PRINT NO.

87623187
1st Service Manual Update
mod. TL70A, TL80A, TL90A, TL100A
Print no. 603.54.511.00

IMPORTANT NOTES

These pages replace the corresponding pages in the Manual

of mod. TL70A, TL80A, TL90A, TL100A

-- title page and verso. 83--84, 115 to 118, 121 to 124, 139
-- contents volume 1 pages 3 to 8. to 148, 191--192.
-- section 21 Chap. 5, pages 19--20, -- contents volume 3 pages 1--2.
39--40. -- section 55 Chap. 8, pages 1--2,
-- section 31 Chap. 1, pages 1 to 18. 7--8, 27--28, 47--48, 87--88.
-- section 31 Chap. 2, pages 1--2. -- section 55 Chap. 9, pages 1 to 10,
-- section 33 Chap. 2, pages 1 to 18. 17--18.
-- section 35 Chap. 2, pages 1--2. -- section 55 Chap. 10, pages 1--2,
-- section 35 Chap. 3, pages 1--2. 25--26, 35--36, 271--272, 275--276,
-- contents volume 2 pages 1 to 4. 279--280.
-- section 55 Chap. 1, pages 5--6. -- section 55 Chap. 11, pa-
-- section 55 Chap. 6, pages 1--2. ges 21--22.
-- section 55 Chap. 7, pages 1--2, 5
to 10, 13 to 16, 19 to 22, 43 to 52,
IMPORTANT NOTES
The following pages are newly issued:
-- section 31 Chap. 1, pages 19 to -- section 55 Chap. 1, pages 27--28.
22. -- section 55 Chap. 10, pages 473
-- section 31 Chap. 2, pages 39 to to 484.
42.
-- section 35 Chap. 3, pages 27 to
30.
CNH ITALIA S.p.A. -- Viale delle Nazioni, 55 -- 41100 MODENA -- Italy
Product Support -- Technical Publications
Print No. 87623187 -- 05 -- 2007
 TRACTORS
TL70A -- TL80A -- TL90A -- TL 100A
SERVICE MANUAL
SECTIONS
GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
POWER TAKE- OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CAB AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PLATFORM, CAB, BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

S E R V I C E
 INTRODUCTORY NOTES

◊ This manual is divided into sections identified by two--figure numbers and each section has independent page
numbering.
For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections.

◊ The different sections can easily be found by consulting the table of contents on the following pages.

◊ The document number of the manual and the edition/update dates are given at the bottom of each page.

◊ Pages updated in the future will be identified by the new document number at the bottom of each page and
by the respective date of issue.
These pages will be supplemented by a reprint of the updated contents page.

◊ The information contained in this manual was current on the date printed on each section. As NEW HOLLAND
constantly improves its product range, some information may be out of date subsequent to modifications im-
plemented for technical or commercial reasons, or to meet legal requirements in different countries.
In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.

IMPORTANT WARNINGS

◊ All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.

◊ Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.

◊ The Manufacturer and all organisations belonging to the Manufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dama-
ge to property caused by abnormal function of parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair of the product manufactured or marketed by the Manufac-
turer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any
kind against personal injury or damage to property caused by abnormal function of parts and/or components
not approved by the Manufacturer.

TEXT AND ILLUSTRATIONS ARE THE PROPERTY OF

CNH ITALIA S.p.A.

No part of the text or illustrations

may be reproduced

PRINTED IN ITALY

CNH ITALIA S.p.A. -- Viale delle Nazioni, 55 -- 41100 MODENA -- Italy

Product Support -- Technical Information
Print No. 87623187 -- 05 -- 2007
 CONTENT 3

CONTENT VOLUME 1
Page Date Page Date
Checks and measure-
00 -- GENERAL GUIDELINES ments -- pistons . . . . . . . . . 86 to 89 03--06
Checks and measure-
General instructions . . . . . 1--2 03--06
ments -- camshaft, tappets
Safety regulations . . . . . . . 3--4--5 03--06 and valves . . . . . . . . . . . . . . 90 to 93 03--06
Consumables . . . . . . . . . . . 6 03--06 Checks and measure-
ments -- cylinder head . . . . 94 03--06
10 -- ENGINE Functional testing on low
engine oil pressure indica-
Summary . . . . . . . . . . . . . . . 1 03--06 tor . . . . . . . . . . . . . . . . . . . . . 95 03--06
General specifications . . . . 2 to 4 03--06 Checks and measure-
Fuel system data . . . . . . . . 5 03--06 ments -- cooling system . . 96 03--06
Replacing crankshaft front
Crankshaft and engine
seal . . . . . . . . . . . . . . . . . . . 97 to 99 03--06
block data . . . . . . . . . . . . . . 6 03--06
Replacing crankshaft rear
Connecting rod data . . . . . 7 03--06 seal . . . . . . . . . . . . . . . . . . . 100 to 102 03--06
Piston data . . . . . . . . . . . . . 7--8 03--06 Adjusting tappet, valve and
Timing gear data . . . . . . . . 8--9 03--06 rocker arm clearance . . . . 103 to 105 03--06
Cylinder head data . . . . . . 9--10 03--06 Removal--Installation -- in-
jectors . . . . . . . . . . . . . . . . . 106 to 108 03--06
Tightening Torques . . . . . . 11--12 03--06
Removal -- Installation --
Tools . . . . . . . . . . . . . . . . . . 13 03--06 Bosch injection pump . . . . 109 to 113 03--06
View of 4--cylinder engine Bosch injection pump -- ti-
mod. TL70A and TL80A . . 14 03--06 ming . . . . . . . . . . . . . . . . . . . 114 to 118 03--06
View of 4--cylinder engine Bosch injection pump -- air
mod. TL90A and TL100A . 15 03--06 bleeding . . . . . . . . . . . . . . . . 118 03--06
Engine cooling and lubrica- Removal--Installation --
tion diagrams . . . . . . . . . . . 16--17 03--06 coolant pump . . . . . . . . . . . 119--120 03--06
Component parts of cylin- Removal--Installation --
der head mod. TL70A and thermostat valve . . . . . . . . . 121--122 03--06
TL80A . . . . . . . . . . . . . . . . . 18 03--06 Removal--Installation -- ra-
Component parts of cylin- diator . . . . . . . . . . . . . . . . . . 123 to 128 03--06
der head mod. TL90A and Coolant pump drive belt ad-
TL100A . . . . . . . . . . . . . . . . 19 03--06 justment . . . . . . . . . . . . . . . . 129 to 130 03--06
Component parts of addi-
tional counterweights . . . . 20 18 -- CLUTCH
03--06
Troubleshooting . . . . . . . . . 21 to 24 03--06 Summary . . . . . . . . . . . . . . . 1 03--06
Engine removal--installa- Specifications . . . . . . . . . . . 2 03--06
tion . . . . . . . . . . . . . . . . . . . . 25 to 44 03--06 Tightening Torques . . . . . . 3 03--06
Engine disassembly--as- Tools . . . . . . . . . . . . . . . . . . 3 03--06
sembly . . . . . . . . . . . . . . . . . 45 to 78 03--06
Sections . . . . . . . . . . . . . . . 4 03--06
Checks and measure- Troubleshooting . . . . . . . . . 5 03--06
ments -- cylinder block and
liners . . . . . . . . . . . . . . . . . . 79 to 81 03--06 Checks and measure-
ments -- clutch . . . . . . . . . . 6--7 03--06
Checks and measure-
ments -- crankshaft, bea- Adjustments -- clutch pedal 8 03--06
rings and flywheel . . . . . . . 82 to 83 03--06 Removal--Installation --
Checks and measure- clutch . . . . . . . . . . . . . . . . . . 9 to 11 03--06
ments -- connecting rods . 84 to 85 03--06 Clutch Overhaul . . . . . . . . . 12 to 15 03--06

87623187 -- 05 -- 2007
4 CONTENT

Page Date Page Date

Adjustments -- clutch disen- Control rod adjustments . . 36 03--06
gagement levers . . . . . . . . 16 03--06 Removal--Installation --
Dual Command (2 Speed
21 -- TRANSMISSIONS Power Shift) solenoid valve 37 to 40 03--06
Working pressure test . . . . 40 03--06
CHAPTER 1 -- Transmission and
Removal--Installation --
range gear (12x4) Dual Command (2 Speed
Summary . . . . . . . . . . . . . . . 1 03--06 Power Shift) control valve 41 to 44 03--06
Specifications . . . . . . . . . . . 2 03--06 Disassembly--Assembly --
Dual Command (2 Speed
Tightening Torques . . . . . . 3 03--06
Power Shift) control valve . 45--46 03--06
Tools . . . . . . . . . . . . . . . . . . 4--5 03--06 Transmission longitudinal
Sections . . . . . . . . . . . . . . . 6--7 03--06 cutaway section view . . . . 47 03--06
Description and Operation 8 03--06
Chapter 4 -- Reverser and creeper unit
Troubleshooting . . . . . . . . . 8 03--06
Summary . . . . . . . . . . . . . . . 1 03--06
Transmission longitudinal
cutaway section view . . . . 9 03--06 Specifications . . . . . . . . . . . 2 03--06
Tightening torque . . . . . . . . 3 03--06
CHAPTER 2 -- Reverser Tools . . . . . . . . . . . . . . . . . . 4 to 5 03--06
Summary . . . . . . . . . . . . . . . 1 03--06 Sections . . . . . . . . . . . . . . . 6 to 7 03--06
Specifications . . . . . . . . . . . 2 03--06 Description and Operation 8 03--06
Tightening Torques . . . . . . 3 03--06 Troubleshooting . . . . . . . . . 8 03--06
Tools . . . . . . . . . . . . . . . . . . 4 03--06 Replacing clutch casing--
Sections . . . . . . . . . . . . . . . 4--5 03--06 reverser and creeper unit . 9 to 13 03--06
End float adjustment bet-
Description and Operation 6 03--06
ween shaft and support . . 14 to 15 03--06
Troubleshooting . . . . . . . . . 6 03--06 Transmission longitudinal
Disassembly--Assembly -- cutaway section view . . . . 16 03--06
clutch casing--reverser . . . 7 to 10 03--06
Transmission longitudinal CHAPTER 5 -- Power Shuttle tran-
cutaway section view . . . . 11--12 03--06 smission with Dual
Command (2 Speed
CHAPTER 3 -- Dual Command Power Shift) function
(2 Speed Power Shift) Summary . . . . . . . . . . . . . . . 1 03--06
Summary . . . . . . . . . . . . . . . 1 03--06 Specifications . . . . . . . . . . . 2--3 03--06
Specifications . . . . . . . . . . . 2--3 03--06 Tightening torque . . . . . . . . 4--5 03--06
Tightening Torques . . . . . . 4 03--06 Tools . . . . . . . . . . . . . . . . . . 6--7 03--06
Tools . . . . . . . . . . . . . . . . . . 5 03--06 Sections . . . . . . . . . . . . . . . 8 to 10 03--06
Sections . . . . . . . . . . . . . . . 6 to 8 03--06 Description and Operation 11 to 17 03--06
Description and Operation 10 to 15 03--06 Range and gear lever posi-
tion sensor adjustment . . . 18--19 03--06
Troubleshooting . . . . . . . . . 16--17 03--06
Disassembly--Assembly --
Removal--Installation -- clutch casing with power
clutch casing with shuttle and Dual Command
Dual Command (2 Speed Power Shift) . . . . 20 to 26 03--06
(2 Speed Power Shift) . . . . 18 to 26 03--06
Disassembly--Assembly --
Disassembly--Assembly -- clutch (A) and (B) . . . . . . . . 27--32 03--06
clutch casing with
Dual Command Calibrations . . . . . . . . . . . . . 33 03--06
(2 Speed Power Shift) . . . . 27 to 35 03--06 HH MENU access . . . . . . . 33--34 03--06

87623187 -- 05 -- 2007
 CONTENT 5

Page Date Page Date

Clutch calibration H1 menu Replacing wheel hub seal
transmission . . . . . . . . . . . . 35 to 37 03--06 with brake. . . . . . . . . . . . . . 42 03--06
Transmission fault codes . 38 to 40 05--07 Replacing steering knuckle
pins and bearings . . . . . . . 43 03--06
23 -- DRIVE LINES
Stub axle adjustments 44--45 03--06
Summary . . . . . . . . . . . . . . . 1 03--06 Adjustments -- bevel drive . . 46 to 52 03--06
Specifications . . . . . . . . . . . 2 03--06
Tightening Torques . . . . . . 3 03--06 27 -- REAR MECHANICAL TRANSMISSION
Tools . . . . . . . . . . . . . . . . . . 3 03--06
Summary . . . . . . . . . . . . . . . 1 03--06
Sections . . . . . . . . . . . . . . . 4 03--06
Specifications . . . . . . . . . . . 2--3 03--06
Description and Operation 5 03--06
Troubleshooting . . . . . . . . . 6 03--06 Tightening Torques . . . . . . 3--4 03--06

Removal--Installation -- ser- Tools . . . . . . . . . . . . . . . . . . 5 to 9 03--06

vices control valve . . . . . . . 7 to 9 03--06 Sections . . . . . . . . . . . . . . . 10 to 14 03--06
Disassembly--Assembly --
services control valve . . . . 10 to 11 03--06 Description and Operation 15 03--06
Removal--Installation -- dri- Troubleshooting . . . . . . . . . 16--17 03--06
ve gear casing . . . . . . . . . . 12 to 16 03--06 Removal--Installation --
Disassembly--Assembly -- transmission--gearbox ca-
drive gear casing . . . . . . . . 17 to 20 03--06 sing . . . . . . . . . . . . . . . . . . . 18 to 31 03--06
Disassembly--Assembly --
25 -- FRONT MECHANICAL TRANSMISSION
transmission--gearbox ca-
Summary . . . . . . . . . . . . . . . 1 03--06 sing . . . . . . . . . . . . . . . . . . . 32 to 39 03--06
Specifications . . . . . . . . . . . 2 to 4 03--06 Gearbox driving shaft end
float adjustment . . . . . . . . . 40 03--06
Tightening Torques . . . . . . 4--5 03--06
Tools . . . . . . . . . . . . . . . . . . 6 to 8 03--06 Adjustments -- differential
lock engagement sleeve
Sections . . . . . . . . . . . . . . . 9 to 13 03--06 position . . . . . . . . . . . . . . . . 41 03--06
Description and Operation 14--15 03--06
Determining the bevel pi-
Rules for correctly fitting the nion positioning adjust-
axle support to the engine 16 03--06 ment ring . . . . . . . . . . . . . . . 42 to 43 03--06
Troubleshooting . . . . . . . . . 17 03--06 Tapered roller bearings
Removal--Installation -- adjustment for pinion shaft 44 03--06
front axle . . . . . . . . . . . . . . . 18 to 21 03--06
Adjusting the bevel crown
Disassembly--Assembly -- wheel bearings and chec-
front axle . . . . . . . . . . . . . . . 22 to 30 03--06 king the clearance betwe-
Overhaul -- front differential 31 03--06 en the sides of the bevel
drive teeth . . . . . . . . . . . . . . 45 to 48 03--06
Overhaul -- front axle diffe-
rential with LIM--SLIP . . . . 32--33 03--06 Differential pinion and side
Overhaul -- differential lock gear backlash adjustment . 49--50 03--06
unit . . . . . . . . . . . . . . . . . . . . 34--35 03--06 Differential lock pedal travel
Disassembly--Assembly -- adjustment . . . . . . . . . . . . . 51 03--06
front epicyclic final drive wi- Removal--Installation -- fi-
thout brake . . . . . . . . . . . . . 36 to 38 03--06 nal drive . . . . . . . . . . . . . . . . 52 to 55 03--06
Replacing wheel hub seal
Disassembly--Assembly --
without brake. . . . . . . . . . . . 39 03--06
epicyclic final drive . . . . . . . 55 03--06
Disassembly--Assembly --
front epicyclic final drive Disassembly--Assembly --
with brake . . . . . . . . . . . . . . 40--41 03--06 drive wheel shaft . . . . . . . . 56--57 03--06

