-31

-31

-31
50 15 30 87 85 86 30 30 85 86 87 88 59 2 4 6 1 3 5 85 79
0.020.6707.4/20

Bd002 Bd001 Bb010 Ba004 Bd004 Bc004

15A

7,5A

20A
15A

5A
3A

D015 D026B
D043 14-14 14-13 12-1 14-2 14-1
D4 D3

D4 D3
14-14 14-13 12-1 14-2 14-1

B001
C0 11
150A

C002

0.020.2857.4/10
0.020.2857.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 10 9 2 3 7 8 1 2 1 2

B ATTE RY

I002 L008 L009

Fig. 2830
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I002 - ECO Saving switch 60 l/min
l I005 - Ignition switch
l I031a - Battery master switch button

40-576
Wiring diagrams
M001

I005 Jc001 Jf001

ENERG Y S AVING E V
30

ECO S AVIN G
50 15
C006 C005

+30

+30

+30
-31

-31

-31
50 15 30 87 85 86 30 30 85 86 87 88 59 2 4 6 1 3 5 85 79
0.020.6707.4/20

Bd002 Bd001 Bb010 Ba004 Bd004 Bc004

15A

7,5A

20A
15A

5A
3A

D015 D026B
D043 14-14 14-13 12-1 14-2 14-1
D4 D3

D4 D3
14-14 14-13 12-1 14-2 14-1

B001
C0 11
150A

C002

0.020.2857.4/10
0.020.2857.4/10
0.020.6714.4
0.021.1202.4

A006 A003 I031a I031b 10 9 2 3 7 8 1 2 1 2

B ATTE RY

I002 L008 L009

Fig. 2830
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l L008 - Eco saving solenoid valve 60 l/min
l L009 - ECO Solenoid valve
l M001 - HLHP control unit

40-577
 Wiring diagrams

Fig. 2832
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I002 - ECO Saving switch 60 l/min
l I005 - Ignition switch
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l L008 - Eco saving solenoid valve 60 l/min
l L009 - ECO Solenoid valve
l M001 - HLHP control unit

40-578
Wiring diagrams

Fig. 2833
l A003 - Battery negative
l A006 - +30 Battery
l B001 - Power fuse (150A)
l Ba004 - Sidelights fuse +30 (15A)
l Bb010 - Rear lift fuse +15 (3A)
l Bc004 - HLHP control unit fuse +30 (20A)
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd006 - Front sidelights fuse (7.5A)
l C005 - Grounding point
l C006 - Grounding point
l C011 - Grounding point
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D043 - Wiring connector for battery wiring loom
l D043 - Wiring connector to cab wiring loom
l I002 - ECO Saving switch 60 l/min
l I005 - Ignition switch

40-579
 Wiring diagrams

Fig. 2833
l I031a - Battery master switch button
l I031b - Battery master switch button
l Jc001 - Start relay (70A - 12V)
l Jf001 - Sidelights relay
l L008 - Eco saving solenoid valve 60 l/min
l L009 - ECO Solenoid valve
l M001 - HLHP control unit
Table 346
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
A003 Battery negative 40-652
A003

A006 +30 Battery 40-654

A006

B001 Power fuse (150A) 40-586

40-580
Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
Ba004 Front suspension 40-586
fuse +30 (7.5A)
Bb010 Cigarette lighter fuse 40-586
+15 (15A)
Bc004 HLHP control unit 40-586
fuse +30 (20A)
Bd001 Front cab roof work- 40-586
ing lights fuse +30
(25A)
Bd002 Low beam head- 40-586
lights fuse +15 (5A)
Bd004 HLHP control unit 40-586
fuse +30 (20A)
Bd006 Electric Pump fuse 40-586
+30 (20A)
C005 Grounding point 40-586

C005

C006 Grounding point 40-586

C006

C011 Battery earth C011

40-652

D015 Wiring connector to 40-586

cab wiring loom
D015

D015 Wiring connector for 40-620

console wiring loom
D015

D025 Wiring connector to 40-586

cab wiring loom

D025

D025 Wiring connector for 40-606

rear wiring loom D025

D043 Wiring connector for 40-654

battery wiring loom
D043 Wiring connector to 40-586
cab wiring loom
I002 2.7659.429.0 ECO Saving switch 40-620
60 l/min

40-581
 Wiring diagrams
System code P/N Description CHARACTERISTICS/ Position Link to wiring
NOTES
I005 0.015.0485.4 Starter switch 40-586
I005

I031a 2.7659.351.0 Battery disconnect 40-652

switch

I031a

I031b 2.7659.351.0 Battery disconnect 40-652

switch

I031b

Jc001 Start relay (70A - 40-586

12V)
Jf001 Sidelights relay 40-586
L008 Eco saving solenoid 40-606
valve 60 l/min
L008

L009 ECO solenoid valve 40-606

L009

M001 HLHP unit 40-586

M001

40-582
Wiring diagrams
40.4 - Wiring harnesses
40.4.1 - 0.019.3018.4/20 - Front wiring loom

D024 AMP
1
2
A001

K017

1
K016

2 1
D032

2 1
D023 K015

Fig. 2835
l A001 - Alternator “D+”
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for rear wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l K015 - Air conditioning pressure switch
l K016 - Air filter pressure sensor
l K017 - Air conditioning compressor

40-583
 Wiring diagrams
L1
A001

D+ GENERATOR 2 L1
D024
COMPRESSOR 1 CN1.5 CN1.5
1 A/C COMPRESSOR K017

N0.75

XGND
V1 2 -31
A/C PRESS SW 6 B0.75
1 INT.FILTRO ARIA K016
GND (-31) 5 N1

OBSTR.AIR FILTER 4 B0.75

D023 FRONT PTO COM. 3 CN1
N1
2 -31
2 CN1
1 FRONT PTO COM.
D032
GV1
A/C PRESS SW 1

V1

K015
GV1

Fig. 2836
l A001 - Alternator “D+”
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for rear wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l K015 - Air conditioning pressure switch
l K016 - Air filter pressure sensor
l K017 - Air conditioning compressor

40-584
Wiring diagrams

Fig. 2837
l A001 - Alternator “D+”
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for rear wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l K015 - Air conditioning pressure switch
l K016 - Air filter pressure sensor
l K017 - Air conditioning compressor

40-585
 Wiring diagrams

Fig. 2838
l A001 - Alternator “D+”
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for rear wiring loom
l D032 - Wiring connector to front PTO solenoid valve wiring loom
l K015 - Air conditioning pressure switch
l K016 - Air filter pressure sensor
l K017 - Air conditioning compressor
Table 347
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
A001 Alternator “D+”
D023 Wiring connector for rear wiring loom
D024 Wiring connector for rear wiring loom
D032 Wiring connector to front PTO solenoid
valve wiring loom
FRONT PTO K015 Air conditioning pressure switch
A/C K016 Air filter pressure sensor
AIR K017 Air conditioning compressor

40-586
Wiring diagrams
40.4.2 - 0.020.6707.4/20 - Cab ()

H003
K023
I006
I029
I026
I030
I027
I028
I025

I005
M001

H001

+12 BAT

E007 / E008 R002 D011 E002

H006

H007
C003

D001

Fig. 2839

40-587
 Wiring diagrams

D002
D015 I073 R001 D001 N005

C005
C009

C006

C007
C004

C008
D001

I010

D025

M001

P007
P010
P006
P029
I004
F010
F009
F008
F007

F005 F006 D045

K037 I042 I044 I040

M005 I033 H023 I041 N004

Fig. 2840

40-588
Wiring diagrams
M001 D015 R001

O009

D025
FOR CAN LINE RESPECT SAE J1939

E007 / E008 D011

Fig. 2841
l B001 - Power fuse (150A)
l Ba001 - Cluster fuse +30 (3A)
l Ba002 - Corner light fuse +30 (15A)
l Ba003 - High beam headlights fuse, +30 (5A)
l Ba004 - Sidelights fuse +30 (15A)
l Ba005 - Low beam headlights fuse, +30 (15A)
l Ba006 - High beam headlights fuse, +30 (15A)
l Ba008 - Rotating beacon fuse +30 (15A)
l Ba009 – Cab Socket fuse +30 (15 A)
l Ba010 - Low front working lights fuse +30 (15A)
l Bb001 - Turn indicator lights fuse +15 (15A)
l Bb002 - Low beam headlights fuse +15 (5A)
l Bb003 – Brake switch fuse +15 (15 A)
l Bb004 - Stoll fuse +15 (7.5A)
l Bb005 - Seat socket fuse +15 (15A)
l Bb006 - Engine fuse +15 (7.5A)
l Bb007 – Ancillary fuse +15 (7.5 A)
l Bb008 - Cluster fuse +15 (3A)
l Bb009 - ISO 11786 line fuse +15 (10A)
l Bb010 - Rear hitch fuse +15 (3A)
l Bb011 - AC system fuse +15 (7.5A)
l Bb012 – Body SV fuse +15 (7.5 A)
l Bb013 – Relay/SW fuse +15 (7.5 A)
l Bb014 - Radio/amplifier fuse +15 (5A)

40-589
 Wiring diagrams
M001 D015 R001

O009

D025
FOR CAN LINE RESPECT SAE J1939

E007 / E008 D011

Fig. 2841
l Bb017 - Trailer braking fuse +15 (7.5A)
l Bb019 – Front windscreen wiper motor/horn fuse +15 (15 A)
l Bb020 - Rear screen wiper motor fuse +15 (15A)
l Bc001 - Not used
l Bc002 - Fan fuse +30 (30A)
l Bc003 - Not used
l Bc004 - HLHP control unit fuse +30 (20A)
l Bc005 - Not used
l Bc006 - Hazard lights fuse +30 (20A)
l Bc007 - Not used
l Bc008 - Power socket fuse +30 (20A)
l Bc009 - Not used
l Bd001 - Power fuse +15 (3A)
l Bd002 - Power fuse +30 (3A)
l Bd003 – LED lights fuse (3 A)
l Bd004 - Rear sidelights fuse (7.5A)
l Bd005 - Compressor fuse (10A)
l Bd006 - Front sidelights fuse (7.5A)
l Bg001 - LH rear cab roof working lights fuse (15A)
l Bg002 - Front cab roof working lights fuse (15A)
l Bg003 - RH rear cab roof working lights fuse (15A)
l C003 - Earthing point
l C004 - Earthing point
l C005 - Earthing point