87623187 -- 05 -- 2007
6 CONTENT

Page Date Page Date

Tightening Torques . . . . . . 2 03--06
31 -- POWER TAKE--OFF
Sections . . . . . . . . . . . . . . . 3--4 03--06
Tools . . . . . . . . . . . . . . . . . . 4--5 03--06
CHAPTER 1 -- Mechanical power
take--off Description and Operation 4 03--06
Summary . . . . . . . . . . . . . . . 1 05--07 Hydraulic diagram -- bra-
kes . . . . . . . . . . . . . . . . . . . . 5 03--06
Specifications . . . . . . . . . . . 2 to 4 05--07
Pilot valve operation . . . . . 6 03--06
Tools . . . . . . . . . . . . . . . . . . 5 05--07
Troubleshooting . . . . . . . . . 7 03--06
Tightening Torques . . . . . . 5--6 05--07 Adjustments -- parking
Sections . . . . . . . . . . . . . . . 7 to 10 05--07 handbrake travel . . . . . . . . 8 03--06
Description and Operation 11--12 05--07 Removal--Installation/Di-
sassembly--Assembly par-
Troubleshooting . . . . . . . . . 12 05--07
king brake casing . . . . . . . . 9 to 11 03--06
Fitting cooler with mechani-
Service brake circuit air
cal transmission and me-
bleeding . . . . . . . . . . . . . . . . 12 03--06
chanical power take--off . . 13 to 15 05--07
Removal--Installation --
Removal--Installation -- po- service brake pump . . . . . . 13--14 03--06
wer take--off . . . . . . . . . . . . 16 to 18 05--07
Adjusting the height of the
Disassembly--Assembly -- service brake pedals . . . . . 14 03--06
power take--off . . . . . . . . . . 19 to 21 05--07
Removal--Installation --
service brake . . . . . . . . . . . 15 to 19 03--06
CHAPTER 2 -- Electro--hydraulic
power take--off Chapter 2 -- Trailer Air Brakes
Summary . . . . . . . . . . . . . . . 1 05--07 Summary . . . . . . . . . . . . . . . 1 05--07
Specifications . . . . . . . . . . . 2 to 5 03--06 Specifications . . . . . . . . . . . 1 05--07
Tools . . . . . . . . . . . . . . . . . . 5 03--06 Tightening Torques . . . . . . 2 05--07
Tightening Torques . . . . . . 6 03--06 Tools . . . . . . . . . . . . . . . . . . 2 05--07
Sections . . . . . . . . . . . . . . . 7 to 12 03--06 Sections . . . . . . . . . . . . . . . 3 to 6 05--07
Description and Operation 13 to 22 03--06 Description and Operation 6--7 05--07
Additional PTO controls for Operation of single trailer
cab--version tractors with brake circuit components . 8 to 13 05--07
Power Shuttle transmis-
Troubleshooting . . . . . . . . . 14 05--07
sions . . . . . . . . . . . . . . . . . . 23--24 03--06
Troubleshooting . . . . . . . . . 25 03--06 Pressure tests . . . . . . . . . . 15 to 19 05--07
Replacing the power take--
off brake . . . . . . . . . . . . . . . 26--27 03--06 35 -- HYDRAULIC SYSTEMS
Removal--Installation -- po-
wer take--off . . . . . . . . . . . . 28 to 31 03--06 CHAPTER 1 -- Rear mechanical
Disassembly--Assembly -- hydraulic lift
power take--off . . . . . . . . . . 32 to 38 03--06 Summary . . . . . . . . . . . . . . . 1 05--07
Fitting cooler with mechani- Specifications . . . . . . . . . . . 2 to 6 03--06
cal transmission and hy-
draulic power take--off . . . . 39 to 41 05--07 Tightening Torques . . . . . . 7--8 03--06
Tools . . . . . . . . . . . . . . . . . . 9 03--06
33 -- BRAKES
Sections . . . . . . . . . . . . . . . 10--11 03--06
CHAPTER 1 -- Brakes Description and Operation 12 to 15 03--06

Summary . . . . . . . . . . . . . . . 1 03--06 Troubleshooting . . . . . . . . . 16--17 03--06

Specifications . . . . . . . . . . . 1 03--06 Hydraulic lift pump compo-
nents . . . . . . . . . . . . . . . . . . 18--19 03--06

87623187 -- 05 -- 2007
 CONTENT 7

Page Date Page Date

Pump seal kit replacement 19 03--06 Description and Operation 4--5 03--06
Disassembly--Assembly -- Control valve components 6 to 9 03--06
LIFT--O--MATIC control . . . 20 03--06 Description and Operation 10 to 18 03--06
Adjustments -- lift rod me- Removal--Installation --
chanism . . . . . . . . . . . . . . . . 21--22 03--06 BOSCH auxiliary control
LIFT--O--MATIC device up- valves . . . . . . . . . . . . . . . . . 19 to 21 03--06
ward travel adjustment . . . 23 03--06 Disassembly--Assembly --
Disassembly--Assembly -- BOSCH auxiliary control
external lift controls . . . . . . . 24 03--06 valves . . . . . . . . . . . . . . . . . 22 to 26 03--06
Removal--Installation -- lift . 25 to 31 03--06 Quick coupler maintenance 27--28 05--07
Disassembly--Assembly -- Troubleshooting . . . . . . . . . 29--30 05--07
lift . . . . . . . . . . . . . . . . . . . . . 32 to 36 03--06
CHAPTER 4 -- Trailer brake auxiliary
Adjusting the lift . . . . . . . . . 37 to 42 03--06
control valve
Removal--Installation -- lift
Summary . . . . . . . . . . . . . . . 1 03--06
control valve . . . . . . . . . . . . 43--44 03--06
Sections . . . . . . . . . . . . . . . 1 03--06
Disassembly--Assembly --
lift control valve . . . . . . . . . 45 to 49 03--06 Description and Operation 1--9 03--06
Lift pressure relief valve -- Troubleshooting . . . . . . . . . 10 to 12 03--06
removal/installation and
setting . . . . . . . . . . . . . . . . . 50 03--06 CHAPTER 5 -- Supplementary
Cylinder
CHAPTER 2 -- Open centre system Summary . . . . . . . . . . . . . . . 1 03--06
auxiliary control valves
Specifications . . . . . . . . . . . 1 03--06
Summary . . . . . . . . . . . . . . . 1 05--07
Sections . . . . . . . . . . . . . . . 1 03--06
Specifications . . . . . . . . . . . 1 05--07
Description and Operation 1 03--06
Tools . . . . . . . . . . . . . . . . . . 1 05--07
Removal--Installation/Di-
Tightening Torques . . . . . . 2 05--07
sassembly--Assembly --
Sections . . . . . . . . . . . . . . . 3 to 5 03--06 supplementary cylinder . . . 2 03--06
Description and Operation 6 to 9 03--06
CHAPTER 6 -- Electronic Lift
Disassembly--Assembly --
auxiliary control valves . . . 10--11 03--06 Summary . . . . . . . . . . . . . . . 1 03--06
Rod hardening test . . . . . . 11 03--06 Precautions . . . . . . . . . . . . . 1 03--06
Blow--by test . . . . . . . . . . . . 12 03--06 Specifications . . . . . . . . . . . 2--3 03--06
Adjustment of the automa- Tightening Torques . . . . . . 4 03--06
tic detent release pressure 12 03--06 Tools . . . . . . . . . . . . . . . . . . 4 03--06
Removal--Installation --
View of electronic lift com-
flow control valve . . . . . . . . 13 03--06
ponents . . . . . . . . . . . . . . . . 5 03--06
Adjustments -- flow control
Electronic lift control layout 6--7 03--06
valve . . . . . . . . . . . . . . . . . . 14--15 03--06
Description and Operation 8 to 11 03--06
CHAPTER 3 -- Auxiliary control Anti--damping device for
valves (BOSCH) implements carried on the
Summary . . . . . . . . . . . . . . . 1 05--07 lift . . . . . . . . . . . . . . . . . . . . . 12 to 13 03--06
Specifications . . . . . . . . . . . 2 05--07 Fault code decoding . . . . . 13 to 14 03--06
Tools . . . . . . . . . . . . . . . . . . 2 05--07 Diagnostics . . . . . . . . . . . . . 14 to 54 03--06
Tightening Torques . . . . . . 3 03--06 Lift electronic control unit . 55 03--06
View of BOSCH auxiliary Removal--Installation --
control valve components . 4 03--06 electronic lift control panel 56 03--06

87623187 -- 05 -- 2007
8 CONTENT

Page Date Page Date

Lift arm potentiometer re-
placement . . . . . . . . . . . . . . 57 03--06 CHAPTER 7 -- Ventral control valves
for Walvoil--type open
Removal --Installation -- centre system
draft sensor . . . . . . . . . . . . . 58--59 03--06
Summary . . . . . . . . . . . . . . . 1 03--06
Calibration of the electro-
nic lift arms potentiometer 60--61 03--06 Ventral control valve
specifications . . . . . . . . . . . 1 03--06
Removal--Installation --
electronic lift . . . . . . . . . . . . 62 to 67 Tightening Torques . . . . . . 2 03--06
03--06
Removal--Installation -- hy- Ventral control valve . . . . . 3--4 03--06
draulic control valve . . . . . . 68--69 03--06 Ventral control valve joy- 03--06
stick . . . . . . . . . . . . . . . . . . . 5 to 7
Control valve circuit . . . . . 8 03--06
Hydraulic diagram . . . . . . . 9 03--06
Description and operation
of ventral control valve . . . 10 to 18 03--06

87623187 -- 05 -- 2007
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 5 19

Adjustment check
In figure 18 there is a diagram of the lever status
switches.
If the adjustment is made during the phase of over-
hauling the gearbox, with the cab detached and with
the aid of a tester switched onto ohmmeter, putting
the rods at the ends of the switch, there must be the
values in Ω listed in the following table with the gear
levers in their various positions.

18

With the Gearbox sensor G

gear Switch Ω Analog--digital
lever status conversion H9
in......... (Channel 16)
Neutral Closed 560 650
1st Open 2760 270
2nd Open 2760 270
3rd Open 2760 270
4th Open 2760 270

Range sensor R1 Range sensor R2

With the
range
Switch Ω Analog--digital Switch Ω Analog--digital
lever
status conversion H9 status conversion H9
in.........
(Channel 17) (Channel 18)

Neutral Open 2760 270 Open 2760 270

Medium Open 2760 270 Closed 560 650

Fast Closed 560 650 Closed 560 650

Slow Closed 560 650 Open 2760 270

If the check must be made with the cab down, it is

then difficult to use the tester at the ends of the vari-
ous buttons, in the diagnostic programs HH MENU in
H9 at channels Ch 16 (G), Ch 17 (R1) and Ch 18
(R2), it is perfectly possible to test the lever status
buttons and the display will show the digital conver-
sion of the above--mentioned tables.

NOTE: With program H9 it is possible to move the

tractor. It is wise to test in motion and on ground that
is not level but rather broken. The jolting produced
and the vibration of the gear levers must not be
enough to accidentally switch over the switches,
even for a short time, thus causing fault code 2040.

87623187 - 05 - 2007
20 SECTION 21 -- TRANSMISSIONS -- CHAPTER 5

OP. 21 110 88
CLUTCH CASING WITH POWER SHUTTLE
AND DUAL COMMAND (2 SPEED POWER
SHIFT) UNITS D.A.
ATTENTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

Proceed as follows.
1. Fix the gearbox to the rotating stand 380000301
(1) using front 380000271 and rear 380000272
brackets. 19
2. Unscrew the retaining screws and remove the
control valve (1).

20
3. Extract the oil drainage union (1).

21
4. Unscrew the retaining screw, detach the bracket
(1) and remove the control valve/internal mani-
fold connecting lines (2).

22

87623187 - 05 - 2007
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 5 39

TRANSMISSION FAULT CODE LISTING

Fault
code Description of Fault
2011 Clutch pedal potentiometer signal too low
2012 Clutch pedal potentiometer signal too high
DUAL COMMAND (2 SPEED POWER SHIFT)
2013
push--buttons pressed at the same time
2014 Voltage from the gear neutral position switch is high
2015 Voltage from the gear neutral position switch is low
2016 Voltage from the range position switch (R1) is high
2017 Voltage from the range position switch (R1) is low
2018 Voltage from the range position switch (R2) is high
2019 Voltage from the range position switch (R2) is low
2021 Transmission harness disconnected
2022 Clutch A solenoid valve short circuit
2023 Clutch B solenoid valve short circuit
2024 All the clutches must be calibrated
2025 Engine speed (rpm) high
2026 Clutch D not calibrated
2027 Clutch C not calibrated
2028 Clutch B not calibrated
2029 Clutch A not calibrated
2031 Clutch C solenoid valve short circuit
2032 Clutch D solenoid valve short circuit
2033 Pressure on clutch A would not decrease
2034 Wheel speed too low
2035 Wheel speed too high
2036 Engine speed (rpm) low
2037 Clutch disconnect switch open circuit
2038 Clutch B solenoid valve short to + 12 volts
2039 Clutch B solenoid valve open circuit or short to ground
2040 Inconsistent gear lever status switches.
2041 Clutch A solenoid valve open circuit or short to ground
2042 Clutch A solenoid valve short to + 12 volts
2043 Pressure on clutch B would not decrease
2047 Clutch disconnect switch set too high
2048 Clutch disconnect switch set too low
2049 Wheel speed sensor too high
2051 Oil temperature sensor open circuit

87623187 - 05 - 2007
40 SECTION 21 -- TRANSMISSIONS -- CHAPTER 5

2052 Oil temperature sensor short circuit

2053 5 volt reference voltage too high
2054 5 volt reference voltage too low
2055 Shuttle lever forward switch voltage high
2056 Shuttle lever forward switch voltage low
2057 Shuttle lever reverse switch voltage high
2058 Shuttle lever reverse switch voltage low
2059 Shuttle Lever sw. disagree
2061 No seat safety switch transition in the last 25 hours of work
2065 Clutch C solenoid valve open circuit or short to ground
2066 Clutch D solenoid valve open circuit or short to ground
2067 Clutch D solenoid valve short to + 12 volts
2068 Clutch C solenoid valve short to + 12 volts
2069 Wheel speed sensor voltage too low
2073 12 VF supply voltage too high
2074 12 VF supply voltage too low
2076 Control unit (MCM) trouble
2077 8 volt reference voltage too high
2078 8 volt reference voltage too low
2081 Clutch A safety pressure switch open circuit or short to ground
2082 Clutch A safety pressure switch short circuit
2083 Clutch B safety pressure switch open circuit or short to ground
2084 Clutch B safety pressure switch short circuit
2085 No supply to pressure switches for clutches A and B
2090 Break in CAN line between PA and ADIC
2092 Signal from the clutch cut--out button shorted to +12 VF
2093 Power supply to HI, LO and clutch cut--out buttons shorted to + 12 VF
2094 Power supply to HI, LO and clutch cut--out buttons shorted to ground
2095 Clutch cut--out button jammed closed

NOTE: For resolution of the error codes, refer to Section 55, Chapter 10.

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 1

SECTION 31 -- POWER TAKE--OFF

Chapter 1 -- Mechanical power take--off

CONTENT

Operation Description Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fitting cooler with mechanical transmission and mechanical power take--off . . . . . . . . . . 13

31 112 20 Power take--off housing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

31 112 45 Power take--off driving shaft D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

31 112 48 Driven shaft and other parts D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

87623187 - 05 - 2007
2 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL POWER TAKE--OFF DATA

TL70A TL80A TL90A
TL100A
540 rev/min power take--off

1. independent with respect to

tractor speed
Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
or:
2. synchronized to gearbox

Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, by means of hand lever

located on the LH and RH side of
the driving position
see page 11 and 12
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . . rpm 2200
PTO revolution speed with engine at max. power
(2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 614
PTO revolution speed synchronized with gearbox revs/
(18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . . . . . . . . . wheel
rev 8.2 8.9
PTO revolution speed synchronized with gearbox revs/
(4WD 24.85 mph (40 km/h) model) . . . . . . . . . . . . . . . . . . . . wheel
rev 6.73 7.25
Diameter of driven shaft at bearings . . . . . . . . . . . . . . . . . . . in (mm) 1.9660 to 1.9685 (49.938 to 50.000)
Diameter of driven shaft at grooved terminal . . . . . . . . . . . . . . . . . . . 13/8” (6 grooves)
PTO 540/750 rpm (on request for all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . same as 540 rpm PTO
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . same as 540 rpm PTO
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . . same as 540 rpm PTO
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of hand lever located on
the rear RH side of the driver’s seat
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . . rpm 2200
Engine speed with PTO at 750 rpm . . . . . . . . . . . . . . . . . . . . rpm 2382
PTO revolution speed with engine at max. power
of 2500 rpm:
-- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 614
-- for 750 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 787
PTO revolution speed (540 rpm) synchronized with gear- revs/
box 18.64 and 24.85 mph (30 and 40 km/h) models . . . . . . wheel
rev see 540 rpm PTO
750 rpm, gearbox synchronized, PTO revolution speed revs/
(18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . . . . . . . . . wheel
rev 10.51 11.4
(continued)

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 3

MECHANICAL POWER TAKE--OFF DATA

(cont)
TL70A TL80A TL90A
TL100A
750 rpm, gearbox synchronized, PTO revolution speed revs/
(4WD 24.85 mph (40 km/h) model) . . . . . . . . . . . . . . . . . . . . wheel
rev 8.59 9.36
Diameter of driven shaft at grooved terminal . . . . . . . . . . . . . . . . . . . 13/8” (6 grooves)
PTO 540/750/1000 rpm (on request for all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . same as PTO 540/750 rpm
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . same as PTO 540/750 rpm
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . . . same as PTO 540/750 rpm
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of hand lever located on
the rear RH side of the driver’s seat
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . . rpm 2200
Engine speed with PTO at 750 rpm . . . . . . . . . . . . . . . . . . . . rpm 2382
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . . rpm 2381
PTO revolution speed with engine at max. power
of 2500 rpm:
-- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 614
-- for 750 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 787
-- PTO 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 1050
For PTO revolution speed (540/750 rpm) synchronized revs/
with gearbox 18.64 and 24.85 mph (30 and 40 km/h) wheel see PTO
models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev 540/750 rpm
PTO revolution speed (1000 rpm) synchronized revs/
with gearbox 18.64 mph (30 km/h) model . . . . . . . . . . . . . . . wheel
rev 14.1 15.2
PTO revolution speed (1000 rpm) synchronized revs/
with gearbox (4WD 24.85 mph (40 km/h) version) . . . . . . . . wheel
rev 11.51 12.4
Diameter of driven shaft at grooved terminal:
-- 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 13/8” (6 grooves)
-- 750 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 13/8” (6 grooves)
-- speed of 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 13/8” (21 grooves)
External diameter of driven gear support bushings . . . . . . . in.
(mm) 1.9655 to 1.9665 (49.925 to 49.950)
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . . in.
(mm) 1.9704 to 1.9720 (50.050 to 50.089)
Clearance between driven gears and bushings . . . . . . . . . . in.
(mm) 0.0039 to 0.0064 (0.100 to 0.164)
Diameter of driven shaft at front and central bushings . . . . in.
(mm) 1.5419 to 1.5429 (39.166 to 39.191)
Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . . in.
(mm) 1.3773 to 1.3779 (34.984 to 35.000)
Internal diameter of front and central bushings . . . . . . . . . . in.
(mm) 1.5433 to 1.5448 (39.200 to 39.239)
Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . . in.
(mm) 1.3783 to 1.3798 (35.009 to 35.048)
Clearance between shaft and front and centre bushings . . in.
(mm) 0.0003 to 0.0028 (0.009 to 0.073)
Clearance between shaft and rear bushing . . . . . . . . . . . . . . in.
(mm) 0.0003 to 0.0025 (0.009 to 0.064)

87623187 - 05 - 2007
4 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL POWER TAKE--OFF for TL90A and TL100A

NORTH AMERICA version (on request)

TL90A and TL100A

PTO 540/1000 rpm
1) independent with respect to
tractor speed
Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) not synchronized to gearbox

mechanical, by means of hand lever

Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . located on the LH and RH side of
the driving position
(see page 10 and 11)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . . rpm 2200
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . . rpm 2381

PTO revolution speed with engine at max. power

of 2500 rpm:
-- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 614
-- PTO 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 1050
Diameter of driven shaft at grooved terminal:
-- 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 13/8” (6 grooves)
-- speed of 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 13/8” (21 grooves)
External diameter of driven gear support bushings . . . . . . . in. 1.9655 to 1.9665 (49.925 to 49.950)
(mm)
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . . in. 1.9704 to 1.9720 (50.050 to 50.089)
(mm)

Clearance between driven gears and bushings . . . . . . . . . . in. 0.0039 to 0.0064 (0.100 to 0.164)
(mm)
Diameter of driven shaft at bushings for 540 and 1000 rpm in. 1.5419 to 1.5429
power take--off gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) (39.166 to 39.191)

Internal diameter of bushings for 540 and 1000 rpm power in. 1.5433 to 1.5448
take--off gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) (39.200 to 39.239)
Backlash between shaft and bushings for 540 and in. 0.0003 to 0.0028
1000 rpm p.t.o. gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) (0.009 to 0.073)

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 5

TOOLS

CAUTION
The operations described in this section can only be
carried out with the ESSENTIAL tools indicated by an
(X).
380000227 Hook for lifting the power take--
To work safely and efficiently and obtain the best re- off.
sults, it is also necessary to use the recommended
specific tools listed below and certain other tools,
which are to be made according to the drawings inclu- 380000233 Drift for PTO driving shaft bea-
ded in this manual. rings.

TIGHTENING TORQUES

C1 -- 221 Nm

C2 -- 25 Nm

C3 -- 162 Nm

C4 -- 294 Nm

26277
540/750/1000 rpm power take--off
1

87623187 - 05 - 2007
6 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

TIGHTENING TORQUES

C1 -- 221 Nm C2 -- 25 Nm C3 -- 162 Nm

C4 -- 294 Nm

540 rev/min power take--off 540/750 rpm power take--off

26276

2
TIGHTENING TORQUES
Tightening torque
PARTS TO BE TIGHTENED Thread
Nm kgm
Bearing support retaining bolts
(PTO 540/750 and 540/1000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
PTO casing retaining bolts (C1, figs. 1 and 2) . . . . . . . . . . . . . . . . M 16 x 1.5 221 22,5
PTO guard retaining bolts (C2, figs. 1 and 2) . . . . . . . . . . . . . . . . . M 8 x 1.25 25 2,6
Self locking nuts for securing grooved terminal
(C3, fig. 2) for 540/750 rpm PTO and
(C3, fig. 1) for 540/750/1000 rpm PTO . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 162 16,5
Nut locking driven gear shaft:
(C4, fig. 2) for 540 rpm and 540/750 rpm PTO . . . . . . . . . . . . . . . . M 32 x 1.5 294 30
(C4, fig. 1) for 540/750/1000 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . M 28 x 1.5 294 30

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 7

1 2

28 3

4
27
5
26
6
25
24
7
23
22
21
8
20
19 9
18
X X 10
17
A 16 B
11
15
14 13 12

26278

3
Longitudinal sectional diagrams of 540 rpm and 540/750 rpm PTO
A. Sectional diagram of 540 rpm PTO. 14. Driven gear.
B. Sectional diagram of 540/750 rpm twin speed PTO. 15. Circlip.
1. 540 rpm PTO casing. 16. Circlip.
2. 540/750 rpm PTO cover. 17. PTO guard retaining bolts.
3. PTO unit retaining bolt. 18. 540 rpm PTO driven shaft.
4. Drive shaft bearings. 19. Driven gears support bushings.
5. Circlip. 20. Driven shaft lock nut.
6. Self locking nut for securing grooved terminal. 21. Fixed gear.
7. 540 rpm grooved terminal. 22. Coupling sleeve.
8. 750 rpm grooved terminal. 23. Driven gear for 750 rpm speed.
9. Seal. 24. Driven gear for 540 rpm speed.
10. Driven shaft bearings. 25. Double driving gear.
11. Cover centering pin. 26. Driving gear
12. Rear transmission casing. 27. Circlip.
13. Rear bearing support. 28. Circlip.

NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the
diagram in fig. 24.

87623187 - 05 - 2007
8 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

2 3 4

5
6
7
X
8
26279

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

26279

4
Cross--sectional views of 540 -- 750 -- 1000 rpm PTO
1. Input shaft. 13. External control lever.
2. Thrust washers. 14. Internal command device.
3. Driven gears. 15. 750 rpm PTO coupling sleeve.
4. Thrust washer. 16. Driven shaft lock nut.
5. Seal.
17. Driven shaft.
6. Driven gear bushings.
18. Guards.
7. ‘O’ Ring Seal.
19. ‘O’ Ring Seal.
8. Washer.
9. Retaining pin. 20. Control fork support rod.
10. 540 or 1000 rpm PTO coupling sleeves. 21. PTO cover.
11. Spring. 22. Rod retaining bolt (20).
12. Pawl. 23. PTO unit retaining bolt.

NOTE: On assembly, apply the type of sealing compound noted on page 1, Sect. 00 on surface X following the
diagram in fig. 24.

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 9

MDM0369A

5
Cross--sectional views of 540 -- 1000 rpm PTOs for TL90A and TL100A NORTH AMERICAN version
(on request) not synchronized with the gearbox (pre--modification)
1. Shaft from PTO clutch. 11. PTO gearbox secondary shaft.
2. Circlip and retaining ring part (3). 12. Oil seal.
3. PTO gearbox driving gear/shaft. 13. Bushing.
4. Circlip retaining part (3). 14. 1000 rpm driven gear.
5. Brake engagement spring.
15. Speed selection sleeve.
6. Movable part of brake.
16. 540 rpm driven gear.
7. Fixed part of brake.
8. Driving gear for part (3). 17. Speed selection pin.
9. Splining key. 18. Speed selection lever.
10. Splined output shaft 1 3/8” (6 grooves) for 19. Fork movement pin.
PTO 540 rpm, 20. Speed selection fork.
NOTE: During assembly apply sealing compound on surfaces marked with an X following the instructions and
diagrams on pages 31 and 30, fig. 43 and 45, chapter 2.

87623187 - 05 - 2007
10 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MDM0370A

6
Cross--sectional views of 540 -- 1000 rpm PTOs for TL90A and TL100A NORTH AMERICAN version
(on request) not synchronized with the gearbox (post--modification)
1. Shaft/gears from PTO clutch. 11. PTO gearbox secondary shaft.
2. Circlip. 12. Oil seal.
3. Bearing. 13. Bushing.
4. Bearing. 14. 1000 rpm driven gear.
5. Brake.
15. Speed selection sleeve.
6. Brake spring.
16. 540 rpm driven gear.
7. Brake travel limiting screw.
8. PTO guard. 17. Speed selection pin.
9. Circlip retaining grooved shaft. 18. Speed selection lever.
10. Splined output shaft 1 3/8” (6 grooves) for 19. Fork movement pin.
PTO 540 rpm, 20. Speed selection fork.
NOTE: During assembly apply sealing compound on surfaces marked with an X following the instructions and
diagrams on page 18 Fig. 24.

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 11

DESCRIPTION AND OPERATION

OF MECHANICAL PTO 1 2
The PTO (1) installed on the tractor transfers motion
to the transported or towed implements. Control is ei-
ther directly from the engine clutch or from the gear-
box clutch.
Mechanically engaged/disengaged PTO devices are
available in three versions:
-- (standard) one speed, 540 rpm.
-- (optional) twin speed, 540/750 rpm.
-- (optional) three--speed, 540/750/1000 rpm.
-- (on request)* two--speed 540/1000 rpm.
* NORTH AMERICAN version 26280

PTO controlled directly from the engine clutch

Proceed as follows: 1
-- disengage the PTO clutch by moving the lever (1,
fig. 8) to position A;
-- move the operation selection lever (1, fig. 9) to
position (B), thereby engaging the PTO sleeve (3,
fig. 10) on the shaft gear coupling (2) which is mo-
ved by the main clutch; A
-- slowly engage the main clutch by moving the le-
ver (1, fig. 8) to position D.
D
26355

When engaged, the PTO grooved terminal rotates

and the relevant lamp on the dashboard illuminates.
In these conditions PTO operation is completely inde-
pendent from the tractor travel, therefore:
-- stop the tractor without stopping the power take--
off;
-- stop the power take--off without stopping the trac-
tor (by disengaging the power take--off clutch).
-- To disengage the PTO move selection lever (1,
fig. 9) to position E.

26356

87623187 - 05 - 2007
12 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

PTO synchronised with gears

Proceed as follows:
-- hold clutch lever (1, fig. 8) in position D;
-- fully press the main gear clutch pedal;
-- wait briefly, then move the lever (1, fig. 9) to posi-
tion C and release the main gear clutch pedal;
In these conditions the PTO coupling sleeve (3,
fig. 10) is directly driven by the main gear toothed
coupling (1).
When the tractor is stationary, the synchronized PTO
does not rotate; reverse the direction of rotation of the
output shaft by moving from forward gear to reverse.

NOTE: When the PTO is not in use, move lever (1,

fig. 9) to position (E), in relation to the neutral position
of the PTO coupling sleeve (3, fig. 10).

26281

10
Selecting the speed with the lever (2, fig. 11)
To select power take--off speeds, proceed as descri-
bed below:
-- pull the stop knob (1) upwards;
-- position lever (2) in the required speed sector (3).
This activates the external control lever (13, fig. 4) by
means of a tie--rod. The external control lever rotates
the internal cam device (14) and selects the required
PTO speed by means of coupling sleeves (10 and
15).

26325

11

MECHANICAL PTO TROUBLESHOOTING

Problems Possible Problem Solutions

Slipping with speed loss on PTO Wear of clutch disk or of engine Check the data on the appropriate
grooved terminal. flywheel pressure plate. pages in Sect. 18, replace the worn
PTO clutch lever adjustment. parts and adjust the clutch lever.

Difficulty in selecting PTO speed External control stiff or incorrec- Lubricate the control cable sheath.
by means of lever 2, fig. 11. tly adjusted. Adjust the control.

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 13

FITTING COOLER WITH MECHANICAL TRANSMISSION

AND MECHANICAL POWER TAKE--OFF

Pressurised oil

Intake oil

Excess oil to the pressure regulating valve

Oil at static rest

1 2 3 4 5 6 7

16

15

14

13 12 11 10 9 8
MMM0497A

12
General hydraulic system

1. Power steering cylinders. 9. By--pass valve protecting the cooler.

2. Gearbox oil pressure switch on services control valve 10. Return line from cooler.
supply line (oil discharge from the power steering).
11. Restrictor.
3. Power steering control valve (orbitrol).
12. Suction filter.
4. Differential lock solenoid valve.
13. Front differential lock.
5. 4WD disengagement solenoid valve.
6. Services pressure regulating valve. 14. Delivery line to cooler.
7. 4WD pressure switch warning light. 15. Cooler.
8. Rear differential lock. 16. Low pressure pump.