40-590
Wiring diagrams
M001 D015 R001

O009

D025
FOR CAN LINE RESPECT SAE J1939

E007 / E008 D011

Fig. 2841
l C006 - Earthing point
l C007 - Earthing point
l C008 - Earthing point
l C009 - Earthing point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D011 - Wiring connector to cab wiring loom
l D011 - Wiring connector to ISO 11786 wiring loom
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D045 - Wiring connector for trailer wiring loom
l D069 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l E002 - Trailer braking system air pressure gauge
l E007 - Instrument panel
l E008 - Instrument panel
l F007 - Rear RH turn indicator
l F008 - Sidelight/rear right brake light
l F009 - Rear LH turn indicator
l F010 - Sidelight/rear left brake light

40-591
 Wiring diagrams
M001 D015 R001

O009

D025
FOR CAN LINE RESPECT SAE J1939

E007 / E008 D011

Fig. 2841
l H001 - H/L selection lever
l H003 - Accelerator pedal
l H006 - Rear PTO rotation speed selection lever
l H007 - Handbrake
l H023 - Lights selector switch
l I004 - LH brake pedal switch
l I005 - Ignition switch
l I006 - SDD switch
l I010 - LED lights control switch
l I025 - RH rear hitch down button
l I026 - Rear PTO control button
l I027 - RH rear hitch up button
l I028 - LH rear hitch down button
l I029 - Rear PTO control button
l I030 - LH rear hitch up button
l I033 - Hazard warning lights switch
l I040 - Top/Low work lights switch
l I041 - Lights switch
l I042 - Switch for front work lights on cab
l I044 - Low work lights switch
l I073 - Front hitch control switch in cab
l I082 - Distributor 7/8 switch
l J005 - Air conditioning compressor relay
l Jc001 - Start relay (70A - 12V)

40-592
Wiring diagrams
M001 D015 R001

O009

D025
FOR CAN LINE RESPECT SAE J1939

E007 / E008 D011

Fig. 2841
l Je003 - Corner light relay
l Je004 - Beacon relay
l Je005 - Low front work lights relay
l Je006 - Trailer brake relay
l Jf001 - Sidelights relay
l Jf002 - High beam headlights relay
l Jf003 - Low beam headlights relay
l Jg001 - Rear roof work lights relay
l Jg002 - Front roof work lights relay
l K037 - Handbrake pressure switch
l M001 - HLHP control unit
l M005 - USA ECU
l N004 - Front windscreen wiper water pump
l N005 - Rear windscreen wiper water pump
l O009 - Resistor, 120 ohm
l P006 - Cigar lighter
l P007 - 25 A socket
l P010 - Socket in cab +12 V
l P029 - Seat socket
l R001 - CAN diagnostics socket
l R002 - Diagnostics socket in cab

40-593
 Wiring diagrams
Table 348
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
B001 Power fuse (150A)
Ba001 Cluster fuse +30 (3A)
Ba002 Corner light fuse +30 (15A)
Ba003 High beam headlights fuse +30 (5A)
Ba004 Sidelights fuse +30 (15A)
Ba005 Low beam headlights fuse +30 (15A)
Ba006 High beam headlights fuse +30 (15A)
Ba008 Rotating beacon fuse +30 (15 A)
Ba009 Cab Socket fuse +30 (15 A)
Ba010 Low front working lights fuse +30 (15A)
Bb001 Turn indicator lights fuse +15 (15A)
Bb002 Low beam headlights fuse, +15 (5A)
Bb003 Brake switch fuse +15 (15 A)
Bb004 Stoll fuse +15 (7.5A)
Bb005 Seat socket fuse +15 (15A)
Bb006 Engine fuse +15 (7.5A)
Bb007 Ancillary fuse +15 (7.5 A)
Bb008 Cluster fuse +15 (3A)
Bb009 ISO 11786 line fuse +15 (10 A)
Bb010 Rear hitch fuse +15 (3A)
Bb011 Climate control fuse +15 (7.5A)
Bb012 Body SV fuse +15 (7.5 A)
Bb013 Relay/SW fuse +15 (7.5 A)
Bb014 Radio/amplifier fuse +15 (5A)
Bb017 Trailer braking fuse +15 (7.5A)
Bb019 Front windscreen wiper motor/horn fuse
+15 (15 A)
Bb020 Rear screen wiper motor fuse +15 (15A)
Bc001 Not used
Bc002 Fan fuse +30 (30A)
Bc003 Not used
Bc004 HLHP control unit fuse, +30 (20A)
Bc005 Not used
Bc006 Hazard lights fuse +30 (20A)
Bc007 Not used
Bc008 Power socket fuse +30 (20A)
Bc009 Not used
Bd001 Power fuse +15 (3A)
Bd002 Power fuse +30 (3A)
Bd003 LED lights fuse (3A)
Bd004 Rear sidelights fuse (7.5A)
Bd005 Compressor fuse (10A)
Bd006 Front sidelights fuse (7.5A)
Bg001 LH rear cab roof work lights fuse (15A)
Bg002 Front cab roof work lights fuse (15A)
Bg003 RH rear cab roof work lights fuse (15A)
PB-31 C003 Grounding point
GND ELE1 C004 Earthing point
GND ELE2 C005 Earthing point
GND POW2 C006 Earthing point
GND POW3 C007 Earthing point
GND ELE3 C008 Earthing point
GND POW1 C009 Earthing point
TO ROOF WH D001 Wiring connector for cab/roof wiring loom
TO ROOF WH D002 Wiring connector for cab/roof wiring loom
ISO11786 D011 Wiring connector for cab/roof wiring loom
TO CONSOLE WH D015 Wiring connector for cab/roof wiring loom
D025 Wiring connector for cab/roof wiring loom
D045 Wiring connector for trailer wiring loom
D069 Wiring connector to cab front lights wiring
loom

40-594
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D070 Wiring connector to cab front lights wiring
loom
PRESS.IND. E002 Trailer braking system air pressure gauge
E007 Instrument panel
E008 Instrument panel
F007 Rear RH turn indicator
F008 Sidelight/rear right brake light
F009 Rear LH turn indicator
F010 Sidelight/rear left brake light
H/L LEVER H001 H/L selection lever
PEDAL GAS H003 Accelerator pedal
PTO 540/1,000 H006 Rear PTO rotation speed selection lever
PARK BRAKE H007 Handbrake
LIGHTS COMMAND AS4 H023 Lights selector switch
LEFT BRAKE I004 LH brake pedal switch
STARTING SW I005 Starter switch
SDD SW I006 SDD switch
LED BAR SW I010 LED lights control switch
I025 RH rear hitch ‘Down’ button
I026 Rear PTO control push button
I027 RH rear hitch ‘Up’ button
I028 LH rear hitch ‘Down’ button
I029 Rear PTO control push button
I030 LH rear hitch ‘Up’ button
I033 Hazard warning lights switch
I040 Top/Low work lights switch
I041 Lights switch
I042 Switch for front work lights on cab
I044 Low work lights switch
UP/DW CAB I073 Front hitch control switch in cab
I082 Distributor 7/8 switch
J005 Air conditioning compressor relay
Jc001 Start relay (70A - 12V)
Je003 Corner lights relay
Je004 Beacon relay
Je005 Low front work lights relay
Je006 Trailer brake relay
Jf001 Sidelights relay
Jf002 High beam headlights relay
Jf003 Low beam headlights relay
Jg001 Rear roof work lights relay
Jg002 Front roof work lights relay
K037 Handbrake pressure switch
M001 HLHP unit
M005 Control unit USA
F. WIPER PUMP N004 Front windscreen wiper water pump
R. WIPER PUMP N005 Rear windscreen wiper water pump
O009 Resistance: 120 ohm
P006 Cigarette lighter
P007 25 A socket
+12 SOCKET P010 Socket in cab +12 V
P029 Seat socket
DIAGNOSTIC CAN SOCKET R001 CAN Diagnostics socket
DIAGNOSTIC SOCKET R002 Diagnostics socket in cab

40-595
 Wiring diagrams
40.4.3 - 0.020.3229.4/30 - Rear wiring loom (5090 C -> ZKDY360200TD10001, 5100 C ->
ZKDY400200TD10001, 5110 C -> ZKDY440200TD10001)

K013

D041

K038
H005
K035

H004
D040
K005

K006 D029
K040 K010 D028
D076

L008 K007

D024
L009
D023
C002
L005
D066
D081
L004 K018
D078 I001 K019

D025
D044
K043

R005
P028
L025
K004

L020

B002
L003

L007

M004
B003
Jf004

M003

Fig. 2846
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l C002 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l D078 - Wiring connector for distributor 7/8 wiring loom
l D078 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D081 - Wiring connector for rear wiring loom
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l I001 - Start enable switch
l Jf004 - Electric pump relay
l K004 - Wheel speed sensor

40-596
Wiring diagrams

K013

D041

K038
H005
K035

H004
D040
K005

K006 D029
K040 K010 D028
D076

L008 K007

D024
L009
D023
C002
L005
D066
D081
L004 K018
D078 I001 K019

D025
D044
K043

R005
P028
L025
K004

L020

B002
L003

L007

M004
B003
Jf004

M003

Fig. 2846
l K005 - Rear hitch position sensor
l K006 - PTO speed sensor
l K007 - Brake fluid sensor
l K010 - Fuel level sensor
l K013 - Transmission oil temperature sensor
l K018 - Water in fuel filter sensor
l K019 - Engine coolant temperature sensor
l K035 - Trailer hydraulic braking pressure sensor
l K038 - Transmission filter sensor
l K040 - Right hand hitch draft tie rod sensor
l K043 - Clogged Pal filter sensor
l L003 - Rear PTO control solenoid valve
l L004 - Rear hitch ‘DOWN’ control solenoid valve
l L005 - Rear hitch ‘UP’ control solenoid valve
l L007 - Differential lock control solenoid valve
l L008 - 60 L. ECO solenoid valve
l L009 - ECO Solenoid valve
l L020 - Four-wheel drive solenoid valve
l L025 - HI/LO solenoid valve
l M003 - Deutz-AG engine control unit
l M004 - Deutz-AG engine control unit
l O003 - Resistor, 120 ohm
l P028 - Services connector
l R005 - Diagnostics port

40-597
 Wiring diagrams
P028 L020 L003 K040 L004 L005 K038 K004 D040 K005 K006 D078

D024

D023

K014

D025
K013

D029

K043

K010 D041 K035 L025 H004 H005 D076 K007 D028 L009 L008 C002 L007

Fig. 2848
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l C002 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l D078 - Wiring connector for distributor 7/8 wiring loom
l D078 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D081 - Wiring connector for rear wiring loom
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l I001 - Start enable switch
l Jf004 - Electric pump relay
l K004 - Wheel speed sensor
l K005 - Rear hitch position sensor
l K006 - PTO speed sensor

40-598
Wiring diagrams
P028 L020 L003 K040 L004 L005 K038 K004 D040 K005 K006 D078