87623187 - 05 - 2007
14 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

13

1. Pipe from the outlet of the services control valve (3) 5. Pressure regulating valve compartment plug with oil
to the cooler, travelled by oil at high temperature. drain line overhead the valve.

6. By--pass valve.
2. Services control valve supply line.
7. Restrictor coupling.
3. Excess oil discharge to the pressure regulating valve;
discharge to the services control valve. 8. Return line from the cooler, connected to the Tee
coupling (9) introducing oil into the transmission hou-
sing, travelled by oil cooled by the cooler.
4. Line from the services control valve outlet (3) to the
inlet hole into the transmission housing; travelled by 9. Tee coupling draining oil into the transmission hou-
oil at low temperature. sing.

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 15

DESCRIPTION AND OPERATION OF THE COOLING SYSTEM

To prevent the transmission oil from reaching too high

a temperature it is possible to fit a cooler on the me-
chanical transmissions with either a hydraulic PTO
(see chap. 2 section 31) or a mechanical PTO.
The oil coming from the control valve of the power
steering via line (2, fig. 13) reaches the services con-
trol valve.
It enters from the side of the pressure regulating valve
that regulates the four--wheel drive disengagement
and front/rear lock engagement oil to a pressure of
15.7 to 16.7 bar (16 to 17 kg/cm2), the excess oil is
sent straight to the transmission housing, where the
cooler is not fitted.
On machines with a cooler, the oil partly leaves the
Tee coupling (3, fig. 13), depending on the tempera-
ture it takes two routes, some of it is discharged direc-
tly through a hole in the control valve.

With cold oil: its density produces an increase in

pressure as it passes into the cooler; this increase
causes the by--pass valve (6, fig. 13) to open and al-
lows the oil to flow straight to the Tee coupling (9,
fig. 13) for introducing oil into the clutch casing; there-
fore, in practice, when the oil is cold it discharges into
the transmission casing via the line (4, fig. 13).

With hot oil: with the increase in temperature and

associated decrease in density, there is a decrease
in the pressure on the line (1, fig. 13) and on the coo-
ler so that the by--pass valve (6, fig. 13) closes and
the oil passes into the cooler through the feed pipe (1,
fig. 13) to then pass via the return pipe from the cooler
(8, fig. 13) and enter the Tee coupling (9, fig. 13) on
the transmission casing, thereby reaching the outlet.

87623187 - 05 - 2007
16 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

OP. 31 112 20
PTO HOUSING R.I.

DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Ensure that no--
one is in the vicinity of the load to be lifted.

1. Disconnect the battery negative cable.

2. Detach the three--point linkage (1).

1

24952

14
3. Detach the tow bar hook (1).
1

24953

15
4. Remove the tow bar (1).
1

24954

16

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 17

5. Remove the six retaining bolts (1) securing the

towbar hook. 1

24955

17
6. Drain the oil from the transmission/gearbox into
a suitable container.

24956

18
7. Remove the two upper bolts (1) securing the PTO
unit to the transmission. 1

24957

19
8. Insert the two guide pins (1) and unscrew the two
lower bolts (2) securing the PTO unit to the tran- 1
smission.

2
24958

20

87623187 - 05 - 2007
18 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

9. Remove the pin spring (1) and detach the PTO

speed selection cable. 1

24959

21
10. Unscrew the PTO speed selection cable sheath
bracket (1) retaining bolts. 1
11. Move lever (1, fig. 9) to position (C), PTO syn-
chronized with gears, so that the sleeve (3,
fig. 10) remains on the shaft (2) during the remo-
val operation.
Extract the PTO unit by a few centimeters and re-
move using a hook and lifting chain 380000227
(1).

24960

22
To assemble, proceed as follows:
-- Clean the contact surface between the transmis-
sion casing and the PTO casing and apply sealing
1
compound as indicated in fig. 24.
-- Clean the mating surface on the PTO unit.
-- Raise and position the PTO unit in front of the tran-
smission casing and insert on the previously instal-
led guide pins.
-- Detach the hook and chain (1, fig. 23) and secure
the PTO unit with the four bolts.
-- Remove the two guide pins.

24961

23
-- Refit the PTO speed selection cable sheath brac-
ket (1, fig. 22), connect the cable to the lever and
insert the pin and spring (1, fig. 21).
-- Reassemble the towbar hook assemble support.
-- Refit the towbar hook and three--point bar.
-- Tighten the drainage plug and then fill up the tran-
smission/gearbox casing.
-- Connect the battery negative lead.

26282

24

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 19

OP. 31 112 45 and 31 112 48

MECHANICAL POWER TAKE--OFF
SHAFTS D.A.

ATTENTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including gog-
gles, gloves and safety footwear.

1. Position the PTO unit in a vice on a workbench

(1).
1

24962

25
2. Using a punch, release the securing ring (1) on
the driven shaft ring nut.
1

24963

26
3. Remove the driven shaft ringnut (1).
1

24964

27

87623187 - 05 - 2007
20 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4. Remove the four retaining bolts (1) securing the

PTO unit internal support.
1

24965

28
5. Remove the fork rod Allen screw (1).
1

24966

29
6. Extract the rod (1) from the rear casing.
1

24967

30
7. Partially extract the end of the shaft (1), remove
the internal support (3) together with the driving
1 2
shaft (2), the driven gears (4), the engaged/disen-
gaged/neutral fork and sleeve, the 540/750 PTO;
also remove the bearing thrust washer on the
gearing side (24, fig. 3).

3
24968

31

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 21

8. Remove the rear bearing thrust washer (1) and

the secondary shaft (2), together with the PTO 1
terminal.
2

24969

32
9. Remove the retaining circlip, bearing (1) and seal
(if it is to be changed) from the rear cover.
1

24970

33
For assembly (see figure 3B) proceed as follows:
-- Fit the seal (9, if it needs to be replaced), the rear
bearing and the snap ring (5) on the rear cover.
-- Refit the driven shaft with the thrust washer.
-- Refit the driven shaft gear (23), the fixed gear
(21), the sleeve (22), the fork and fork support
rod.
-- Insert the gear (24) on the driven shaft, assemble
the internal support (13) together with the driving
shaft (25). Secure the support (13) with the four
bolts, tightening to the torque value noted on pa-
ge 6.
-- Fit the thrust washer on the gear (24), install the
bearing on the internal support (13) of the driven
shaft.
-- Secure the rod that supports the PTO speed se-
lection fork with the Allen screw.
-- Tighten the driven shaft ring nut to the torque va-
lue noted on page 6, secure the ringnut to pre-
vent it from loosening.

87623187 - 05 - 2007
22 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 1

SECTION 31 -- POWER TAKE--OFF

Chapter 2 -- Electro--hydraulic power take--off

CONTENT

Operation Description Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Description of operation and hydraulic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Additional PTO controls for cab--version tractors with Power Shuttle transmissions . . . . 23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

31 114 64 Power take--off clutch brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

31 116 21 Electro--hydraulic power take--off housing R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

31 116 47 Speed selection control device D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

31 116 55 Power take--off driving shaft D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

31 116 58 PTO driven shaft D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Fitting cooler with mechanical transmission and hydraulic power take--off . . . . . . . . . . . . 39

Services control valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (See operation 23 202 20)

Services control valve for tractors

without Dual command (2 Speed Power Shift) D.A. (See operations 23 202 24 -- 23 202 29)

87623187 - 05 - 2007
2 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

ELECTRO--HYDRAULIC PTO DATA

TL70A TL80A TL90A

TL100A

Power take--off 540 rpm (standard for mod. TL100A,

on request for all the other models)

1. independent with respect to

tractor speed
Type (two functions, see page 19) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
or:
2. synchronized to gearbox

1. electrohydraulic/mechanical
by means of knob and hand le-
ver
Engagement and control (see page 13) . . . . . . . . . . . . . . . . . . . . . .
2. mechanical, by means of hand
lever located to the RH side of
the driving position
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . . . . . . clockwise

Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . . rpm 2200

PTO revolution speed with engine at max. power

of (2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 614

PTO revolution speed synchronized with gearbox revs/

(18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . . . . . . . . . wheel
rev 8.2 8.9

PTO revolution speed synchronized with gearbox revs/

(4 WD (24.85 mph (40 km/h) model) . . . . . . . . . . . . . . . . . . . wheel
rev 6.73 7.25

Diameter of driven shaft (6, fig. 6) at rear bearing . . . . . . . . in.

(mm) 1.5741 to 1.5748 (39.984 to 40.000)

Diameter of driven shaft (6) at front bearing . . . . . . . . . . . . . in.

(mm) 1.3773 to 1.3779 (34.984 to 35.000)

Diameter of shaft at grooved terminal . . . . . . . . . . . . . . . . . . in.

(mm) 13/8” (6 grooves)
(continued)

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 39

FITTING COOLER WITH MECHANICAL TRANSMISSION

AND HYDRAULIC POWER TAKE--OFF

Pressurised oil

Intake oil
Excess oil to the pressure regulating valve
(PTO lubrication)
Oil at static rest

1 2 3 5 4 6 7 8

21

9
20

10
19

11

5 17 16 15 14 13 12
MMM0495A

69
General hydraulic system

1. Power steering cylinders. 12. Rear differential lock.

2. Gearbox oil pressure switch on services control valve 13. Services operating pressure regulating valve.
supply line (oil discharge from the power steering).
14. 4WD disengagement solenoid valve.
3. Power steering control valve (orbitrol).
15. Restrictor coupling.
4. Differential lock solenoid valve.
5. PTO engagement solenoid valve. 16. Return line from the cooler, discharge into
the transmission.
6. Pressure line to the PTO clutch.
17. Suction filter.
7. 4WD pressure switch warning light.
18. Front differential lock.
8. Pressure line to the PTO brake.
9. Hydraulic PTO unit. 19. Delivery line to cooler.

10. Lubricating pressure regulating valve. 20. Cooler.

11. PTO lubrication line. 21. Low pressure pump.

87623187 - 05 - 2007
40 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

70

1. Pipe from the outlet of the services control valve (3) 6. PTO lubrication line.
to the cooler, travelled by oil at high temperature.

2. Services control valve supply line. 7. L--coupling draining oil into the transmission housing.

3. Excess oil discharge to the pressure regulating valve;

oil destined partly for lubrication and partly for di- 8. Restrictor coupling.
scharge.

4. PTO clutch engagement solenoid valve unit. 9. Return line from the cooler, connected to the L--cou-
pling (7) introducing oil into the transmission housing,
5. Pressure regulating valve compartment plug with oil travelled by the excess oil for PTO clutch lubrication
drain line overhead the valve. cooled by the cooler.

87623187 - 05 - 2007
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2 41

DESCRIPTION AND OPERATION OF THE COOLING SYSTEM

To prevent the transmission oil from reaching too high

a temperature it is possible to fit a cooler on the me-
chanical transmissions with either a mechanical PTO
(see chap. 1 section 31) or a hydraulic PTO.
The oil coming from the control valve of the power
steering via line (2, fig. 70) reaches the services con-
trol valve.
It enters from the side of the pressure regulating valve
that regulates the four--wheel drive disengagement
and front/rear lock engagement oil to a pressure of
15.7 to 16.7 bar (16 to 17 kg/cm2), the excess oil is
sent partly to PTO lubrication, it reaches the PTO
clutch unit and acts on the lubricating pressure regu-
lating valve that regulates the pressure to 4.4 to
5.9 bar (4.5 to 6 kg/cm2), and partly to the discharge,
where the cooler is not fitted.
On machines with a cooler, the oil leaves the Tee cou-
pling (3, fig. 70) partly goes to lubrication via line (6,
fig. 70), partly, depending on the temperature takes
two routes.

With cold oil: its density produces an increase in

pressure as it passes via the restrictor coupling (8,
fig. 70) and into the cooler, then it goes straight to the
outlet in the transmission casing, partly via a passage
inside the control valve and partly via the opening of
the lubricating pressure regulating valve on the PTO
unit.

With hot oil: with the increase in temperature and

associated decrease in density, there is a decrease
in the pressure on the line (1, fig. 70) and on the re-
strictor coupling (8, fig. 70) then on the cooler, the oil
flows into it through the feed pipe (1, fig. 70) to then
pass via the return pipe from the cooler (9, fig. 70),
and enter the L--coupling (7, fig. 70) on the transmis-
sion casing, thereby reaching the outlet.

87623187 - 05 - 2007
42 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 2

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 1

SECTION 33 -- BRAKING SYSTEM

Chapter 2 -- Trailer Air Brakes

CONTENT

Operation Description Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
View of air brake components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diagram of air brake components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation of single air brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SPECIFICATIONS

Circuit data (for German market):

Working pressure of the dual--line system . . . . . . . . . . . . psi (bar) 113.1 to 120.35 (7.8 to 8.3)
Working pressure of the single--line system . . . . . . . . . . psi (bar) 72.5 to 87 (5.0 to 6.0)
Low pressure warning light switch activation . . . . . . . . . psi (bar) 65.25 to 72.5 (4.5 to 5.0)
Maintenance:
Tank condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Transmission belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . Hz 310 ± 15
-- Tension checking frequency . . . . . . . . . . . . . . . . . . . . h 300
Compressor:
-- Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand side of engine
-- Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By belt via crankshaft
-- Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single cylinder
air cooled
-- Speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 3.000
-- Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm) 2.9527/1.4173 (75/36)
-- Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 159
-- Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (bar) 261 (18)
Tank:
-- Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right--hand side of tractor in
front of final drive
-- Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qty_ 1
-- Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L 15

87623187 - 05 - 2007
2 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

1
TIGHTENING TORQUES
Tightening torque
PARTS TO BE TIGHTENED Thread
Nm kgm
Belt tensioner fixing screw (C1, fig. 1) . . . . . . . . . . . . . . . . M10 x 1.5 42 to 51 4.28 to 5.20
Belt tensioner pivot fixing nut (C2) . . . . . . . . . . . . . . . . . . M10 x 1.5 42 to 51 4.28 to 5.20
Idler pulley fixing screws (C3) . . . . . . . . . . . . . . . . . . . . . . M10 x 1.5 40 to 50 4.08 to 5.09
Compressor pulley fixing nut (C2) . . . . . . . . . . . . . . . . . . . M18 x 1.5 100 to 120 10.2 to 12.2

SPECIAL TOOLS

Warning -- The operations described in this section

can only be carried out with ESSENTIAL tools indi-
cated by an (X).
To work safely and efficiently and obtain the best re-
sults, it is also necessary to use the recommended
specific tools listed below and certain other tools,
which are to be made according to the drawings in-
cluded in this manual.

380001268 Belt Tension Meter.

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 3

VIEW OF AIR BRAKE COMPONENTS

B C
1
NOTE: For the key see page 6.

87623187 - 05 - 2007
4 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

AIR BRAKE COMPONENTS SECTIONS

D
F

2
NOTE: For the key see page 6.

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 5

DIAGRAM OF AIR BRAKE COMPONENTS

21

3
NOTE: For the key see page 6.

87623187 - 05 - 2007
6 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

AIR BRAKE DIAGRAM AND SECTIONS KEY

NOTE: Refer to the tables on page 3, 4 and 5.

A. Air brake components assembly.
B. Detail of the dual--line control valve.
C. Detail of the handbrake actuator on the dual--line
control valve.
D. Compressor suction and lubrication.
E. Detail of compressor drive belt.
F. Brake circuit pressure switch.
G. Couplers (German market).
H. Braking diagram.

1. Air intake pipe. 20. Braking pressure line between the two control valves.
2. Air delivery pipe from compressor. 21. Dual--line control valve.
3. Compressor lubrication oil drain pipe. 22. Compressor suction pipe.
4. Condensate antifreeze pump. 23. Compressor.
5. Antifreeze tank. 24. Hydraulic left--hand rear brake actuator line.
6. Pressure regulating valve. 25. Hydraulic brake bleed screws on the dual--line
7. Pipe delivering air to the tank. control valve.
8. Pipe delivering air to the pressure switch. 26. Handbrake tie--rod.
9. Pressure switch. 27. External handbrake lever.
10. Tank. 28. Handbrake return spring.
11. Condensate drain valve. 29. Compressor lubricating oil suction pipe.
12. Single--line control valve. 30. Compressor pulley.
13. Red line delivering air at maximum pressure to the 31. Belt tensioner.
coupler. 32. Crankshaft pulley
14. Black line for braking (single--line). 33. Idler pulley.
15. Yellow line for braking (dual--line). 34. Belt.
16. Ports. 35. Yellow connection.
17. Hydraulic right--hand rear brake actuator line. 36. Black connection.
18. Maximum pressure line from the dual--line to the 37. Red connection.
single--line control valve. 38. Ground cable terminal.
19. Maximum pressure line from the tank to the dual--line 39. Pressure switch signal “G” cable terminal.
control valve. 40. Spare “WK” cable terminal.

DESCRIPTION AND OPERATION

German market
An air brake system designed in accordance with
German TUV specifications providing both single,
see connection (1), and dual line operation.

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 7

BRAKES DISENGAGED
Dual Line Braking System.
The air from the compressor (23) passes from the
antifreeze pump (4) and reaches the pressure relief
valve (6) that regulates the system pressure in the
tank (10) on 113.1 to 120.35 psi (7.8 to 8.3 bar).
This pressure is supplied to the trailer via the red
coupler (37) through the delivery line (13) to disen-
gage the brakes.
The air in the system acts, via line (8), on the pressure
transmitter (9), which sends a variable electrical sig-
nal to the dashboard that will display the pressure
gauge and indicate the pressure in the system.
If the pressure drops below 65.25 to 72.5 psi (4.5 to
5.0 bar), will cause the warning light (1) on the dash-
board to light up. 1

5
Single Line Braking System.
The air from the tank flows through lines (19 and 18)
to reach the single--line control valve (12) and through
the black line (14) to reach the black connection (36)
at the maximum pressure of 72.5 to 87 psi
(5.0 to 6.0 bar) to disengage the trailer brakes.

BRAKES ENGAGED
Dual Line Braking System.
As the tractor’s brakes are applied, hydraulic pres- Single Line Braking System.
sure is transmitted from the brake control pumps and,
As pressure in the Yellow Line (15) progressively in-
through lines (17 and 24), via the rear reduction gears
creases, it is sensed via line (18) at the Single Line
it reaches the dual--line control valve so as to in-
Control Valve (12), to gradually vent the air pressure
crease the pressure in the yellow pipe (15) reaching
supplied to the trailer via the Black Line (14) to apply
the yellow connection (35) where there will be a pres-
the trailer’s brakes in line with the tractor’s brakes. At
sure of from 0 bar (0 kg/cm2) up to a maximum of
the black connection (36) there will be a maximum
113.1 to 120.35 psi (7.8 to 8.3 bar) corresponding to
pressure of 72.5 to 87 psi (5.0 to 6.0 bar), brakes not
maximum braking or to the parking brake engaged.
applied at a pressure of 0 bar corresponding to maxi-
mum braking or to the parking brake engaged.

87623187 - 05 - 2007
8 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

OPERATION OF SINGLE AIR BRAKE CIRCUIT COMPONENTS

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 9

DESCRIPTION AIR BRAKE CIRCUIT

COMPONENTS

A -- Compressor (23, fig. 3)

Belt driven via the crankshaft.
It takes the filtered air (see fig. 1 and 2) and compres-
ses it to supply pressurized air to the tank.
The compressor is lubricated from the engine lube
system.

The drive belt is tensioned as follows:

A. Loosen the screw (1) and the nut (2) on the ad-
justable idler pulley. Place 1/2” sq.drive into posi-
tion (3) and apply pressure to tension drive belt.
Tighten bolt (2) and nut (1) and remove 1/2”
sq.drive.
B. With the use of a special tool 380001268
measure the tension of the belt at point ‘X’, by
“pinging” the belt. The required measurement at
‘X’ should be 310Hz , +/--15Hz.
C. If further adjustments are required, repeat steps
A and B.
D. Tighten screw (1) to 42 to 51 Nm (4.28 to
5.20 kgm) and nut (2) to 42 to 51 Nm (4.28 to
5.20 kgm).

87623187 - 05 - 2007
10 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

B -- Antifreeze pump (4, fig. 3)

During the winter the fluid in the tank (2) prevents the
condensate from freezing.
The tank should be filled with 0.5 l of “Ambra Super
Fluid” the pump will mix it with the compressed air
preventing the condensate from freezing.
Periodically check the level of fluid in the tank and in
the summertime shut cock (3) taking care that there
is a sufficient amount of fluid in the tank to cover the
bottom of it.

C -- Pressure regulating valve (6, fig. 3)

Controls the operating pressure within the system to
prevent system damage from excess pressure. It is
supplied with the pressure already set and with the
adjuster screw (1) sealed with leaden seals.
NOTE: The dealer must not remove the leaden seal.
Also removes any contamination from the system
during unloading, which takes place via pipe (3).
On this valve it is possible to attach a quick coupler
(2) connected directly to the compressor to inflate the
tyres or for cleaning by blowing.

10

D -- Dual line control valve (12, fig. 3)

Controls the dual--line braking system jointly with the
hydraulic pressure supplied by the pump via the con-
nection (17 and 24) to the rear brakes. brakes.
There are two screws on this control valve for bleed-
ing the service brakes (25).
A mechanical connection to the handbrake (26) pro-
vides full trailer braking when the handbrake is ap-
plied.

NOTE: Remember that when bleeding the brakes on

tractors with air brakes there are another two screws
on the dual--line control valve to bleed. 11

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 11

E -- Pressure switch (10, fig. 3)

Connected directly in line with the reservoir, provides
a variable electrical signal to the dashboard that dis-
plays the pressure gauge (1, fig. 18).
When the pressure drops to 65.25 to 72.5 psi (4.5 to
5.0 bar) or lower, the warning light on the dashboard
comes on (1, fig. 5) and an active warning not dis-
played is stored in the control unit (2, fig. 19).

12

The electrical connection of the pressure switch to

the dashboard is composed of a wire with an 8 pin
connection connected to the fitting for the hydraulic
trailer brake. under the control panel.
This cable is composed of two wires, one connected
to pin 1 of colour M (brown) connected to ground (1,
fig. 12) while the other cable of colour V (green) is
connected to pin 2 of the connection and collects the
signal on pin G (marked on the pressure switch), pin
WK of the pressure switch is not used.
The position of the connection for the fitting on the
cab cable is found under the control panel on the left--
hand side.
The following table gives the resistances, which are 13
found by measuring the values in Ohm with a tester
putting one rod on pin G and the other on ground, as
the pressure varies.
psi (bar) 0 29 (2) 58 (4)
Ohms 5 to 13 52 ± 4 88 ± 4
psi (bar) 87 (6) 116 (8) 145 (10)
Ohms 124 ± 5 145 to 170 184 ± 30

F -- Tank (10, fig. 3)

Provides storage for the compressed air generated
by the compressor.
At the base of the tank there is a valve for draining off
the condensate (1), at the end of a day’s work drain
off the condensate from the tank.

14

87623187 - 05 - 2007
12 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

G -- Single line control valve (12, fig. 3)

Controls the single line trailer brake system in con-
junction with the dual line control valve and brake
master cylinder pressure.
When the tractor leaves the factory, this control is set
to allow maximum available braking effort to the
trailer. Under most conditions, the control will remain
in this position and will give well balanced braking.
Occasionally, with some trailers this setting may
provide sharper tractor braking than is ideal. In this
case the braking force to the trailer may be reduced
slightly by turning the adjuster inside the guard (1,
fig. 15) in an anti--clockwise direction.
To turn the valve, it is necessary to use a wrench (2,
fig. 15). The adjuster must be reset to the fully
clockwise position when a different trailer is used.

ATTENTION
The brake balance adjustment is extremely sensitive;
it should not be rotated more than one half turn before
testing with the attached trailer fully loaded. If further
adjustments are required, they should be carried out
following the same procedure. Failure to do this may
result in an imbalance between tractor and trailer
braking forces if the valve is rotated too far in the anti--
clockwise direction.
15

H -- Black connection (36, fig. 3)

The black coupler is for single line systems.
Pressure is available at the coupler (1) with the brake
pedal released, 72.5 to 87 psi (5.0 to 6.0 bar) and
pressure decreases as the pedal is depressed, to
reach 0 bar with the parking brake on.

16

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 13

I -- Red / yellow connection (37 and 35, fig. 3)

Red and yellow couplers for dual line systems.
The red one (2) is the supply coupler with full pressure
available all the time, 113.1 to 120.35 psi (7.8 to
8.3 bar).
The yellow coupler (1) is the control line.
Air pressure at the coupler is increased as the brake
pedal is depressed, to reach 113.1 to 120.35 psi (7.8
to 8.3 bar) with the parking brake on.

17

L -- ADIC dashboard
Pressure gauge (1) operated electrically by a signal
received from the pressure transmitter assembly.
With the advanced dashboard the pressure gauge is
called up with the button on the keypad, with the stan-
dard dashboard, or the advanced one without the
keypad provided that braking has been configured in
the H3 program of the HH MENUs, the pressure
gauge will always be displayed, a few seconds after
starting where the engine hours will have been dis-
played, unless there are fault codes.

18
In the event of low circuit air pressure, lower than
65.25 to 72.5 psi (4.5 to 5.0 bar), besides blinking, for
5 sec., and then lighting up the warning light (1, fig. 5)
there will be a warning not displayed.
The warning light (2) to the right of the information
monitor, amber with an exclamation mark, will come
on and with the keypad or the CAL button it will be
possible to call up the active warnings not displayed
and, on the information monitor where the pressure
gauge is normally displayed, there will be the pres-
sure gauge (1) showing the pressure with the bars at
the time of the fault warning.
NOTE: This test is performed at a speed > 1000 rpm.
NOTE: To configure the air brake, refer to the HH
MENU chapter 11 of section 55.
As regards resolving the fault codes, refer to
chapter 10 of section 55.
To display the active warnings not displayed, see
chapter 1 section 55. 19

87623187 - 05 - 2007
14 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

TROUBLESHOOTING

Description Causes Corrective action

Instrument cluster light illuminates 1. System pressure below 1. Compressor drive belt broken.
when system is running.
running 65.25/50.75
65 25/50 75 psi (4.5/3.5
(4 5/3 5 bar).
bar)
2. Check system for leaks.

3. Unload valve failed, stuck

open.

4. Compressor fault.

5. Reservoir drain tap faulty.

2. Pressure switch or relayed wi- 1. Disconnect wiring to switch.

ring faulty. Check it is not shorted neither
to ground nor to + 12 Volt.

2. Using a tester, switched onto

ohmmeter, check that the
resistance values mirror the
values in the table on page 11.

Trailer brakes not functioning 1. Air in the braking system. 1. Bleed the brakes.
(system air pressure okay).
okay)
2. Dual--line control valve. 1. Disconnect the supply line from
the control valve. Operate the
brakes, if oil is expelled, the li-
nes are okay. If no oil is expel-
led, remove and inspect the
control valve.

3. Dual Line Control Valve faulty. 1. Repair/replace as required.

Delay in trailer brake operation. 1. Air in the braking system. 2. Bleed the brakes.

System pressure too high, 1. Faulty unload valve. 1. Remove valve clean/replace.
exceeds 120.35 psi (8.3 bar)

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 15

PRESSURE TESTING

Tractor Preparation
1. Position the tractor on a flat, level surface and in
a suitable location to allow the engine to run dur-
ing the testing.
2. Chock the wheels and ensure the parking brake
is in the OFF position.
3. To perform the test it will be necessary to obtain
the correct trailer side couplers for the system, to
couple up to the tractor connectors.

20

Use suitable fittings to connect to each trailer side

coupler a 0--145 psi (0--10 bar), undamped
3.93 in. (100 mm), pressure gauge. Connect the
appropriately coloured couplers to the correspon-
ding tractor coupler.

21

Pre--Test Procedure
NOTE: For all pressure testing illustrations the
gauges represent the following coupler colours:
A = Dual line control (Yellow)
B = Single line supply (Black
C = Dual line supply (Red)
D = Cab Gauge
1. Switch tractor ignition on.
2. All test gauges, including vehicle gauge located
on the left hand ‘B’ pillar, must read zero pressure
(drain tanks if required).
NOTE: Tractor ‘B’ pillar gauge reads line pressure
which is the same as that shown on the red line
coupler gauge.
3. Low pressure warning indicator for the air brake
system must be illuminated on the instrument
cluster. Warning light located in top right hand
corner of the instrument cluster. 22

87623187 - 05 - 2007
16 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

1. Start the tractor

2. System should be fully pressurised within 40 to
60 seconds depending on engine rev setting (a
maximum period of 3 minutes is permitted for the
system to reach operating pressure). When the
system is fully pressurised the gauges must read
as follows:
Pressure
Pressure Gauges
psi (bar)
0
Dual Line Control (yellow) (A)
(0)
72.5 to 87
Single Line Supply (black) (B)
(5.0 to 6.0)
23
113.1 to
Dual Line Supply (red) (C) 120.35
(7.8 to 8.3)
Cab (D) 116 (8.0)
NOTE: Cab gauge reads 116 psi (8.0 bar) in the
green segment.

3. As the system is being pressurised, the air brake

low pressure warning light on the instrument
cluster should extinguish between 65.25 to
79.75 psi (4.5 to 5.5 bar).
NOTE: Indication of malfunctioning must be investi-
gated and the defect rectified before continuing with
the test.

24

4. Apply tractor parking brake

The gauges must now read the following values:
Pressure
Pressure Gauges
psi (bar)
113.1 to
Dual Line Control (yellow) (A) 120.35
(7.8 to 8.3)
0
Single Line Supply (black) (B)
(0)
113.1 to
Dual Line Supply (red) (C) 120.35
(7.8 to 8.3)
Cab (D) 116 (8.0) 25
In cases where the gauges do not exhibit the above
values, adjust the handbrake cable to the dual line
control valve as described on the following page.

87623187 - 05 - 2007
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2 17

Handbrake Control Cable Adjustment

1. With the handbrake off and the system (red) (C)
at full pressure 113.1 to 120.35 (7.8 to 8.3) (igni-
tion key ON, engine off), check that the yellow
pressure gauge (A) is at zero.
2. Handbrake up four clicks.

26

3. Adjust the tie--rod (by lengthening or shortening

it) until the pointer of the yellow pressure gauge
(A) just starts to move, then lock the locknuts with
the length of the tie--rod that causes the maxi-
mum pressure on the yellow connection.
4. Check operation of handbrake.
• Parking brake on 113.1 to 120.35 (7.8 to 8.3) at
the yellow connection.
• Parking brake off 0 bar at the yellow connection.

27

Leak Test
1. Engine off -- tractor parking brake applied.
2. No deterioration of the red line pressure, 113.1 to
120.35 (7.8 to 8.3) must occur over a 10 minute
period. Indication of any leakage must be investi-
gated, the defect rectified and the test repeated.