D024

D023

K014

D025
K013

D029

K043

K010 D041 K035 L025 H004 H005 D076 K007 D028 L009 L008 C002 L007

Fig. 2848
l K007 - Brake fluid sensor
l K010 - Fuel level sensor
l K013 - Transmission oil temperature sensor
l K018 - Water in fuel filter sensor
l K019 - Engine coolant temperature sensor
l K035 - Trailer hydraulic braking pressure sensor
l K038 - Transmission filter sensor
l K040 - Right hand hitch draft tie rod sensor
l K043 - Clogged Pal filter sensor
l L003 - Rear PTO control solenoid valve
l L004 - Rear hitch ‘DOWN’ control solenoid valve
l L005 - Rear hitch ‘UP’ control solenoid valve
l L007 - Differential lock control solenoid valve
l L008 - 60 L. ECO solenoid valve
l L009 - ECO Solenoid valve
l L020 - Four-wheel drive solenoid valve
l L025 - HI/LO solenoid valve
l M003 - Deutz-AG engine control unit
l M004 - Deutz-AG engine control unit
l O003 - Resistor, 120 ohm
l P028 - Services connector
l R005 - Diagnostics port

40-599
 Wiring diagrams
I001 K018 K019 M004 M003 D044

O009

Jf004 B003

B002

D025

Fig. 2850
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l C002 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l D078 - Wiring connector for distributor 7/8 wiring loom
l D078 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D081 - Wiring connector for rear wiring loom
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l I001 - Start enable switch
l Jf004 - Electric pump relay
l K004 - Wheel speed sensor
l K005 - Rear hitch position sensor

40-600
Wiring diagrams
I001 K018 K019 M004 M003 D044

O009

Jf004 B003

B002

D025

Fig. 2850
l K006 - PTO speed sensor
l K007 - Brake fluid sensor
l K010 - Fuel level sensor
l K013 - Transmission oil temperature sensor
l K018 - Water in fuel filter sensor
l K019 - Engine coolant temperature sensor
l K035 - Trailer hydraulic braking pressure sensor
l K038 - Transmission filter sensor
l K040 - Right hand hitch draft tie rod sensor
l K043 - Clogged Pal filter sensor
l L003 - Rear PTO control solenoid valve
l L004 - Rear hitch ‘DOWN’ control solenoid valve
l L005 - Rear hitch ‘UP’ control solenoid valve
l L007 - Differential lock control solenoid valve
l L008 - 60 L. ECO solenoid valve
l L009 - ECO Solenoid valve
l L020 - Four-wheel drive solenoid valve
l L025 - HI/LO solenoid valve
l M003 - Deutz-AG engine control unit
l M004 - Deutz-AG engine control unit
l O003 - Resistor, 120 ohm
l P028 - Services connector
l R005 - Diagnostics port

40-601
 Wiring diagrams

Fig. 2852
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l C002 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D040 - Wiring connector for hydraulic trailer braking wiring loom
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l D076 - Wiring connector for rear wiring loom

40-602
Wiring diagrams

Fig. 2852
l D076 - Wiring connector for SDD wiring loom
l D078 - Wiring connector for distributor 7/8 wiring loom
l D078 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D081 - Wiring connector for rear wiring loom
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l I001 - Start enable switch
l Jf004 - Electric pump relay
l K004 - Wheel speed sensor
l K005 - Rear hitch position sensor
l K006 - PTO speed sensor
l K007 - Brake fluid sensor
l K010 - Fuel level sensor
l K013 - Transmission oil temperature sensor
l K018 - Water in fuel filter sensor
l K019 - Engine coolant temperature sensor
l K035 - Trailer hydraulic braking pressure sensor
l K038 - Transmission filter sensor
l K040 - Right hand hitch draft tie rod sensor
l K043 - Clogged Pal filter sensor

40-603
 Wiring diagrams

Fig. 2852
l L003 - Rear PTO control solenoid valve
l L004 - Rear hitch ‘DOWN’ control solenoid valve
l L005 - Rear hitch ‘UP’ control solenoid valve
l L007 - Differential lock control solenoid valve
l L008 - 60 L. ECO solenoid valve
l L009 - ECO Solenoid valve
l L020 - Four-wheel drive solenoid valve
l L025 - HI/LO solenoid valve
l M003 - Deutz-AG engine control unit
l M004 - Deutz-AG engine control unit
l O003 - Resistor, 120 ohm
l P028 - Services connector
l R005 - Diagnostics port
Table 349
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
B002 Fbat 1 fuse
B003 Fbat 2 fuse
C002 Grounding point
D023 Wiring connector for front wiring loom
D023 Wiring connector for rear wiring loom

40-604
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D024 Wiring connector for front wiring loom
D024 Wiring connector for rear wiring loom
D025 Wiring connector to cab wiring loom
D025 Wiring connector for rear wiring loom
D028 Wiring connector for front light wiring loom-
horn
D028 Wiring connector for rear wiring loom
D029 Wiring connector for rear wiring loom
SBA D029 Wiring connector for SBA/ASM wiring loom
HYDR SV D040 Wiring connector for hydraulic trailer brak-
ing solenoid valve wiring loom
D040 Wiring connector for rear wiring loom
D041 Wiring connector for rear wiring loom
AIR D041 Wiring connector for Air braking pressure
switch wiring loom
D044 Wiring connector for engine wiring loom
D066 Wiring connector to cab wiring loom
D066 Wiring connector for electric pump wiring
loom
D076 Wiring connector for rear wiring loom
D076 Wiring connector for SDD wiring loom
D078 Wiring connector for distributor 7/8 wiring
loom
D078 Wiring connector for rear wiring loom
D081 Wiring connector to STOLL wiring loom
D081 Wiring connector for rear wiring loom
H004 Rear PTO rotation mode selection lever
(Standard-Economic)
H005 Synchronised rear PTO selection lever
I001 Starter enable switch
Jf004 Electric pump relay
WHEEL K004 Wheels speed sensor
POS K005 Rear hitch position sensor
K006 PTO speed sensor
K007 Brake fluid sensor
FUEL K010 Fuel level sensor
TEMP K013 Transmission oil temperature sensor
K018 Water in fuel filter sensor
K019 Engine coolant temperature sensor
HYDR K035 Trailer hydraulic braking pressure sensor
K038 Transmission filter sensor
K040 Right hand hitch draft tie-rod sensor
K043 Clogged Pal filter sensor
REAR PTO L003 Rear PTO control solenoid valve
DW L004 Rear hitch DOWN control solenoid valve
UP L005 Rear hitch ‘UP’ control solenoid valve
EV DF L007 Differential lock control solenoid valve
SAV L008 60 L./ECO solenoid valve
ECO L009 ECO solenoid valve
L020 Four-wheel drive solenoid valve
L025 HI/LO solenoid valve
M003 DEUTZ-AG engine control unit
M004 DEUTZ-AG engine control unit
O003 Resistance: 120 ohm
SERVICE P028 Services connector
R005 Diagnostics socket

40-605
 Wiring diagrams
40.4.4 - 0.020.2857.4/10 - Rear wiring loom (5100 C -> ZKDY480200TD10001, 5110 C ->
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

K038
D041

H005
D040
H004
K035
K005

L010
L011
L012
K006 D029
K040 K010 D028
D076
L008 P007

L009 D024
D023
L005 C002
K044
D066
D081
L004 K018
D078 I001 K012
K019
D025
K043
D044
D026
R005
P028

K003
K004

L025
L020

L013
L014
L024
B002
L003
L007

K045
K013

M004
B003
Jf004

M003

Fig. 2855
P028 L020 L003 K040 L004 L005 K038 K004 L010 L011 L012 D040 K005 K006 D078

D024

D023

D081
D025/D026

L024
L014

L013

K045
K013

K012
D029

K044

K043

K010 D041 K035 L025 H004 H005 D076 K007 D028 L009 L008 C002 L007 K003

Fig. 2856

40-606
Wiring diagrams
I001 K018 K019 M004 M003 D044

O009

Jf004 B003

B002

D025

Fig. 2857
l B002 – Fbat 1 fuse
l B003 – Fbat 2 fuse
l C002 - Grounding point
l D023 - Wiring connector for front wiring loom
l D023 - Wiring connector for rear wiring loom
l D024 - Wiring connector for front wiring loom
l D024 - Wiring connector for rear wiring loom
l D025 - Wiring connector to cab wiring loom
l D025 - Wiring connector for rear wiring loom
l D026 - Wiring connector to cab wiring loom
l D026 - Wiring connector for rear wiring loom
l D028 - Wiring connector for front light wiring loom-horn
l D028 - Wiring connector for rear wiring loom
l D029 - Wiring connector for rear wiring loom
l D029 - Wiring connector for SBA/ASM wiring loom
l D040 - Wiring connector for hydraulic trailer braking solenoid valve
l D040 - Wiring connector for rear wiring loom
l D041 - Wiring connector for rear wiring loom
l D041 - Wiring connector for Air braking pressure switch wiring loom
l D044 - Wiring connector for engine wiring loom
l D066 - Wiring connector to cab wiring loom
l D066 - Wiring connector for electric pump wiring loom
l D076 - Wiring connector for rear wiring loom
l D076 - Wiring connector for SDD wiring loom
l D078 - Wiring connector for distributor 7/8 wiring loom
l D078 - Wiring connector for rear wiring loom
l D081 - Wiring connector for Stoll wiring loom
l D081 - Wiring connector for rear wiring loom
l H004 - Rear PTO rotation mode selection lever (Standard-Economic)
l H005 - Synchronised rear PTO selection lever
l I001 - Start enable switch
l Jf004 - Electric pump relay

40-607
 Wiring diagrams
I001 K018 K019 M004 M003 D044

O009

Jf004 B003

B002

D025

Fig. 2857
l K003 – HML speed sensor
l K004 - Wheel speed sensor
l K005 - Rear lift position sensor
l K006 - PTO speed sensor
l K007 - Brake oil sensor
l K010 - Fuel level sensor
l K012 - Gearbox output shaft speed sensor
l K013 - Transmission oil temperature sensor
l K018 - Water in fuel filter sensor
l K019 - Engine coolant temperature sensor
l K035 - Trailer hydraulic braking pressure sensor
l K038 - Transmission filter sensor
l K040 - Right hand lift draft tie-rod sensor
l K043 - Clogged Pal filter sensor
l K044 - Radar
l K045 - Front suspended axle speed sensor
l L003 - Rear PTO control solenoid valve
l L004 - Rear lift ‘DOWN’ control solenoid valve
l L005 - Rear lift ‘UP’ control solenoid valve
l L007 - Differential lock control solenoid valve
l L008 - 60 L. ECO solenoid valve
l L009 - ECO Solenoid valve
l L010 - “HIGH” range solenoid valve
l L011 - “Medium” range solenoid valve
l L012 - “Low” range solenoid valve
l L013 - Reverse proportional solenoid valve
l L014 - Forward drive solenoid valve
l L020 - Four-wheel drive solenoid valve
l L024 - R (Reverse) solenoid valve
l L025 - HI/LO solenoid valve
l M003 - Deutz-AG engine control unit
l M004 - Deutz-AG engine control unit

40-608
Wiring diagrams
I001 K018 K019 M004 M003 D044

O009

Jf004 B003

B002

D025

Fig. 2857
l O003 - Resistor, 120 ohm
l P028 - Services connector
l R005 - Diagnostics port

Table 350
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
B002 Fbat 1 fuse
B003 Fbat 2 fuse
C002 Grounding point
D023 Wiring connector for front wiring loom
D023 Wiring connector for rear wiring loom
D024 Wiring connector for front wiring loom
D024 Wiring connector for rear wiring loom
D025 Wiring connector to cab wiring loom
D025 Wiring connector for rear wiring loom
D026 Wiring connector to cab wiring loom
D026 Wiring connector for rear wiring loom
D028 Wiring connector for front light wiring loom-
horn
D028 Wiring connector for rear wiring loom
D029 Wiring connector for rear wiring loom
SBA D029 Wiring connector for SBA/ASM wiring loom
HYDR SV D040 Wiring connector for hydraulic trailer brak-
ing solenoid valve wiring loom
D040 Wiring connector for rear wiring loom
D041 Wiring connector for rear wiring loom
AIR D041 Wiring connector for Air braking pressure
switch wiring loom
D044 Wiring connector for engine wiring loom
D066 Wiring connector to cab wiring loom

40-609
 Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D066 Wiring connector for electric pump wiring
loom
D076 Wiring connector for rear wiring loom
D076 Wiring connector for SDD wiring loom
D078 Wiring connector for distributor 7/8 wiring
loom
D078 Wiring connector for rear wiring loom
D081 Wiring connector to STOLL wiring loom
D081 Wiring connector for rear wiring loom
H004 Rear PTO rotation mode selection lever
(Standard-Economic)
H005 Synchronised rear PTO selection lever
I001 Starter enable switch
Jf004 Electric pump relay
SPEED SENSOR K003 HML speed sensor
WHEEL K004 Wheels speed sensor
POS K005 Rear lift position sensor
K006 PTO speed sensor
K007 Brake oil sensor
FUEL K010 Fuel level sensor
WHEEL K012 Gearbox output shaft speed sensor
TEMP K013 Transmission oil temperature sensor
K018 Water in fuel filter sensor
K019 Engine coolant temperature sensor
HYDR K035 Trailer hydraulic braking pressure sensor
K038 Transmission filter sensor
K040 Right hand lift draft tie-rod sensor
K043 Clogged Pal filter sensor
BRAKE K044 Radar
K045 Front suspended axle speed sensor
REAR PTO L003 Rear PTO control solenoid valve
DW L004 Rear lift DOWN control solenoid valve
UP L005 Rear lift ‘UP’ control solenoid valve
EV DF L007 Differential lock control solenoid valve
SAV L008 60 L./ECO solenoid valve
ECO L009 ECO solenoid valve
H L010 “HIGH” range solenoid valve
M L011 “Medium” range solenoid valve
L L012 “Low” range solenoid valve
P L013 Reverse proportional solenoid valve
F L014 Forward drive solenoid valve
L020 Four-wheel drive solenoid valve
L024 R (Reverse) solenoid valve
L025 HI/LO solenoid valve
M003 DEUTZ-AG engine control unit
M004 DEUTZ-AG engine control unit
O003 Resistance: 120 ohm
SERVICE P028 Services connector
R005 Diagnostics socket

40-610
Wiring diagrams
40.4.5 - 0.014.1567.4/20 - Front windscreen wiper
N001

H1

A1

D033
N001

AB1

AN1

TABELLA COLORI / COLOURS TABL E

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

D033

Fig. 2860
l D033 - Wiring connector for roof line wiring loom
l N001 - Front PTO control solenoid valve
Table 351
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D033 Wiring connector for cab roof wiring loom
N001 Front PTO control solenoid valve

40-611
 Wiring diagrams
40.4.6 - 0.014.8453.4 - Front wiper motor - fixed windscreen version

D033 N002

H1 (53a/+12V)
A1 (53/1SP)
TABELLA COLORI / COLOURS TABL E

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

N002 D033 Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

AB1 (-31/GND)
S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

AN1 (31b/ZERO)

Fig. 2861
l D033 - Wiring connector for roof line wiring loom
l N002 - Windscreen wiper motor (fixed windscreen)
Table 352
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D033 Wiring connector for cab roof wiring loom
N002 Windscreen wiper motor (fixed windscreen)

40.4.7 - 0.020.6706.4/20 - Roof

P015 G007
D031
P013

D060
N019

D058
I078

I037

N007 K046 I079

N006

M012
F027
P011 F026
F025 I080

I081

I039

D033

C017 C016

D058
J001 J007 D061
D030

D001
D002

Fig. 2862
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom

40-612
Wiring diagrams
P015 G007
D031
P013

D060
N019

D058
I078

I037

N007 K046 I079

N006

M012
F027
P011 F026
F025 I080

I081

I039

D033

C017 C016

D058
J001 J007 D061
D030

D001
D002

Fig. 2862
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D030 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D031 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D033 - Wiring connector for roof wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l G007 - Light in cab
l I037 - Rotating beacon switch
l I039 - Rear screen wiper switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l J007 - AC system fan relay
l K046 - Evaporator sensor
l M012 - A/C control unit
l N006 - Rear window wiper motor
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer
l P011 - LH loudspeaker

40-613
 Wiring diagrams
P015 G007
D031
P013

D060
N019

D058
I078

I037

N007 K046 I079

N006

M012
F027
P011 F026
F025 I080

I081

I039

D033

C017 C016

D058
J001 J007 D061
D030

D001
D002

Fig. 2862
l P013 - RH loudspeaker
l P015 - Radio

40-614
Wiring diagrams

D002

P013
P011

F026
F025 D060 D061 M012

F027

G007
P015

D001

D032

D031 N006

N007

I039 K046

N007

J007
I037
D002

D059 D058 C017 C016 N019 D033 I080 I081 I079 I078
J001

Fig. 2865
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D030 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D031 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom

40-615
 Wiring diagrams
l D033 - Wiring connector for roof wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light
l G007 - Light in cab
l I037 - Rotating beacon switch
l I039 - Rear screen wiper switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l J007 - AC system fan relay
l K046 - Evaporator sensor
l M012 - A/C control unit
l N006 - Rear window wiper motor
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer
l P011 - LH loudspeaker
l P013 - RH loudspeaker
l P015 - Radio

40-616
Wiring diagrams

Fig. 2866
l C016 - Grounding point
l C017 - Grounding point
l D001 - Wiring connector to cab wiring loom
l D001 - Wiring connector for roof wiring loom
l D002 - Wiring connector to cab wiring loom
l D002 - Wiring connector for roof wiring loom
l D030 - Wiring connector for rotating beacon 1 wiring loom
l D030 - Wiring connector for roof wiring loom
l D031 - Wiring connector for rotating beacon 2 wiring loom
l D031 - Wiring connector for roof wiring loom
l D033 - Wiring connector for windscreen wiper wiring loom
l D033 - Wiring connector for roof wiring loom
l D058 - Wiring connection for work lights wiring loom
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connection for work lights wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connection for work lights wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connection for work lights wiring loom
l D061 - Wiring connector for roof wiring loom
l F025 - Left hand ambient light
l F026 - Spot light
l F027 - Right hand ambient light

40-617
 Wiring diagrams

Fig. 2866
l G007 - Light in cab
l I037 - Rotating beacon switch
l I039 - Rear screen wiper switch
l I078 - Switch for rear work lights on roof
l I079 - Switch for front work lights on roof
l I080 - Windscreen wiper switch
l I081 - Windscreen washer pump switch
l J001 - Windscreen wiper relay
l J007 - AC system fan relay
l K046 - Evaporator sensor
l M012 - A/C control unit
l N006 - Rear window wiper motor
l N007 - Air-conditioning fan
l N019 - Temperature control potentiometer
l P011 - LH loudspeaker
l P013 - RH loudspeaker
l P015 - Radio
Table 353
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
C016 Grounding point
C017 Grounding point
D001 Wiring connector for cab/roof wiring loom

40-618
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D002 Wiring connector for cab/roof wiring loom
D030 Wiring connector for rotating beacon 1/roof
wiring loom
D031 Wiring connector for rotating beacon 2/roof
wiring loom
D033 Wiring connector for windscreen wiper/roof
wiring loom
REAR D058 Wiring connection to work lights/roof wiring
loom
REAR D059 Wiring connection to work lights/roof wiring
loom
FRONT D060 Wiring connection to work lights/roof wiring
loom
FRONT D061 Wiring connection to work lights/roof wiring
loom
F025 Left hand ambient light
F026 Spot light
F027 Right hand ambient light
G007 Cab light
FLASHER I037 Rotating beacon switch
WIPER I039 Rear screen wiper switch
I078 Switch for rear work lights on roof
I079 Switch for front work lights on roof
I080 Windscreen wiper switch
I081 Windscreen washer pump switch
J001 Windscreen wiper relay
J007 A/C fan relay
K046 Evaporator sensor
M012 Air conditioning control unit
N006 Rear window wiper motor
N007 Air-conditioning fan
N019 Temperature control valve
P011 LH loudspeaker
P013 RH loudspeaker
P015 Radio

40-619
 Wiring diagrams
40.4.8 - 0.020.7971.4/10 - Right hand console
I062

I061

I063

I066

D015

I065

I067

H020

I002
I068

H009

I071

I070
Fig. 2868
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l H009 - Hitch control console
l H020 - Mechanical hand throttle
l I002 - ECO Saving switch 60 l/min
l I061 - Automatic PTO control switch
l I062 - Front PTO clutch control push button
l I063 - Rear PTO clutch control push button
l I065 - Rear hitch up push-button
l I066 - Rear hitch stop push-button
l I067 - Rear hitch down push-button
l I070 - Dual traction activation push button
l I071 - Differential lock switch

40-620
Wiring diagrams
I002 I061 I071 I070 H020 I068 H009 I065 I066 I067 I062 I063

D015

Fig. 2869
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l H009 - Hitch control console
l H020 - Mechanical hand throttle
l I002 - ECO Saving switch 60 l/min
l I061 - Automatic PTO control switch
l I062 - Front PTO clutch control push button
l I063 - Rear PTO clutch control push button
l I065 - Rear hitch up push-button
l I066 - Rear hitch stop push-button
l I067 - Rear hitch down push-button
l I070 - Dual traction activation push button
l I071 - Differential lock switch