28

87623187 - 05 - 2007
18 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 2

Brake Pedal Test Procedure

1. Start the tractor. Engine revs not to exceed
1000 rev/min.
2. Do NOT apply tractor parking brake.

29
3. Release brake pedal link pin so that pedals will
work individually.
4. Apply left hand and right hand brake pedals indi-
vidually.
The behaviour of the pressure measured on the
pressure gauges must not change by braking
with the pedals coupled.
The system (red) (C, fig. 29) at full pressure 113.1
to 120.35 (7.8 to 8.3), on the yellow line (A,
fig. 29) the pressure will be directly proportional
to the intensity of the braking from a minimum of
0 bar, brake not applied, to a maximum of 113.1
to 120.35 (7.8 to 8.3).
On the black one--way braking line (B, fig. 29), the
30
pressure will be inversely proportional to the in-
tensity of the braking from a maximum of 72.5 to
87 psi (5.0 to 6.0 bar), brake not applied, to a mini-
mum of 0 bar maximum braking.
The pressure gauge in the cab (D, fig. 29) will be-
have like the red line and will show approximately
8 symbols lit.

Pressure Regulator ON/OFF Test Procedure

1. Set engine at idle revs.
2. Do NOT apply tractor parking brake.
3. With the system fully pressurised 113.1 to 120.35
(7.8 to 8.3), depress the brake pedals several
times until the pressure drops below 94.25 psi
(6.5 bar) on Red system gauge (C) and gauge in
cab.
4. The unload valve, located on the RHS of the en-
gine must recharge the system to 94.25 psi
(6.5 bar).
5. In cases where an unload valve is found to be
faulty, a new unload valve must be fitted and the
test repeated.

31

87623187 - 05 - 2007
 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 2 -- Open centre system auxiliary control valves
CONTENT

Operation Description Page

Data -- Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chap. 1
35 204 46 Auxiliary control valves D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
35 204 46 Flow control valve D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Quick coupler maintenance . . . . . . . . . . . . . . . . . . . . . . (see section 35 chapter 3, page 27)
SPECIFICATIONS
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow, with replaceable paper
cartridge, (common to the hy-
draulic lift circuit)
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pump (common to the hydraulic
lift circuit see Chap. 1)
AUXILIARY CONTROL VALVES
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve stack up to a maximum of
5 control valves, 3 of which fixed
to the cover of the gear control
rod support and 2 on the support
fitted on the right--hand side of
the engine
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever
Pressure release valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . psi 2755 to 2827 (190 to 195)
(bar)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . convertible for operation of single
or double--acting actuators, con-
vertible for operation of single or
double--acting actuators and with
automatic detent release, con-
vertible for operation of double--
acting actuators with float control
and automatic detent release,
convertible for operation of
double--acting actuators with
float control.

SPECIAL TOOLS
CAUTION List of specific tools required for the various oper-
The operations described in this section can only be ations described in this Sect.
carried out with the ESSENTIAL tools indicated by
an (X). To work safely and efficiently and obtain the 380000240 Universal pressure testing kit.
best results, it is also necessary to use the recom- 380000241 Seal guard for Kontak control
mended specific tools listed below and certain other valve check valve.
tools, which are to be made according to the drawings
included in this manual. 380000701 Flow control valve adjustment
tool.

87623187 -- 05 -- 2007
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2 3

25722

TIGHTENING TORQUES
Parts to tighten Thread Tightening Torques
Control valve element locknuts (1) 3/8” -- 24 UNF Nm 20.4 kgm 2.1
Front and rear cover retaining bolts (2) 1/4” -- 20 UNC Nm 11 kgm 1
Auxiliary control valve retaining bolts (3) M 10 x 1.25 Nm 59 kgm 6

87623187 -- 05 -- 2007
 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 1

SECTION 35 -- HYDRAULIC SYSTEMS

Chapter 3 -- Auxiliary control valves for remote control (BOSCH)

CONTENT

Operation Description Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Auxiliary control valve components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control valve inter--connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lifting oil flow (cylinder extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lowering oil flow (cylinder retraction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil flow in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil flow in float operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Automatic release pressure regulating valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation of two or more control valves simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35 204 40 Auxiliary control valves R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35 204 46 Auxiliary control valves. D.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick coupler maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

87623187 - 05 - 2007
2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

SPECIFICATIONS

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . groups of 2 or 3 control valves

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever

Nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . litres 70

/min

Maximum flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . litres 80

/min

Automatic release valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . psi 2537 (175)

(bar)

Pressure release valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . psi 2755 to 2827 (190 to 195)

(bar)

Control valve types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . single and double--acting, with

automatic release and float
mode.

SPECIAL TOOLS
List of specific tools required for the various opera-
Warning -- The operations described in this section tions described in this Sect.
can only be carried out with ESSENTIAL tools indica-
ted by an (X).
To work safely and efficiently and obtain the best re-
sults, it is also necessary to use the recommended
specific tools listed below and certain other tools,
which are to be made according to the drawings inclu-
ded in this manual.
380000240 Universal pressure testing kit.

87623187 - 05 - 2007
 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 27

QUICK COUPLER MAINTENANCE

INTRODUCTION

The main causes for poor operation or breakage of

the quick couplers are:
-- dirt;
-- type of male quick coupler not compatible, or
damaged (dents, for instance);
-- forced extraction of the mail coupler when there
is pressure in the hydraulic system.

ATTENTION
Before removing the protective caps for the male con-
nections, remove all the debris that has accumulated
on the pressure points to avoid contaminating the hy-
draulic system.
Before disconnecting the couplers you must:
-- lower the connected attachments;
-- stop the engine;
-- move the relevant levers forwards and backwards
to discharge pressure from the hydraulic system.

MAINTENANCE OPERATIONS
The correct procedure in using and servicing the hy-
draulic connections is vital for their durability and effi-
ciency.
There follow helpful tips for using the quick couplers
correctly and avoiding operational trouble.

If the female couplers are not used, always protect

the male ones with the special plugs provided.

39

87623187 - 05 - 2007
28 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Spray solvent for a few seconds into the gap between

the movable outer portion (1) of the male connection
and the inner portion (2) supporting the balls.

40
Spray solvent for a few seconds into the coupling
zone and on the locking balls.

41
Perform some hooking/unhooking operations and if
necessary do the cleaning again to make the coupling
fluid.

42

87623187 - 05 - 2007
 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 29

Troubleshooting

PERSISTENT
FAULT POSSIBLE CAUSE SOLUTION
TROUBLE
Engagement impossible. The male coupler is not Replace the male con-
--
compatible. nection.
Dirt or soil in the female Spray solvent inside and
coupling. outside the female pres-
sure point (see
figs. 40 -- 41) and wait for
a few seconds for the sol- If coupling is still not pos-
vent to react. sible, replace the connec-
Perform some hooking/ tor.
unhooking operations
(see fig. 42) and if neces-
sary do the cleaning again
to make the coupling fluid.
Difficult engagement. Dirt or soil in the female Spray solvent inside and
coupling. outside the female pres-
sure point (see
figs. 40 -- 41) and wait for
a few seconds for the sol- If coupling is still not pos-
vent to react. sible, replace the connec-
Perform some hooking/ tor.
unhooking operations
(see fig. 42) and if neces-
sary do the cleaning again
to make the coupling fluid.
Oil leakage from the fe- Dirt or soil in the female Spray solvent inside and
male coupling after disen- coupling. outside the female pres-
gagement of the male sure point (see
connector. figs. 40 -- 41) and wait for
a few seconds for the sol- If coupling is still not pos-
vent to react. sible, replace the connec-
Perform some hooking/ tor.
unhooking operations
(see fig. 42) and if neces-
sary do the cleaning again
to make the coupling fluid.
Valve gasket damaged. Replace it. --
Oil leakage from the fe- Internal gaskets dama- Replace it.
male coupling after disen- ged.
--
gagement or engagement
of the male connector.

87623187 - 05 - 2007
30 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

PERSISTENT
FAULT POSSIBLE CAUSE SOLUTION
TROUBLE
Oil leakage from the cou- Dirt or soil in the seal area. Spray solvent inside and
plings after engagement. outside the female pres-
sure point (see
figs. 40 -- 41) and wait for
a few seconds for the sol- If coupling is still not pos-
vent to react. sible, replace the connec-
Perform some hooking/ tor.
unhooking operations
(see fig. 42) and if neces-
sary do the cleaning again
to make the coupling fluid.
Gasket damaged. Disconnect the connec-
tors, replace the dama-
ged gasket and, if neces- --
sary, the anti--extrusion
ring.

87623187 - 05 - 2007
 CONTENT 1

CONTENT VOLUME 2
Page Date Page Date
View of hydrostatic stee-
35 − HYDRAULIC SYSTEMS (*) ring control valve compo-
nents . . . . . . . . . . . . . . . . . . 6 03−06
Description and Operation 7 to 10 03−06
CHAPTER 8 − Front Loader
Troubleshooting . . . . . . . . . 11−12 03−06
Summary . . . . . . . . . . . . . . 1 03−06 Tools . . . . . . . . . . . . . . . . . . 12 03−06
Specifications . . . . . . . . . . . 2−3 03−06 Removal−Installation − hy-
Maximum permissible front drostatic steering control
axle weights . . . . . . . . . . . . 3 03−06 valve . . . . . . . . . . . . . . . . . . 13 to 17 03−06
Disassembly−Assembly −
Tightening Torques . . . . . . 4 03−06
hydrostatic control valve . . 18 to 31 03−06
Diagrams . . . . . . . . . . . . . . 5 to 7 03−06
Hydrostatic steering con-
Ventral control valve speci- trol valve bench testing . . . 32−33 03−06
fications . . . . . . . . . . . . . . . . 8−9 03−06
Pressure relief valve te-
Ventral control valve joy- sting . . . . . . . . . . . . . . . . . . . 33 03−06
stick . . . . . . . . . . . . . . . . . . . 10 to 12 03−06 Power steering pump com-
System switching full and ponents . . . . . . . . . . . . . . . . 34−35 03−06
dipped beam headlights on Disassembly − Assembly
lights fitted on handrails . . 13 to 16 03−06 of hydraulic pump to repla-
Ballasting the tractor for ce seal kit . . . . . . . . . . . . . . 35 03−06
front loader operation . . . . 17 03−06 Removal−Installation −
Loader general description 18 to 27 03−06 steering cylinder . . . . . . . . 36−37 03−06
Loader installation − remo-
val . . . . . . . . . . . . . . . . . . . . 28 to 32 03−06 44 − AXLES AND WHEELS
Implement installation − re- Summary . . . . . . . . . . . . . . 1 03−06
moval . . . . . . . . . . . . . . . . . . 33 to 36 03−06
Specifications . . . . . . . . . . . 1 03−06
Lift arm types and functions 37 to 45 03−06 Front wheel track diagram 2 03−06
“Smooth ride” control . . . . 46 to 48 03−06 Sections . . . . . . . . . . . . . . . 3 03−06
Multi Quick coupler con- Tightening Torques . . . . . . 4−5 03−06
nection − disconnection . . 49 to 60 03−06
Tools . . . . . . . . . . . . . . . . . . 5 03−06
Hydraulic functions and
Troubleshooting . . . . . . . . . 5 03−06
flow diagram of loaders . . 61 to 71 03−06
Disassembly−Assembly −
Hydraulic Flow Diagrams . 72 to 88 03−06 wheel axle hub . . . . . . . . . . 6 to 8 03−06
Repair instructions . . . . . . 89 to 94 03−06 Removal−Installation −
Hydraulic components . . . 95 to 99 03−06 front axle . . . . . . . . . . . . . . . 9 to 11 03−06
Troubleshooting . . . . . . . . . 100 to 105 03−06 Stub axle hub overhaul . . . 12 to 14 03−06
Checking leading wheel
41 − STEERING alignment . . . . . . . . . . . . . . 15−16 03−06

Summary . . . . . . . . . . . . . . 1 03−06 50 − SUBSIDIARY PARTS

Specifications . . . . . . . . . . . 2 to 4 03−06 Summary . . . . . . . . . . . . . . 1 03−06
Tightening Torques . . . . . . 5 03−06 Safety regulations . . . . . . . 2 03−06
View of hydraulic pump Data . . . . . . . . . . . . . . . . . . . 3−4 03−06
components . . . . . . . . . . . . 5 03−06
Tools . . . . . . . . . . . . . . . . . . 4 03−06
Operating principles . . . . . 5−6 03−06
Conditioning system com-
(*) Chapters prior to section 35 are in volume 1. ponents . . . . . . . . . . . . . . . . 7 to 11 03−06

87623187 − 05 − 2007
2 CONTENT

Page Date Page Date

Warnings for air conditio- Transmitters, sensors and
ning system repair opera- switches . . . . . . . . . . . . . . . 19−26 03−06
tions . . . . . . . . . . . . . . . . . . . 11 03−06 Maintenance . . . . . . . . . . . . 26 03−06
Cab controls . . . . . . . . . . . . 12 to 14 03−06 Resetting hours on the da-
Instructions for use − air shboard . . . . . . . . . . . . . . . . 27−28 05−07
conditioning system . . . . . 15 03−06
Air−conditioning system CHAPTER 2 − Components
charging and evacuation
Summary . . . . . . . . . . . . . . 1 03−06
recovery/recycling station 15 03−06
Introduction . . . . . . . . . . . . . 1 03−06
Leak detector . . . . . . . . . . . 16 03−06
Dashboard controls . . . . . . 2 to 8 03−06
Air conditioning system
maintenance . . . . . . . . . . . . 17 03−06 Controls on right−hand
mudguard . . . . . . . . . . . . . . 9 to 11 03−06
Troubleshooting . . . . . . . . . 18 03−06
In−Cab Controls . . . . . . . . . 12 to 14 03−06
Troubleshooting . . . . . . . . . 19 to 22 03−06
Controls on right−hand cab
System functional testing . 23 03−06
upright . . . . . . . . . . . . . . . . . 15−16 03−06
Checking for and elimina-
External controls . . . . . . . . 17 03−06
ting gas leaks . . . . . . . . . . . 24 03−06
Maintenance . . . . . . . . . . . . 18−19 03−06
Compressor drive belt
tension adjustment . . . . . . 25−26 03−06
CHAPTER 3 − Components
Removal−Installation −
compressor . . . . . . . . . . . . . 27 to 29 03−06 Summary . . . . . . . . . . . . . . 1 03−06
Heating and air conditio- Technical data . . . . . . . . . . 1 03−06
ning systems piping repla- Tightening Torques . . . . . . 1 03−06
cement . . . . . . . . . . . . . . . . 30−31 03−06
Description and Operation 2 03−06
Air conditioning piping re-
Troubleshooting . . . . . . . . . 3 03−06
placement . . . . . . . . . . . . . . 32 to 37 03−06
Starting and recharging cir-
Condenser replacement 38 03−06
cuit (pre−modification) . . . 4−5 03−06
Dryer filter replacement . . 39−40 03−06
Starting and recharging cir-
Removal−Installation − cuit (post−modification) . . 6−7 03−06
heater unit . . . . . . . . . . . . . . 41 to 43 03−06
System testing . . . . . . . . . . 8 to 10 03−06
Replacing the air−conditio-
Starter motor removal, in-
ner evaporator . . . . . . . . . . 44 to 46 03−06
stallation and overhaul . . . 10 to 13 03−06
Removal−Installation −
Bench testing . . . . . . . . . . . 13−14 03−06
electric fan . . . . . . . . . . . . . 47−48 03−06
CHAPTER 4 − Charging system
55 − ELECTRICAL SYSTEM
Summary . . . . . . . . . . . . . . 1 03−06
CHAPTER 1 − Instruments Technical data . . . . . . . . . . 1 03−06
Summary . . . . . . . . . . . . . . 1 03−06 Tightening Torques . . . . . . 1 03−06
Control panel . . . . . . . . . . . 2−3 03−06 Description and Operation 2−3 03−06
Analog/digital instruments 4 03−06 System testing and trou-
bleshooting . . . . . . . . . . . . . 4 to 9 03−06
Liquid crystal display . . . . . 5 to 7 03−06
Removal, Installation and
Access to the setup menu Overhaul . . . . . . . . . . . . . . . 10 03−06
via keypad . . . . . . . . . . . . . 8−13 03−06
Alternator components . . . 11 03−06
Calling up functions from
keypad . . . . . . . . . . . . . . . . . 13 to 16 03−06 Tests . . . . . . . . . . . . . . . . . . 12 to 14 03−06
Access to the setup menu Disassembly . . . . . . . . . . . . 15 03−06
with the CAL button . . . . . . 17−18 03−06 Electronic voltage regulator 15 to 16 03−06
Calling up functions with Inductor winding insulation
the CAL button . . . . . . . . . . 18 03−06 test . . . . . . . . . . . . . . . . . . . . 16−17 03−06

87623187 − 05 − 2007
 CONTENT 3

Page Date Page Date

Overhaul, installation . . . . 17−18 03−06 Dual Command (2 Speed
Power Shift) ISO deck ver-
CHAPTER 5 − Battery sion . . . . . . . . . . . . . . . . . . . 155 to 178 03−06

Summary . . . . . . . . . . . . . . 1 03−06 Dual Command (2 Speed

Power Shift) NASO deck
Technical data . . . . . . . . . . 1 03−06 version . . . . . . . . . . . . . . . . . 179 to 202 03−06
Description and Operation 1 03−06 Control unit input − output
Removal−Installation − diagrams . . . . . . . . . . . . . . . 203 to 208 03−06
battery . . . . . . . . . . . . . . . . . 2−3 03−06
Battery maintenance . . . . . 4 to 5 03−06 CHAPTER 7 − Electrical circuits
(post−modification)
Battery charging . . . . . . . . 5−6 03−06
Summary . . . . . . . . . . . . . 1 05−07
Battery testing . . . . . . . . . . 6 to 8 03−06
Maxi power fuses box . . . . 02 to 04 03−06
Battery problems −
frequent causes . . . . . . . . . 8 03−06 Fuse and relay box . . . . . . 04 to 22 03−06
Power sockets . . . . . . . . . . 23 03−06
CHAPTER 6 − Electrical circuits Grid heater . . . . . . . . . . . . . 24 03−06
(pre−modification)
Electronic flasher . . . . . . . . 24 03−06
Summary . . . . . . . . . . . . . . 1 05−07
How to use the linear wiring
Maxi power fuses box . . . . 2 to 4 03−06 diagrams . . . . . . . . . . . . . . . 25 to 27 03−06
Fuse and relay box . . . . . . 4 to 16 03−06 Ground location points . . . 28−29 03−06
Power sockets . . . . . . . . . . 17 03−06 Electric wire colour code . 30 03−06
Operator safety circuit . . . 18 03−06 Symbols used in electrical
Grid heater . . . . . . . . . . . . . 18−19 03−06 circuits . . . . . . . . . . . . . . . . . 31−32 03−06
Electronic flasher . . . . . . . . 19 03−06 Wiring diagram compo-
nents . . . . . . . . . . . . . . . . . . 33 to 40 03−06
Ground location points . . . 20−21 03−06
Power Shuttle cab version 41 to 76 03−06
How to use the linear wiring
diagrams . . . . . . . . . . . . . . . 22 to 24 03−06 Dual Command (2 Speed
Power Shift) cab version . 77 to 112 03−06
Symbols used in electrical
circuits . . . . . . . . . . . . . . . . . 25−26 03−06 Power Shuttle ISO deck
version . . . . . . . . . . . . . . . . . 113 to 136 03−06
Electric wire colour code . 26 03−06
Power Shuttle NASO deck
Wiring diagram compo-
version . . . . . . . . . . . . . . . . . 137 to 160 03−06
nents . . . . . . . . . . . . . . . . . . 27 to 34 03−06
Dual Command (2 Speed
Power Shuttle cab version 35 to 70 03−06
Power Shift) ISO deck ver-
Dual Command (2 Speed sion . . . . . . . . . . . . . . . . . . . 161 to 184 03−06
Power Shift) cab version . 71 to 106 03−06
Dual Command (2 Speed
Power Shuttle ISO deck Power Shift) NASO deck
version . . . . . . . . . . . . . . . . . 107 to 130 03−06 version . . . . . . . . . . . . . . . . . 185 to 207 03−06
Power Shuttle NASO deck Control unit input − output
version . . . . . . . . . . . . . . . . . 131 to 154 03−06 diagrams . . . . . . . . . . . . . . . 208 to 214 03−06

87623187 − 05 − 2007
4 CONTENT

87623187 − 05 − 2007
 SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1 5

LIQUID CRYSTAL DISPLAYS

CLOCK
There is a digital clock (1) on the right−hand side of
the instrument panel.
To adjust the time display turn the key−start on, press
and hold the Hour or Minute button until the read out
starts to flash. To adjust the hours, press button ‘H’
(2). Each time the button is pressed, the display will
advance by 1 hour. Alternatively, hold the button in
and the display will advance automatically. Release
the button when the hour display is correct.
To adjust the minutes, repeat the same procedure
using button ‘M’ (3). To save the setting, do not touch
the buttons for 10 seconds.
5

Change the display mode with buttons ‘H’ and

‘M’
The clock is set at the factory to display a 12 hour rea- 1
ding.
To pass on to a 24−hour display, press buttons ‘H’
and ‘M’ simultaneously with the ignition key turned
onto OFF.
Turn the ignition switch onto ON and keep both but-
tons pressed for three seconds, the clock will pass on
to a 24−hour display.
Repeat the procedure to change back to a 12 hour
display. Turn the ignition switch to OFF to save the
setting.

Resetting hours worked

The ADIC permits resetting the hours worked three 1
times within the first 100 hours worked.
Proceed as follows:
− With the starter key ON (the monitor displays the
hours worked).
− Press and hold down the hour adjustment button
H [1] for longer than 10 seconds.
After the first 6 seconds have passed (while holding
down button H) the monitor will show:
− H = 3 resets available
− F = 2 resets available
− L = 1 reset available 7

NOTE: Since software release 03.00.00.00 resetting

the hours worked has changed procedure, see pa-
ge 27 in this section.

87623187 − 05 − 2007
6 SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1

Setting hours worked on a new dashboard

When renewing the tractor’s instrument panel it is 1
possible to set the hours worked of the panel being
replaced.
Proceed as follows:
− With the starter key ON (the monitor displays the
hours worked).
− Press and hold down the adjustment button for
H (2) and M (1) for longer than 15 seconds.
− The display will flash.
− Set the hours worked with the H and M buttons.
− Press and hold down the adjustment button for
H (2) and M (1) for longer than 15 seconds to sa- 8
ve.

NOTE: It is not possible to decrease the hours wor-

ked already stored in memory on the panel.

CENTRAL DISPLAY
The information presented on the central display (3)
varies depending on the tractor specification level.
Use the switch on the advanced keypad (if installed)
to select the various displays (2, fig.12).
The central display (3) shows the following
information.

− Rear wheel slip (with radar option only). 3

− PTO speed.
− During forward speed calibration the conversion
factor will be shown on this display.
9

GROUND SPEED DISPLAY

The information on the left display (1) is:
− speed in Mph or in Km/h.
− if calibrating the speed the display will show
“CAL”.

10

87623187 − 05 − 2007
 SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1 27

RESETTING HOURS ON THE DASHBOARD

NOTE: On machines following software code 03.00.00.00 (see in the dashboard HH programs, more specifically
in H4 the second and third series of numbers, the first series is the type of software) the hours worked are reset
as described here.

1. Turn the ignition switch (1, fig. 56) to A (OFF) and

connect tool 380000843 (2) to the relevant dia-
gnosis socket (1).

55

2. Turn the ignition switch (1) to B.

MDB1669A

56

The information monitor will show HH MENU.

HH

MENU

57

87623187 − 05 − 2007
28 SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1

Resetting hours worked

Press and hold down the brightness adjustment but-

ton [1] for 15 seconds.
After the first 12 seconds have passed (while holding
down the brightness adjustment button) the monitor
will show: 0
x100

− H = 3 resets available
− F = 2 resets available
− L = 1 reset available
If the button is immediately released the reset proce-
dure is not successful. If the button is kept pressed 1
for another 3 seconds the number of hours worked is
reset.
58

87623187 − 05 − 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 6 -- ELECTRICAL CIRCUITS

Series TL- A
Until chassis frame no. HJS062849 (cab versions),
HJS064464 (deck versions), EKS004891 (production St. Valentin)
CONTENT

Description Page
Maxi power fuses box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuses and relays layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuses and relays layout (model with cab -- Version with Power Shuttle) . . . . . . . . . . . . . . . 5
Fuses and relays layout
(model with cab -- Version with dual command (2--speed power shift)) . . . . . . . . . . . . . . . . 7
Fuses and relays layout
(model without cab ISO -- Version with Power Shuttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuses and relays layout
(model without cab North America -- Version with Power Shuttle) . . . . . . . . . . . . . . . . . . . . 11
Fuses and relays layout
(model without cab ISO -- Version with dual command (2--speed power shift)) . . . . . . . . 13
Fuses and relays layout (model without cab North America --
Version with dual command (2--speed power shift)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operator safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grid heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electronic flasher module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ground location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to use the linear wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electric wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power Shuttle cab version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dual command (2 speed power shift) cab version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Power Shuttle ISO deck version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Power Shuttle North America deck version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Dual Command (2 Speed Power Shift) ISO deck version . . . . . . . . . . . . . . . . . . . . . . . . . 155
Dual command (2 speed power shift) North America deck version . . . . . . . . . . . . . . . . . 179
Control unit input -- output diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

87623187 - 05 - 2007
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

MAXI FUSE BOX

The maxi fuse box is located inside the engine compartment, on the left--hand side near the brake fluid reservoir.

2 4

1 3

MPF0640A

Version with Cab

Power Shuttle version

Valves Amps PROTECTED CIRCUITS

1 40 25 A / 40 A power socket.
2 40 Power supply fuses No. 7 -- 8-- 9-- 10-- 11 and +30 relay RVI side lights relay
(fuse F3 and F4).
50 Power supply +30 starter switch (fuses 1 -- 2 -- 12 -- 13 -- 14 -- 15 -- 16 -- 17 -- 21 -- 22 --
3
23) and +30 relay I starter circuit.
4 40 Power supply fuses 5 -- 6 -- 19 -- 24 (work lights).

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 7 -- ELECTRICAL CIRCUITS

Series TL- A
From chassis frame no. HJS062849 (cab versions),
HJS064464 (deck versions) and EKS004891 (production St. Valentin)

CONTENT

Description Page
Maxi power fuses box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuse and relay box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuses and relays layout (model with cab, version with Power Shuttle) . . . . . . . . . . . . . . . . 5

Fuses and relays layout

(model with cab, version with dual command (2--speed power shift)) . . . . . . . . . . . . . . . . . 8

Fuses and relays layout (model without cab, version with Power Shuttle -- ISO ) . . . . . . . 11
Fuses and relays layout
(model without cab, version with Power Shuttle -- North America) . . . . . . . . . . . . . . . . . . . 14
Fuses and relays layout
(model without cab, Version with dual command (2--speed power shift) -- ISO) . . . . . . . . 17

Fuses and relays layout (model without cab, version with dual command
(2--speed power shift) -- North America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Power sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Grid heater relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Grid heater control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Electronic flasher module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

How to use the linear wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ground location points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electric wire colour codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring diagram components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Power Shuttle cab version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dual command (2 speed power shift) cab version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Power Shuttle ISO deck version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Power Shuttle North America deck version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Dual Command (2 Speed Power Shift) ISO deck version . . . . . . . . . . . . . . . . . . . . . . . . . 161

Dual command (2 speed power shift) North America deck version . . . . . . . . . . . . . . . . . 185
Control unit input -- output diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

87623187 - 05 - 2007
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

MAXI FUSE BOX

The maxi fuse box is located inside the engine compartment, on the left--hand side near the brake fluid reservoir.

2 4

1 3

MPF0640A

Version with cab

Power Shuttle version

Valves Amps PROTECTED CIRCUITS

1 40 25 A / 40 A power socket.
2 40 Power supply fuses No. 16 -- 17 -- 18 -- 19 -- 20, +30 side lights relay (fuse 7 -- 8).
50 Power supply +30 starter switch (fuses No. 1 -- 2 -- 3 -- 4 -- 5 -- 6 -- 21 -- 22 -- 23 -- 24--
3
25) and +30 starter relay.
4 40 Power supply fuses 9 -- 10 -- 11 -- 12 (work lights).

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 5

FUSE AND RELAY LAYOUT

(Version with cab, version with Power Shuttle)

DANGER
If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted
in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could
seriously compromise tractor control with dangerous results.

Ready for:
-- Electrohydraulic differential lock. -- Electrohydraulic power take--off.
-- Electrohydraulic 4WD. -- North America lights circuit.
-- Trailer brake circuit. -- Front loader.
-- Air brake circuit. -- Electronic rear lift.

1 2 3 +12V KEY 16 17 18
10A 5A 10A CAB
15A 15A 5A
4 5 6 +12V KEY 19 20 21
15A 5A 10A ENG--TRANSM 15A 15A 10A
7 8 9 22 23 24
15A 5A 15A 10A 10A
STOP 25A
10 11 12 25 26 27
MF31

MF32

15A 15A 15A 5A

13 14 15 28 29 30

MPH2035A

87623187 - 05 - 2007
6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Fuses

POWER SHUTTLE VERSION

Valves Amps PROTECTED CIRCUITS

F1 10 (+15 Key) TCM circuit.

F2 5 (+15 Key) Engine stop circuit.

F3 10 (+15 Key) Miscellaneous circuits inside cab.

F4 15 (+15 Key) EDC circuit.

F5 5 (+15 Key) Instrument (ADIC).

F6 10 (+15 Key) Engine and transmission services, trailer brake circuit, front loader fitting.

F7 15 (+12V 87 R7) Front right--hand and rear left--hand side lights, seven--pole connector.

F8 5 (+12V 87 R7) Front left--hand and rear right--hand side lights, control instrument panel
light.

F9 15 (+12V MF4 40A) Lower front work lights.

F10 15 (+12V MF4 40A) Upper rear work lights.

F11 15 (+12V MF4 40A) Upper front work lights.

F12 15 (+12V MF4 40A) Grille swivel lights.

F13 -- Not used.

F14 -- Not used.

F15 -- Not used.

F16 15 (+12V MF2 40A) Full beam headlights.

F17 15 (+12V MF2 40A) Dipped beam headlights.

F18 5 (+12V MF2 40A) EDC, TCM, ADIC, handbrake circuit.

F19 15 (+12V MF2 40A) Direction indicator and hazard lights.

F20 15 (+12V MF2 40A) Horn, 8A power socket, cigar lighter, rotating beacon, courtesy light, car
radio, buzzer.

F21 10 (+15 Key) Front -- rear wipers and washers.

F22 10 (+15 Key) Power take--off and air--conditioner compressor circuit.

F23 10 (+15 Key) Brake lights, seat.

F24 25 (+15 Key) Fan unit, radio.