40-621
 Wiring diagrams

Fig. 2870
l D015 - Wiring connector to cab wiring loom
l D015 - Wiring connector for console wiring loom
l H009 - Hitch control console
l H020 - Mechanical hand throttle
l I002 - ECO Saving switch 60 l/min
l I061 - Automatic PTO control switch
l I062 - Front PTO clutch control push button
l I063 - Rear PTO clutch control push button
l I065 - Rear hitch up push-button
l I066 - Rear hitch stop push-button
l I067 - Rear hitch down push-button
l I070 - Dual traction activation push button
l I071 - Differential lock switch
Table 354
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D015 Wiring connector to cab wiring loom
HITCH CONSOLE H009 Hitchcontrol instrument panel
HAND GAS H020 Mechanical hand throttle
60L I002 ECO Saving switch 60 l/min
PTO AUTO I061 Automatic PTO control switch

40-622
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
FRONT PTO I062 Front PTO clutch control push button
REAR PTO I063 Rear PTO clutch control push button
UP I065 Rear hitch up push-button
STOP I066 Rear hitch stop push-button
DW I067 Rear hitch down push-button
DT I070 Dual traction activation push button
DF I071 Differential lock activation switch

40.4.9 - 0.019.9803.4 - Front light-horn - High (5090 C -> ZKDY360200TD10001)

F011

F013

F014

F012

F015

K027 D028
F017

F018
E004
F016
Fig. 2871
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor

40-623
 Wiring diagrams
CV0.75 AUTO CLIMA TEMP.
1
RV0.75 AUTO CLIMA TEMP.
2
K027

N1.5 GND
1
ZN1.5 W.L.LT F018
2
N1.5 GND
1
C1.5 W.L.RH F013
2
Z0.75 CLACSON
1
N0.75 GND
2 E004
N1.5 GND
1
ZG1.5 HIGH BEAM LIGHT RH
2 F011
N1.5 GND
1
X3 ZG1.5 HIGH BEAM LIGHT LT
X1
2 F016
N1.5 GND
1
LB1.5 LOW BEAM LIGHT RH
2 F012
N1.5 GND
1
X4 LB1.5 LOW BEAM LIGHT LT F015
2
X2
CB1 LED BAR RH
1
N0.75 GND
2 F014
ZB1 LED BAR LT
1
N0.75 GND
2 F017
X5
CV0.75 AUTO CLIMA TEMP.

RV0.75 AUTO CLIMA TEMP.

ZG1.5 HIGH BEAM LIGHT
LB1.5 LOW BEAM LIGHT

Z0.75 CLACSON
ZB1 LED BAR LT

CB1 LED BAR RH

ZN1.5 W.L.LT

C1.5 W.L.RH
N0.75 GND
N0.75 GND

N1.5 GND
N1.5 GND

N1.5 GND
N1.5 GND

21
11
16
19
20

12
14

15
18
17

4
10
2

3
13
5

8
7
1
9

D028

Fig. 2872
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor
Table 355
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D028 Wiring connector for rear wiring loom
E004 Horn
D028 Wiring connector for rear wiring loom
E004 Horn

40-624
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F011 Rh high beam headlight
F012 Rh low beam headlight
F013 RH work light
F014 Right LED light
F015 Lh low beam headlight
F016 Lh high beam headlight
F017 Left LED light
F018 LH work light
K027 Ambient temperature sensor

40.4.10 - 0.019.9803.4 - Front light-horn - High (5100 C -> ZKDY400200TD10001)

F011

F013

F014

F012

F015

K027 D028
F017

F018
E004
F016
Fig. 2873
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor

40-625
 Wiring diagrams
CV0.75 AUTO CLIMA TEMP.
1
RV0.75 AUTO CLIMA TEMP.
2
K027

N1.5 GND
1
ZN1.5 W.L.LT F018
2
N1.5 GND
1
C1.5 W.L.RH F013
2
Z0.75 CLACSON
1
N0.75 GND
2 E004
N1.5 GND
1
ZG1.5 HIGH BEAM LIGHT RH
2 F011
N1.5 GND
1
X3 ZG1.5 HIGH BEAM LIGHT LT
X1
2 F016
N1.5 GND
1
LB1.5 LOW BEAM LIGHT RH
2 F012
N1.5 GND
1
X4 LB1.5 LOW BEAM LIGHT LT F015
2
X2
CB1 LED BAR RH
1
N0.75 GND
2 F014
ZB1 LED BAR LT
1
N0.75 GND
2 F017
X5
CV0.75 AUTO CLIMA TEMP.

RV0.75 AUTO CLIMA TEMP.

ZG1.5 HIGH BEAM LIGHT
LB1.5 LOW BEAM LIGHT

Z0.75 CLACSON
ZB1 LED BAR LT

CB1 LED BAR RH

ZN1.5 W.L.LT

C1.5 W.L.RH
N0.75 GND
N0.75 GND

N1.5 GND
N1.5 GND

N1.5 GND
N1.5 GND

21
11
16
19
20

12
14

15
18
17

4
10
2

3
13
5

8
7
1
9

D028

Fig. 2874
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor
Table 356
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D028 Wiring connector for rear wiring loom
E004 Horn
D028 Wiring connector for rear wiring loom
E004 Horn

40-626
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F011 Rh high beam headlight
F012 Rh low beam headlight
F013 RH work light
F014 Right LED light
F015 Lh low beam headlight
F016 Lh high beam headlight
F017 Left LED light
F018 LH work light
K027 Ambient temperature sensor

40.4.11 - 0.019.9803.4 - Front light-horn - High (5110 C -> ZKDY440200TD10001)

F011

F013

F014

F012

F015

K027 D028
F017

F018
E004
F016
Fig. 2875
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor

40-627
 Wiring diagrams
CV0.75 AUTO CLIMA TEMP.
1
RV0.75 AUTO CLIMA TEMP.
2
K027

N1.5 GND
1
ZN1.5 W.L.LT F018
2
N1.5 GND
1
C1.5 W.L.RH F013
2
Z0.75 CLACSON
1
N0.75 GND
2 E004
N1.5 GND
1
ZG1.5 HIGH BEAM LIGHT RH
2 F011
N1.5 GND
1
X3 ZG1.5 HIGH BEAM LIGHT LT
X1
2 F016
N1.5 GND
1
LB1.5 LOW BEAM LIGHT RH
2 F012
N1.5 GND
1
X4 LB1.5 LOW BEAM LIGHT LT F015
2
X2
CB1 LED BAR RH
1
N0.75 GND
2 F014
ZB1 LED BAR LT
1
N0.75 GND
2 F017
X5
CV0.75 AUTO CLIMA TEMP.

RV0.75 AUTO CLIMA TEMP.

ZG1.5 HIGH BEAM LIGHT
LB1.5 LOW BEAM LIGHT

Z0.75 CLACSON
ZB1 LED BAR LT

CB1 LED BAR RH

ZN1.5 W.L.LT

C1.5 W.L.RH
N0.75 GND
N0.75 GND

N1.5 GND
N1.5 GND

N1.5 GND
N1.5 GND

21
11
16
19
20

12
14

15
18
17

4
10
2

3
13
5

8
7
1
9

D028

Fig. 2876
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor
Table 357
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D028 Wiring connector for rear wiring loom
E004 Horn
D028 Wiring connector for rear wiring loom
E004 Horn

40-628
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F011 Rh high beam headlight
F012 Rh low beam headlight
F013 RH work light
F014 Right LED light
F015 Lh low beam headlight
F016 Lh high beam headlight
F017 Left LED light
F018 LH work light
K027 Ambient temperature sensor

40.4.12 - 0.019.9803.4 - Front light-horn - High (5100 C -> ZKDY480200TD10001)

F011

F013

F014

F012

F015

K027 D028
F017

F018
E004
F016
Fig. 2877
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor

40-629
 Wiring diagrams
CV0.75 AUTO CLIMA TEMP.
1
RV0.75 AUTO CLIMA TEMP.
2
K027

N1.5 GND
1
ZN1.5 W.L.LT F018
2
N1.5 GND
1
C1.5 W.L.RH F013
2
Z0.75 CLACSON
1
N0.75 GND
2 E004
N1.5 GND
1
ZG1.5 HIGH BEAM LIGHT RH
2 F011
N1.5 GND
1
X3 ZG1.5 HIGH BEAM LIGHT LT
X1
2 F016
N1.5 GND
1
LB1.5 LOW BEAM LIGHT RH
2 F012
N1.5 GND
1
X4 LB1.5 LOW BEAM LIGHT LT F015
2
X2
CB1 LED BAR RH
1
N0.75 GND
2 F014
ZB1 LED BAR LT
1
N0.75 GND
2 F017
X5
CV0.75 AUTO CLIMA TEMP.

RV0.75 AUTO CLIMA TEMP.

ZG1.5 HIGH BEAM LIGHT
LB1.5 LOW BEAM LIGHT

Z0.75 CLACSON
ZB1 LED BAR LT

CB1 LED BAR RH

ZN1.5 W.L.LT

C1.5 W.L.RH
N0.75 GND
N0.75 GND

N1.5 GND
N1.5 GND

N1.5 GND
N1.5 GND

21
11
16
19
20

12
14

15
18
17

4
10
2

3
13
5

8
7
1
9

D028

Fig. 2878
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor
Table 358
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D028 Wiring connector for rear wiring loom
E004 Horn
D028 Wiring connector for rear wiring loom
E004 Horn

40-630
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F011 Rh high beam headlight
F012 Rh low beam headlight
F013 RH work light
F014 Right LED light
F015 Lh low beam headlight
F016 Lh high beam headlight
F017 Left LED light
F018 LH work light
K027 Ambient temperature sensor

40.4.13 - 0.019.9803.4 - Front light-horn - High (5110 C -> ZKDY520200TD10001)

F011

F013

F014

F012

F015

K027 D028
F017

F018
E004
F016
Fig. 2879
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor

40-631
 Wiring diagrams
CV0.75 AUTO CLIMA TEMP.
1
RV0.75 AUTO CLIMA TEMP.
2
K027

N1.5 GND
1
ZN1.5 W.L.LT F018
2
N1.5 GND
1
C1.5 W.L.RH F013
2
Z0.75 CLACSON
1
N0.75 GND
2 E004
N1.5 GND
1
ZG1.5 HIGH BEAM LIGHT RH
2 F011
N1.5 GND
1
X3 ZG1.5 HIGH BEAM LIGHT LT
X1
2 F016
N1.5 GND
1
LB1.5 LOW BEAM LIGHT RH
2 F012
N1.5 GND
1
X4 LB1.5 LOW BEAM LIGHT LT F015
2
X2
CB1 LED BAR RH
1
N0.75 GND
2 F014
ZB1 LED BAR LT
1
N0.75 GND
2 F017
X5
CV0.75 AUTO CLIMA TEMP.

RV0.75 AUTO CLIMA TEMP.

ZG1.5 HIGH BEAM LIGHT
LB1.5 LOW BEAM LIGHT

Z0.75 CLACSON
ZB1 LED BAR LT

CB1 LED BAR RH

ZN1.5 W.L.LT

C1.5 W.L.RH
N0.75 GND
N0.75 GND

N1.5 GND
N1.5 GND

N1.5 GND
N1.5 GND

21
11
16
19
20

12
14

15
18
17

4
10
2

3
13
5

8
7
1
9

D028

Fig. 2880
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor
Table 359
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D028 Wiring connector for rear wiring loom
E004 Horn
D028 Wiring connector for rear wiring loom
E004 Horn

40-632
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F011 Rh high beam headlight
F012 Rh low beam headlight
F013 RH work light
F014 Right LED light
F015 Lh low beam headlight
F016 Lh high beam headlight
F017 Left LED light
F018 LH work light
K027 Ambient temperature sensor

40.4.14 - 0.019.9803.4 - Front light-horn - High (5120 C -> ZKDY560200TD10001)

F011

F013

F014

F012

F015

K027 D028
F017

F018
E004
F016
Fig. 2881
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor

40-633
 Wiring diagrams
CV0.75 AUTO CLIMA TEMP.
1
RV0.75 AUTO CLIMA TEMP.
2
K027

N1.5 GND
1
ZN1.5 W.L.LT F018
2
N1.5 GND
1
C1.5 W.L.RH F013
2
Z0.75 CLACSON
1
N0.75 GND
2 E004
N1.5 GND
1
ZG1.5 HIGH BEAM LIGHT RH
2 F011
N1.5 GND
1
X3 ZG1.5 HIGH BEAM LIGHT LT
X1
2 F016
N1.5 GND
1
LB1.5 LOW BEAM LIGHT RH
2 F012
N1.5 GND
1
X4 LB1.5 LOW BEAM LIGHT LT F015
2
X2
CB1 LED BAR RH
1
N0.75 GND
2 F014
ZB1 LED BAR LT
1
N0.75 GND
2 F017
X5
CV0.75 AUTO CLIMA TEMP.

RV0.75 AUTO CLIMA TEMP.

ZG1.5 HIGH BEAM LIGHT
LB1.5 LOW BEAM LIGHT

Z0.75 CLACSON
ZB1 LED BAR LT

CB1 LED BAR RH

ZN1.5 W.L.LT

C1.5 W.L.RH
N0.75 GND
N0.75 GND

N1.5 GND
N1.5 GND

N1.5 GND
N1.5 GND

21
11
16
19
20

12
14

15
18
17

4
10
2

3
13
5

8
7
1
9

D028

Fig. 2882
l D028 - Wiring connector for rear wiring loom
l E004 - Horn
l F011 - RH high beam headlight
l F012 - RH low beam headlight
l F013 - RH work light
l F014 - Right hand LED light
l F015 - LH low beam headlight
l F016 - LH high beam headlight
l F017 - Left hand LED light
l F018 - LH work light
l K027 - Ambient temperature sensor
Table 360
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D028 Wiring connector for rear wiring loom
E004 Horn
D028 Wiring connector for rear wiring loom
E004 Horn

40-634
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F011 Rh high beam headlight
F012 Rh low beam headlight
F013 RH work light
F014 Right LED light
F015 Lh low beam headlight
F016 Lh high beam headlight
F017 Left LED light
F018 LH work light
K027 Ambient temperature sensor

40.4.15 - 0.020.8203.4 - Cab roof work lights

F003/F042

D060/D061

FRONT WORK LIGHT1 B1.5 06

4
GND N1.5
2 1
TO ROOF W.H. D060/D061
F003/F042 WORK LIGHT FRONT1
2
21 3

F044/F065

F045/F066

F046/F067 4a HAZARD USA CN 1.5

F044/F065 HAZARD LIGHT 2
1 GND N1.5 RIGHT USA DIR

4 7
REAR WORK LIGHT1 V1.5
F045/F066 1 4
WORK LIGHT REAR 12 GND N1.5
REAR WORK LIGHT2 V1.5
1
TO ROOF W.H. D058/D059
2
GND N1.5 3
5
F046/F067 1
WORK LIGHT REAR 22

Fig. 2883
l D058 - Wiring connector for roof wiring loom
l D059 - Wiring connector for roof wiring loom
l D060 - Wiring connector for roof wiring loom
l D061 - Wiring connector for roof wiring loom

40-635
 Wiring diagrams
F003/F042

D060/D061

FRONT WORK LIGHT1 B1.5 06

4
GND N1.5
2 1
TO ROOF W.H. D060/D061
F003/F042 WORK LIGHT FRONT1
2
21 3

F044/F065

F045/F066

F046/F067 4a HAZARD USA CN 1.5

F044/F065 HAZARD LIGHT 2
1 GND N1.5 RIGHT USA DIR

4 7
REAR WORK LIGHT1 V1.5
F045/F066 1 4
WORK LIGHT REAR 12 GND N1.5
REAR WORK LIGHT2 V1.5
1
TO ROOF W.H. D058/D059
2
GND N1.5 3
5
F046/F067 1
WORK LIGHT REAR 22

Fig. 2883
l F003 - Front work light on cab
l F042 - Front work light on cab
l F044 - Hazard Light
l F045 - Rear work light on cab
l F046 - Rear work light on cab
l F065 - Hazard Light
l F066 - Rear work light on cab
l F067 - Rear work light on cab
Table 361
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D058 Wiring connector for roof wiring loom
D059 Wiring connector for roof wiring loom
D060 Wiring connector for roof wiring loom
D061 Wiring connector for roof wiring loom
F003 Front work light on cab
F042 Front work light on cab

40-636
Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
F044 Hazard Light
F045 Rear work light on cab
F046 Rear work light on cab
F065 Hazard Light
F066 Rear work light on cab
F067 Rear work light on cab

40.4.16 - 0.020.9462.4/10 - Rotating beacon

F001/F002 D030/D031

Fig. 2885
l D030 - Wiring connector for roof wiring loom
l D031 - Wiring connector for roof wiring loom
l F001 - Rotating beacon connection
l F002 - Rotating beacon 2 connection

40-637
 Wiring diagrams

Fig. 2886
l D030 - Wiring connector for roof wiring loom
l D031 - Wiring connector for roof wiring loom
l F001 - Rotating beacon connection
l F002 - Rotating beacon 2 connection
Table 362
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D030 Wiring connector for roof wiring loom
D031 Wiring connector for roof wiring loom
F001 Rotating beacon connection
F002 Rotating beacon connection 2

40-638
Wiring diagrams
40.4.17 - 0.021.1196.4 – Lower front work lights wiring loom – H9
RV 1 RV 1
M1 M1

D069/D070 F047/F048

Fig. 2887
l D069 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l F047 - Lower front work light
l F048 - Lower front work light

Fig. 2888
l D069 - Wiring connector to cab front lights wiring loom
l D070 - Wiring connector to cab front lights wiring loom
l F047 - Lower front work light

40-639
 Wiring diagrams

Fig. 2888
l F048 - Lower front work light
Table 363
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D069 Wiring connector to cab front lights wiring
loom
D070 Wiring connector to cab front lights wiring
loom
F047 Lower front work light
F048 Lower front work light

40-640
Wiring diagrams
40.4.18 - 0.012.2756.3 - Front PTO solenoid valve

D032 L001

D032 L001

Fig. 2890
l D032 - Wiring connector for front wiring loom
l L001 - Front PTO control solenoid valve
Table 364
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D032 Wiring connector for front wiring loom
L001 Front PTO control solenoid valve

40.4.19 - 0.011.3797.3 - SBA-ASM (GS-LS 110 HP) (5100 C -> ZKDY480200TD10001, 5110 C
-> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

D029 K001

K001
6 TABELLA COLORI / COLOURS TABLE
5
D029 M Marrone/B rown C Arancio/Oran ge
4 V Verde/Green A Azzur ro/Blue
N1 Z Viola/Violet B Bianco/White
3 3
V1 N Nero/Bla ck L Blu/Dark Blue
2 2 S Rosa/Pink G Giallo/ Yell ow
C1
1 1 R Rosso/Red H Grigio/Gr ay

Fig. 2891
l D029 - Wiring connector for rear wiring loom
l K001 - Steering angle sensor (SBA)
Table 365
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D029 Wiring connector for rear wiring loom
K001 Steering angle sensor (SBA)

40-641
 Wiring diagrams
40.4.20 - 0.017.9311.4/30 – Hydraulic reverse shuttle wiring loom - Stoll (GS only) (5100 C
-> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

I086

I085

I084 H024

I083

D082

D081 D082

Fig. 2892
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l H024 - Single lever Stoll controller
l I083 - Comfort Drive switch
l I084 - Hydro Lock switch
l I085 - Return to level / 3rd function switch
l I086 - Quick empty / 4th function switch

40-642
Wiring diagrams

1
2 6
7
3 5
4
H024

1
2
3
4

1
2
3
2
4

1
3
2
1
3
2
1

I083 I085
D082

I084 I086
drop down / quick dump

rescoop / return to level

1 + 12V
2 GND
Joystick Service 3
Joystick Service 4
2 Loader dump.
2 Hydro Lock

Service 4
Service 3
Service 3

+ 12V
1 + 12V

1 + 12V
3 GND

3 GND

1
3
2
4
2
3
4
1

Fig. 2893
l D081 - Wiring connector for Stoll wiring loom
l D082 - Wiring connector for Stoll wiring loom switches
l H024 - Single lever Stoll controller
l I083 - Comfort Drive switch
l I084 - Hydro Lock switch
l I085 - Return to level / 3rd function switch
l I086 - Quick empty / 4th function switch
Table 366
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D081 Wiring connector to STOLL wiring loom

40-643
 Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D082 Wiring connector for Stoll wiring loom
switches
H024 Single lever Stoll controller
I083 Comfort Drive switch
I084 Hydro Lock switch
I085 Return to level / 3rd function switch
I086 Quick empty / 4th function switch

40.4.21 - 0.015.1440 – Shuttle SV wiring loom, 100 HP (for GS 110/120 HP only) (5110 C
-> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
1-C1 1-C1
2-Z1
2-Z1

D079/D080 L014/L024

Fig. 2894
l D079 - Wiring connector for wiring loom, 100/110 HP
l D080 - Wiring connector for wiring loom, 100/110 HP
l L014 - Forward drive solenoid valve
l L024 - R solenoid valve
Table 367
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D079 Wiring connector for wiring loom, 100/110
HP
D080 Wiring connector for wiring loom, 100/110
HP
L014 Forward drive solenoid valve
L024 R solenoid valve

40-644
Wiring diagrams
40.4.22 - 0.014.1645.4/10 - ITA-D Air braking pressure switch

K002 1 1 D041

K002 1 1 D041

TABELLA COLORI / COLOURS TABLE

M Marrone/Brow n C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/V iolet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Y ellow
R Rosso/Red H Grigio/Gray

Fig. 2895
l D041 - Wiring connector for rear wiring loom
l K002 - Front PTO control solenoid valve
Table 368
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D041 Wiring connector for rear wiring loom
K002 Front PTO control solenoid valve

40.4.23 - 0.019.8827.4 - S.D.D (5100 C -> ZKDY480200TD10001, 5110 C -> ZK-

DY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)

40-645
 Wiring diagrams

AMP

2
L019

1
2 3 4 5
D076 AMP

3
AMP

K032

2
1
1 SDD VALVE
L019
2 -31
AN0.75
SDD VALVE 1
N0.75
-31 2
C0.75
D076 SDD SENSOR 3
RN0.75
+5V 4 1 +5V
GNDCOM 5 MN0.75
2 GNDCOM K032
3 SDD SENSOR

Fig. 2896
l D076 - Wiring connector for central wiring loom
l K032 - SDD proximity sensor
l L019 - SDD Solenoid valve

40-646
Wiring diagrams

Fig. 2897
l D076 - Wiring connector for central wiring loom
l K032 - SDD proximity sensor
l L019 - SDD Solenoid valve
Table 369
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D076 Wiring connector for central wiring loom
K032 SDD proximity sensor
L019 SDD solenoid valve

40-647
 Wiring diagrams
40.4.24 - 0.016.1001.4/20 - Hydraulic trailer braking valve

L002

2
D040

1
C1
1 1
D040 Z1 L002
2 2

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

Fig. 2898
l D040 - Wiring connector for rear wiring loom
l L002 - Trailer parking brake control solenoid valve
Table 370
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D040 Wiring connector for rear wiring loom
L002 Trailer parking brake control solenoid valve

40-648
Wiring diagrams
40.4.25 - 0.018.5346.4 – 2-way electronic distributor electrical system wiring loom
L023

L021

D078
L022

BY 255
X com

D078
BY 255
VA 1
EV 1 EV 1 1 1 EV COM EV COM
EV 2 EV 2 2
VS 1 N1 2 -31 -31
L023
N1
-31 -31 3
X1
1 EV 1 EV 1
N1 2 -31 -31
L021
X GND

1 EV 2 EV 2
X2 N1 2 -31 -31 L022

Fig. 2899
l D078 - Wiring connector for wiring loom 7/8
l L021 - Solenoid valve SV 1
l L022 - Solenoid valve SV 2
l L023 - COM SV solenoid valve
l

40-649
 Wiring diagrams

Fig. 2900
l D078 - Wiring connector for wiring loom 7/8
l L021 - Solenoid valve SV 1
l L022 - Solenoid valve SV 2
l L023 - COM SV solenoid valve
l

Table 371
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D078 Wiring connector for wiring loom 7/8
L021 Solenoid valve SV 1
L022 Solenoid valve SV 2
L023 COM SV solenoid valve

40-650
Wiring diagrams
40.4.26 - 0.020.0726.4 - Fuel pre-filter

N014

D066

N015

R 2.5
N014
1 +30
D066
2 -31 GND
N 2.5
N015

TABELLA COLORI / COLOURS TABL E

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

Fig. 2901
l D066 - Wiring connector for central wiring loom
l N014 - Pump + power
l N015 - Pump - power

40-651
 Wiring diagrams

Fig. 2902
l D066 - Wiring connector for central wiring loom
l N014 - Pump + power
l N015 - Pump - power
Table 372
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D066 Wiring connector for central wiring loom
N014 Pump + power
N015 Pump - power

40-652
Wiring diagrams
40.4.27 - 0.020.6714.4 - Battery wiring (-)

I031b A003

I031a C011

Fig. 2903
l A003 - Alternator “B+”
l C011 - Battery ground
l I031a - Battery master switch button
l I031b - Battery master switch button

40-653
 Wiring diagrams

Fig. 2904
l A003 - Alternator “B+”
l C011 - Battery ground
l I031a - Battery master switch button
l I031b - Battery master switch button
Table 373
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
A003 Alternator “B+”
C011 Battery earth
I031a Battery disconnect switch
I031b Battery disconnect switch

40-654
Wiring diagrams
40.4.28 - 0.021.1202.4 - Battery wiring (+)
A006 B001 D043

A005
D042

A002 D042

Fig. 2905
l A002 - +30 Battery
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l D042 - Wiring connector
l D043 - Wiring connector to cab wiring loom

40-655
 Wiring diagrams

Fig. 2906
l A002 - +30 Battery
l A005 - Alternator “B+”
l A006 - +30 Battery
l B001 - Power fuse (150A)
l D042 - Wiring connector
l D043 - Wiring connector to cab wiring loom
Table 374
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
A002 +30 Battery
A005 Alternator “B+”
A006 +30 Battery
B001 Power fuse (150A)
D042 Wiring connector
D043 Wiring connector to cab wiring loom

40-656
Wiring diagrams
40.4.29 - 04219367 - Alternator fuse wiring loom (GS 100/110 HP - LS) (5090 C -> ZK-
DY360200TD10001, 5100 C -> ZKDY400200TD10001, 5100 C -> ZKDY480200TD10001,
5110 C -> ZKDY440200TD10001, 5110 C -> ZKDY520200TD10001)

A005

B004

Fig. 2907
l B004 - Pre-heating power feed fuse (150A)
l A005 - Alternator “B+”
Table 375
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
B004 Pre-heat power fuse (150 A)

40-657
 Wiring diagrams
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
A005 Alternator “B+”

40.4.30 - 0.019.5702.4 - ISO 11786

P014

M008

D011

L 0.75 +12 VOLT B 0.5 CAN L

2B
C 0.75 LIFT ON/OFF
N 0.75 -VCC 3B
G 0.75 PTO SPEED
Z 0.75 RADAR 4B
V 0.75 WHEEL
P014 Z 0.75 RADAR
5B
6B
V0.75 WHEEL S 0.75 LIFT POS 7B
123 L 0.75 +12 VOLT
X2 8B
S0.75 LIFT POS A 0.5 CAN H
456 2C
N 0.75 -VCC 8C
C 0.75 LIFT ON/OFF X1
G 0.75 PTO SPEED

M008

L 0.75 +12 VOLT

N 0.75 -VCC
A 0.5 CAN H
B 0.5 CAN L
D011

Fig. 2908
l D011 - Wiring connector for central wiring loom
l M008 - ECU ISO 11786 control unit
l P014 - Outlet power and signals ISO 11786

40-658
Wiring diagrams

Fig. 2909
l D011 - Wiring connector for central wiring loom
l M008 - ECU ISO 11786 control unit
l P014 - Outlet power and signals ISO 11786
Table 376
CODE STAMPED ON CONNECTOR INTERCONNECTION CODE DESCRIPTION
D011 Wiring connector for central wiring loom
M008 ECU 11786 control unit
P014 Outlet power and signals ISO 11786

40-659
 Wiring diagrams

PAGE LEFT INTENTIONALLY BLANK

40-660
INDEX

0
0.011.3797.3 - SBA-ASM (GS-LS 110 HP) (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 40-641
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
0.012.2756.3 - Front PTO solenoid valve 40-640
0.014.1567.4/20 - Front windscreen wiper 40-611
0.014.1645.4/10 - ITA-D Air braking pressure switch 40-644
0.014.8453.4 - Front wiper motor - fixed windscreen version 40-611
0.015.1440 – Shuttle SV wiring loom, 100 HP (for GS 110/120 HP only) (5110 C -> ZKDY520200TD10001, 40-644
5120 C -> ZKDY560200TD10001)
0.016.1001.4/20 - Hydraulic trailer braking valve 40-647
0.017.9311.4/30 – Hydraulic reverse shuttle wiring loom - Stoll (GS only) (5100 C -> ZKDY480200TD10001, 40-642
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
0.018.5346.4 – 2-way electronic distributor electrical system wiring loom 40-648
0.019.3018.4/20 - Front wiring loom 40-583
0.019.5702.4 - ISO 11786 40-658
0.019.8827.4 - S.D.D (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C -> ZK- 40-645
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
0.019.9803.4 - Front light-horn - High (5090 C -> ZKDY360200TD10001) 40-623
0.019.9803.4 - Front light-horn - High (5100 C -> ZKDY400200TD10001) 40-625
0.019.9803.4 - Front light-horn - High (5100 C -> ZKDY480200TD10001) 40-629
0.019.9803.4 - Front light-horn - High (5110 C -> ZKDY440200TD10001) 40-627
0.019.9803.4 - Front light-horn - High (5110 C -> ZKDY520200TD10001) 40-631
0.019.9803.4 - Front light-horn - High (5120 C -> ZKDY560200TD10001) 40-633
0.020.0726.4 - Fuel pre-filter 40-650
0.020.2857.4/10 - Rear wiring loom (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 40-606
5120 C -> ZKDY560200TD10001)
0.020.3229.4/30 - Rear wiring loom (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 40-596
5110 C -> ZKDY440200TD10001)
0.020.6706.4/20 - Roof 40-612
0.020.6707.4/20 - Cab () 40-586
0.020.6714.4 - Battery wiring (-) 40-652
0.020.7971.4/10 - Right hand console 40-620
0.020.8203.4 - Cab roof work lights 40-635
0.020.9462.4/10 - Rotating beacon 40-637
0.021.1196.4 – Lower front work lights wiring loom – H9 40-638
0.021.1202.4 - Battery wiring (+) 40-654
04217755 - Engine control unit 40-158
04219367 - Alternator fuse wiring loom (GS 100/110 HP - LS) (5090 C -> ZKDY360200TD10001, 5100 C 40-657
-> ZKDY400200TD10001, 5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 5110 C ->
ZKDY520200TD10001)

2
2.8339.285.0/30 - Digital instrument cluster (MTA 2.0) 40-164
2.8519.148.0 - ISO 11786 ECU 40-165
2.8519.171.0/20 - HLHP2 ECU (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001, 5110 40-160
C -> ZKDY440200TD10001)
2.8519.171.0/20 - HLHP2 ECU (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 40-162
C -> ZKDY560200TD10001)
2-way distributor 30-556

3
3-point linkage 30-597

4
4-rear way ancillary utility distributor 30-560
4WD shaft () 30-513

I
 INDEX

6
60 l/min. ECO AUX block 10-170
60L ECO 8-way distributor solenoid valve 30-552
6-rear way ancillary utility distributor 30-563

A
A - Starting and charging (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-26
A - Starting and charging (5100 C -> ZKDY480200TD10001) 40-28
A - Starting and charging (5110 C -> ZKDY440200TD10001) 40-26
A - Starting and charging (5110 C -> ZKDY520200TD10001) 40-28
A - Starting and charging (5120 C -> ZKDY560200TD10001) 40-30
A/C compressor belt 30-125
A/C system - High visibility version 10-118
A/C system - Version with standard roof 10-116
A/C unit 30-528
AC system alarms 20-195
Actuating elements 30-91
Adjustment of the differential - Bevel gear set (5090 C -> ZKDY360200TD10001, 5100 C -> ZK- 30-415
DY400200TD10001)
Adjustment of the differential - Bevel gear set (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 30-424
DY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Air filter container 30-154
Alternator 30-179, 30-180
Alternator / water pump belt 30-126
Alternator tightening torques 0-12
Auxiliary hitch cylinders 30-593

B
B - Fuses (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-30
B - Fuses (5100 C -> ZKDY480200TD10001) 40-43
B - Fuses (5110 C -> ZKDY440200TD10001) 40-37
B - Fuses (5110 C -> ZKDY520200TD10001) 40-49
B - Fuses (5120 C -> ZKDY560200TD10001) 40-55
B0 - Engine 30-30
Basic electronics for mechanics (1/2) 40-4
Basic electronics for mechanics (2/2) 40-7
Battery mount with wiring loom 30-569
Battery terminal tightening torques 0-11
Blower fan 30-167
Bodywork - Cab - Platform 10-116
Brake carrier (versions without Park Brake) 30-504
Braking system 10-201
Bushes 30-592

C
C - Grounds (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 40-61
C - Grounds (5100 C -> ZKDY480200TD10001) 40-64
C - Grounds (5110 C -> ZKDY440200TD10001) 40-63
C - Grounds (5110 C -> ZKDY520200TD10001) 40-66
C0 - Engine accessories 30-147
Cab 30-520
Cab access steps 30-531
Camshaft speed sensor 30-180
Care and maintenance work - Belt transmissions 10-58
Care and maintenance work - Cooling system 10-51
Care and maintenance work - Electrical system 10-62
Care and maintenance work - Engine cleaning 10-55
Care and maintenance work - Fuel distribution system 10-46
Care and maintenance work - Intake system 10-55
Care and maintenance work - Lubricant oil system 10-42
Cartridge valve tightening torques 0-25
Catalytic converter 30-148
Charge air duct 30-90

II
INDEX
Charge air manifold 30-90
Check the piston (L3) 30-136
Checking piston rings (L3) 30-141
Closing components 30-47
Clutch housing - Separation from transmission 30-221
Coefficient of friction 0-14
Commercially available tools 30-2
Commissioning (939571) - Accelerators calibration (5090 C -> ZKDY360200TD10001, 5100 C -> ZK- 20-139
DY400200TD10001, 5110 C -> ZKDY440200TD10001)
Commissioning (939571) - Accelerators calibration (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 20-141
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Commissioning (939571) - Basic procedure 20-132
Commissioning (939571) - Clutch pedal calibration (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 20-143
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Commissioning (939571) - Eeprom re-initialisation 20-135
Commissioning (939571) - Hicth calibration 20-145
Commissioning (939571) - Line end programming of the tractor 20-135
Commissioning (939571) - Options selection 20-144
Commissioning (939571) - Steering sensor calibration (SDD) (5100 C -> ZKDY480200TD10001, 5110 C -> 20-147
ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Commissioning and calibrating the tractor 20-128
Components 40-26
Condenser 30-526
Connecting rod drum check (L3) 30-126
Connection (crankcase, exhaust gas recovery, coolant pipe) 30-97
Connector casing 30-117
Console 30-118
Coolant fluid radiator 30-149

D
D - Intermediate connections (5090 C -> ZKDY360200TD10001) 40-67
D - Intermediate connections (5100 C -> ZKDY400200TD10001) 40-72
D - Intermediate connections (5100 C -> ZKDY480200TD10001) 40-81
D - Intermediate connections (5110 C -> ZKDY440200TD10001) 40-76
D - Intermediate connections (5110 C -> ZKDY520200TD10001) 40-86
D - Intermediate connections (5120 C -> ZKDY560200TD10001) 40-91
D0 - Transmission 30-187
Dehydrator filter 30-528
Diagnostic tool screens 20-93
Diagnostic tools 20-2
Digital Instrument Calibration 20-128
Disassembling cover assembly (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 30-197
C -> ZKDY560200TD10001)
Disassembling EasyShift DT clutch system 30-461
Disassembling front PTO 30-575
Disassembling M-L clutches (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C 30-275
-> ZKDY560200TD10001)
Disassembling PTO engagement clutch (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-351
Disassembling PTO engagement clutch (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 30-355
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Disassembling PTO final flange shaft - 4 speed version (5090 C -> ZKDY360200TD10001, 5100 C -> ZK- 30-367
DY400200TD10001)
Disassembling PTO final flange shaft - 4 speed version (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 30-371
DY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Disassembling shuttle solenoid valve block (5110 C -> ZKDY520200TD10001, 5120 C -> ZK- 30-542
DY560200TD10001)
Disassembling the 2-way distributor 30-557
Disassembling the 60L ECO 8-way distributor solenoid valve 30-554
Disassembling the ancillary solenoid valve block 30-539
Disassembling the brake carrier (versions without Park Brake) 30-503
Disassembling the complete pump assembly 30-547
Disassembling the condenser 30-527
Disassembling the gearbox input shaft (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 30-315
5120 C -> ZKDY560200TD10001)
Disassembling the ground speed PTO clutch engage mechanism 30-435
Disassembling the ground speed PTO flange output shaft 30-433
Disassembling the H clutch (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> 30-280
ZKDY560200TD10001)

III
 INDEX
Disassembling the HI range clutch housing (5090 C -> ZKDY360200TD10001, 5100 C -> ZK- 30-242
DY400200TD10001)
Disassembling the HI-LO planetary reduction gearbox (5090 C -> ZKDY360200TD10001, 5100 C -> ZK- 30-265
DY400200TD10001)
Disassembling the HI-LO planetary reduction gearbox (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 30-266
DY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Disassembling the hitch assembly (SAC) 30-587
Disassembling the HML unit 30-272
Disassembling the HML unit output shaft (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 30-330
5120 C -> ZKDY560200TD10001)
Disassembling the LO range clutch housing (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 30-254
DY440200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Disassembling the PTO flange shaft - 2-speed version () 30-363
Disassembling the PTO output shaft - 2-speed version 30-341
Disassembling the radiator assembly 30-158
Disassembling the range selector assembly 30-225
Disassembling the rear hitch control distributor 30-594
Disassembling the reverse drive clutch unit (5100 C -> ZKDY480200TD10001) 30-206
Disassembling the reverse drive clutch unit (5110 C -> ZKDY520200TD10001, 5120 C -> ZK- 30-211
DY560200TD10001)
Disassembling the shuttle unit (5100 C -> ZKDY480200TD10001) 30-191
Disassembling the shuttle unit (5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001) 30-194
Disassembly and assembly of the connector box 30-108, 30-109, 30-
111, 30-113, 30-115
Disassembly and assembly of the starter 30-176, 30-178
Disassembly and assembly the cylinder head (fastening elements) (L3) 30-142
Disassembly of dual traction clutch - Easyshift with mechanical park brake 30-465
Disassembly of dual traction output shaft (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-436
Disassembly of dual traction output shaft (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 30-441
5120 C -> ZKDY560200TD10001)
Disassembly of dual traction output shaft (5110 C -> ZKDY440200TD10001) 30-438
Disassembly of HI-LO unit output shaft (5090 C -> ZKDY360200TD10001, 5100 C -> ZKDY400200TD10001) 30-328
Disassembly of HI-LO unit output shaft (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY440200TD10001, 30-329
5110 C -> ZKDY520200TD10001, 5120 C -> ZKDY560200TD10001)
Disassembly of secondary shaft - Version with HI-LO () 30-322
Disassembly of secondary shaft - Version with HI-LO (5090 C -> ZKDY360200TD10001, 5100 C -> ZK- 30-318
DY400200TD10001)
Disassembly of the HML planetary reduction gearbox (5100 C -> ZKDY480200TD10001, 5110 C -> ZK- 30-289
DY520200TD10001, 5120 C -> ZKDY560200TD10001)
Disassembly of the main shaft 30-326
Distributor hydraulic circuits 10-122
Distributor unit 10-190
DT shaft in transmission 30-220

E
E - On-board instruments and visual and audible indicators (5090 C -> ZKDY360200TD10001) 40-96
E - On-board instruments and visual and audible indicators (5100 C -> ZKDY400200TD10001) 40-97
E - On-board instruments and visual and audible indicators (5100 C -> ZKDY480200TD10001) 40-98
E - On-board instruments and visual and audible indicators (5110 C -> ZKDY440200TD10001) 40-97
E - On-board instruments and visual and audible indicators (5110 C -> ZKDY520200TD10001) 40-98
E - On-board instruments and visual and audible indicators (5120 C -> ZKDY560200TD10001) 40-99
E0 - Rear axle 30-475
ECU alarms 20-166
ECU interrogation 20-94
Electrical and electronic components (1/2) 40-13
Electrical and electronic components (2/2) 40-21
Engine 10-2, 30-121
Engine alarms 20-166
Engine cowl 30-532
Engine description - Coolant diagram 10-14
Engine description - Electrical/electronic system 10-17
Engine description - Exhaust gas after-treatment 10-16
Engine description - Exhaust gas recovery 10-15
Engine description - Fuel circuit diagram 10-13
Engine description - Lubricant oil diagram 10-12
Engine description - Views of engine 10-8
Engine flywheel (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C -> ZK- 30-120
DY560200TD10001)
Engine mounting 30-106, 30-107, 30-107

IV
INDEX
Engine torsional spring plate (5100 C -> ZKDY480200TD10001, 5110 C -> ZKDY520200TD10001, 5120 C 30-187
-> ZKDY560200TD10001)
Exhaust manifold (turbocharger) 30-102, 30-102, 30-102
Exhaust pipe 30-153
Expansion valve 30-531

F
F - External lights (rotating beacon) (5090 C -> ZKDY360200TD10001) 40-99
F - External lights (rotating beacon) (5100 C -> ZKDY400200TD10001) 40-102
F - External lights (rotating beacon) (5100 C -> ZKDY480200TD10001) 40-108
F - External lights (rotating beacon) (5110 C -> ZKDY440200TD10001)