F25 5 (+50 Key) Starter safety circuit.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 7

MR1 R10 R2 R1
R9

38 37 34 33

R25 R12 R11 R4 R3

STOP

R26 R13 R6 R5
R14

40 39 36 35

R7
R28 R27 R16 R15 R8

MPH2036A

Relays

MR1. Engine starter circuit (70A). R11. Upper rear work lights circuit.
R1. Full beam headlight circuit. R12. Upper front work lights circuit.
R2. Dipped beam headlight circuit.
R13. Air--conditioner circuit.
R3. Grille work lights circuit.
R14. Not used.
R4. Brake lights circuit.
R15. Not used.
R5. Trailer brake circuit.
R16. Not used.
R6. Trailer brake circuit.
R25. Not used.
R7. Side lights circuit.
R26. Diodes.
R8. Not used.
R27. Not used.
R9. Not used.
R28. Not used.
R10. Lower front work lights circuit.

87623187 - 05 - 2007
8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

FUSE AND RELAY LAYOUT

(Version with cab, version with Dual Command (2 Speed Power Shift))

DANGER
If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted
in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could
seriously compromise tractor control with dangerous results.

Ready for:

-- Electrohydraulic differential lock. -- Air brake circuit.

-- Electrohydraulic 4WD. -- North America lights circuit.
-- Electrohydraulic power take--off. -- Front loader.
-- Trailer brake circuit. -- Electronic rear lift.

1 2 3 +12V KEY 16 17 18
10A 5A 10A CAB 15A 15A 5A
4 5 6 +12V KEY 19 20 21
ENG--TRANSM
15A 5A 10A 15A 15A 10A
7 8 9 22 23 24
15A 5A 15A STOP
10A 10A 25A
10 11 12 25 26 27
MF31

MF32

15A 15A 15A 5A 15A

13 14 15 28 29 30

MPH2034A

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 9

Fuses

VERSION WITH DUAL COMMAND (2 SPEED POWER SHIFT)

Valves Amps PROTECTED CIRCUITS

F1 10 (+15 Key) Dual Command (2 Speed Power Shift) circuit.

F2 5 (+15 Key) Engine stop circuit.

F3 10 (+15 Key) Miscellaneous circuits inside cab.

F4 15 (+15 Key) EDC circuit.

F5 5 (+15 Key) Instrument (ADIC).

F6 10 (+15 Key) Engine and transmission services, trailer brake circuit, front loader fitting

F7 15 (+12V 87 R7) Front right--hand and rear left--hand side lights, seven--pole connector.

F8 5 (+12V 87 R7) Front left--hand and rear right--hand side lights, control instrument panel
light.

F9 15 (+12V MF4 40A) Lower front work lights.

F10 15 (+12V MF4 40A) Upper rear work lights.

F11 15 (+12V MF4 40A) Upper front work lights.

F12 15 (+12V MF4 40A) Grille swivel lights.

F13 -- Not used.

F14 -- Not used.

F15 -- Not used.

F16 15 (+12V MF2 40A) Full beam headlights.

F17 15 (+12V MF2 40A) Dipped beam headlights.

F18 5 (+12V MF2 40A) EDC, ADIC, handbrake circuit.

F19 15 (+12V MF2 40A) Direction indicator and hazard lights.

F20 15 (+12V MF2 40A) Horn, 8A power socket, cigar lighter, rotating beacon, courtesy light, car
radio, buzzer.

F21 10 (+15 Key) Front -- rear wipers and washers.

F22 10 (+15 Key) Power take--off and air--conditioner compressor circuit.

F23 10 (+15 Key) Brake lights, seat.

F24 25 (+15 Key) Fan unit, radio.

F25 5 (+50 Key) Starter safety circuit.

F26 -- Not used.

F27 15 (+15 Key) Differential lock and four--wheel drive circuit.

87623187 - 05 - 2007
10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

MR1 R10 R9 R2 R1

38 37 34 33

R25 R12 R11 R4 R3

STOP

R26 R14 R13 R6 R5

40 39 36 35

R28 R27 R16 R15 R8 R7

HI--LO

MPH2036A

Relays

MR1. Engine starter circuit (70A). R10. Lower front work lights circuit.

R1. Full beam headlight circuit. R11. Upper rear work lights circuit.

R2. Dipped beam headlight circuit. R12. Upper front work lights circuit.

R3. Grille work lights circuit. R13. Air--conditioner circuit.

R4. Brake lights circuit. R14. Differential lock circuit.

R5. Trailer brake circuit. R15. Four--wheel drive and brake lights circuit.

R6. Trailer brake circuit. R16. Differential lock circuit.

R7. Side lights circuit. R25. Not used.

R8. Dual Command (2 Speed Power Shift) circuit. R26. Diode circuit.

R9. Differential lock, four--wheel drive and brake R27. Electrohydraulic PTO circuit.
lights circuit.
R28. Electrohydraulic PTO circuit.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 13

R50 MR1 R2 R1

34 33

R25 R4 R3
STOP

R6 R5
R26

36 35

R28 R27 R8 R7

MPH2042A

Relays

MR1. Engine starter circuit (70A). R5. Trailer brake circuit.

R1. Full beam headlight circuit. R6. Trailer brake circuit.
R2. Dipped beam headlight circuit. R7. Not used.
R3. Grille work lights circuit. R8. Not used.
R4. Brake lights circuit. R50. Electronic flasher.

87623187 - 05 - 2007
14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

FUSE AND RELAY LAYOUT

(Version without cab and version with Power Shuttle -- North America)

DANGER
If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted
in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could
seriously compromise tractor control with dangerous results.

Ready for:

-- Electrohydraulic differential lock. -- Electrohydraulic power take--off.

-- Electrohydraulic 4WD. -- Trailer brake circuit.

1 2 3 +12V KEY 16 17 18 +12V

10A 5A 10A MODULE 15A 15A 5A BATT
4 +12V KEY 5 +12V 6 19 20 21
10A ENG--TRANSM 5A KEY 10A 15A 10A 10A
7 8 9 22 23 24
5A 5A STOP
10A
10 11 12 25 26 27
MF31

MF32

15A 5A
13 14 15 28 29 30

MPH2043A

10

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 15

Fuses

VERSION WITH POWER SHUTTLE - (NORTH AMERICA)

Valves Amps PROTECTED CIRCUITS

F1 10 (+15 Key) TCM circuit.

F2 5 (+15 Key) Engine stop circuit.

F3 10 (+15 Key) Miscellaneous circuits, steering module.

F4 10 (+15 Key) Engine and transmission services, trailer brake circuit, front loader
power supply.

F5 5 (+15 Key) Instrument (ADIC).

F6 10 (+15 Key) Rear work light.

F7 15 (+12V 87 R7) Left--hand side lights, seven--pole connector.

F8 5 (+12V 87 R7) Right--hand side lights, control instrument panel light.

F9 -- Not used.

F10 -- Not used.

F11 -- Not used.

F12 15 (+12V MF2 40A) Grille swivel lights.

F13 -- Not used.

F14 -- Not used.

F15 -- Not used.

F16 15 (+12V MF2 40A) Full beam headlights.

F17 15 (+12V MF2 40A) Dipped beam headlights.

F18 5 (+12V MF2 40A) TCM, ADIC, handbrake circuit.

F19 15 (+12V MF2 40A) Direction indicator and hazard lights.

F20 10 (+12V MF2 40A) Horn, 8A power socket.

F21 -- Not used.

F22 -- Not used.

F23 10 (+15 Key) Brake lights, seat.

F24 -- Not used.

F25 5 (+50 Key) Starter safety circuit.

87623187 - 05 - 2007
16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

MR1 R2 R1

34 33

R25 R4 R3
STOP

R6 R5
R26

36 35

R7
R28 R27 R8

MPH2053A

11

Relays

MR1. Engine starter circuit (70A). R5. Trailer brake circuit.

R1. Full beam headlight circuit. R6. Trailer brake circuit.
R2. Dipped beam headlight circuit. R7. Side lights circuit.
R3. Grille work lights circuit. R8. Not used.
R4. Brake lights circuit.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 19

R50 MR1 R9 R2 R1
R10

38 37 34 33

R25 R4 R3
R12 R11 STOP

R14 R6 R5
R26 R13

40 39 36 35

R28 R27 R16 R15 R8

HI--LO R7

MPH2038A

13

Relays

MR1. Engine starter circuit (70A). R11. Not used.

R1. Full beam headlight circuit. R12. Not used.
R2. Dipped beam headlight circuit. R13. Not used.
R3. Grille work lights circuit. R14. Differential lock circuit.
R4. Brake lights circuit. R15. Four--wheel drive and brake lights circuit.
R5. Trailer brake circuit. R16. Differential lock circuit.
R6. Trailer brake circuit. R25. Not used.
R7. Not used. R26. Not used.
R8. Dual Command (2 Speed Power Shift) circuit. R27. Electrohydraulic PTO circuit.
R9. Differential lock, four--wheel drive and brake R28. Electrohydraulic PTO circuit.
lights circuit.
R50. Electronic flasher.
R10. Not used.

87623187 - 05 - 2007
20 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

FUSE AND RELAY LAYOUT

(Version without cab, version with Dual Command (2 Speed Power Shift) -- North America)

DANGER
If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted
in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could
seriously compromise tractor control with dangerous results.

Ready for:

-- Electrohydraulic differential lock. -- Electrohydraulic power take--off.

-- Electrohydraulic 4WD. -- Trailer brake circuit.

1 2 3 +12V KEY 16 17 18 +12V

10A 5A 10A MODULE BATT
15A 15A 5A
4 +12V KEY 5 +12V 6 19 20 21
10A ENG--TRANSM 5A KEY 10A 15A 10A 10A
7 8 9 22 23 24
STOP
5A 5A 10A
10 11 12
MF31

MF32

25 26 27
15A 5A 10A
13 14 15 28 29 30

MPH2039A

14

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 21

Fuses

DUAL COMMAND (2 SPEED POWER SHIFT) VERSION - (NORTH AMERICA)

Valves Amps PROTECTED CIRCUITS

F1 10 (+15 Key) Dual Command (2 Speed Power Shift) circuit.

F2 5 (+15 Key) Engine stop circuit.

F3 10 (+15 Key) Miscellaneous circuits, steering module.

F4 10 (+15 Key) Engine and transmission services, trailer brake circuit, front loader fitting.

F5 5 (+15 Key) Instrument (ADIC).

F6 10 (+15 Key) Rear work light.

F7 15 (+12V 87 R7) Left--hand side lights, pin 2, 7--pole connector, North America.

F8 5 (+12V 87 R7) Right--hand side lights, control instrument panel light.

F9 -- Not used.

F10 -- Not used.

F11 -- Not used.

F12 15 (+12V MF2 40A) Grille swivel lights circuit.

F13 -- Not used.

F14 -- Not used.

F15 -- Not used.

F16 15 (+12V MF2 40A) Full beam headlights.

F17 15 (+12V MF2 40A) Dipped beam headlights.

F18 5 (+12V MF2 40A) ADIC, handbrake circuit.

F19 15 (+12V MF2 40A) Direction indicator and hazard lights.

F20 10 (+12V MF2 40A) Horn, 8A power socket.

F21 10 (+15 Key) Power take--off circuit.

F22 -- Not used.

F23 10 (+15 Key) Brake lights, seat.

F24 -- Not used.

F25 5 (+50 Key) Starter safety circuit.

F26 -- Not used.

F27 15 (+15 Key) Differential lock circuit, four--wheel drive circuit.

87623187 - 05 - 2007
22 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

MR1 R9 R2 R1
R10

38 37 34 33

R25 R4 R3
R12 R11 STOP

R14 R6 R5
R26 R13

40 39 36 35

R28 R27 R16 R15 R8 R7

HI--LO

MPH2040A

15

Relays

MR1. Engine starter circuit (70A). R6. Trailer brake circuit.

R1. Full beam headlight circuit. R7. Side lights circuit.
R2. Dipped beam headlight circuit. R8. Dual Command (2 Speed Power Shift) circuit.
R3. Grille work lights circuit. R9. Differential lock, four--wheel drive and brake
lights circuit.
R4. Brake lights circuit.
R5. Trailer brake circuit.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 43

MPH2007A

87623187 - 05 - 2007
44 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

TAIL/SIDE LIGHTS, FULL BEAM, DIPPED BEAM,

NUMBER PLATE AND HORN CIRCUIT
(Diagram B)

6 Front LH headlamp

7 Front RH headlamp

8 Horn

14 Front lights connection

17 RH front direction indicator and side light

41 LH number plate light

48 RH tail light

55 LH front direction indicator and side light

56 RH number plate light

57 LH tail light

89 External lights control switch

155 Front main connection (51 PIN -- PURPLE)

163 Front loader system connection

F7 Front right--hand and rear left--hand side lights fuse, seven--pole connector

F8 Front left--hand and rear right--hand side lights fuse, control instrument panel light

F16 Full beam headlights fuse

F17 Dipped beam headlights fuse

R1 Full beam headlights circuit relay

R2 Dipped beam headlights circuit relay

R7 Side/tail lights circuit relay

Y See diagram O.
D Jumper to be connected when there is no front loader circuit.
z Second part of the node, diagram M.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 45

MPH2009A

87623187 - 05 - 2007
46 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT

(Diagram D)

17 RH front direction indicator and side light

22 Dashboard (ADIC)

39 Connection for auxiliary work light and RH rear extra direction indicator

47 Connection for auxiliary work light and LH rear extra direction indicator

48 RH tail light

55 LH front direction indicator and side light

57 LH tail light

89 External lights control switch

91 Flashing hazard warning lights switch

125 Electronic flasher

F19 Direction indicator and hazard lights fuse

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 47

MPH2010A

87623187 - 05 - 2007
48 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

POWER SHUTTLE CIRCUIT

(Diagram D1)

22 Dashboard (ADIC)

155 Front main connection (51 PIN -- PURPLE)

156 Transmission system connection (51 PIN -- GREEN)

165 Keypad

168 Diagnostics connection

169 Transmission control unit (TCM)

F1 TCM circuit fuse

F18 EDC, TCM, ADIC, handbrake circuit fuse

Y See diagrams E1 -- E2.

z Second part of the node, diagram D2.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 49

MPH2014A

87623187 - 05 - 2007
50 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

POWER SHUTTLE CIRCUIT

(Diagram D2)

22 Dashboard (ADIC)

90 Instrument CAL -- SEL control switch

97 Seat safety switch

126 Clutch pedal switch

129 Clutch pedal sensor

130 Power Shuttle control lever

156 Transmission system connection (51 PIN -- GREEN)

169 Transmission control unit (TCM)

182 Dual Command (2 Speed Power Shift) clutch cut--in and clutch cut--out switches

F25 Starter safety circuit fuse

Y See diagrams E1 -- E2.

z Second part of the node, diagram D1.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 51

MPH2015A z

87623187 - 05 - 2007
52 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SENSORS AND TRANSMITTERS CIRCUIT, TRANSMISSION SIDE

(Diagram E1)

62 PTO speed sensor

66 Differential lock indicator switch

67 Fuel level transmitter

69 Differential lock solenoid valve

70 Four--wheel drive indicator pressure switch

72 Four--wheel drive solenoid valve

138 Transmission oil temperature sensor

156 Transmission system connection (51 PIN -- GREEN)

Y See diagrams D1 -- D2.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 83

MPH2010A

87623187 - 05 - 2007
84 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

KEYPAD, FAULT DIAGNOSIS SOCKET CIRCUIT

(Diagram D/1)

22 Dashboard (ADIC)

155 Front main connection (51 PIN -- PURPLE)

156 Transmission system connection (51 PIN -- GREEN)

165 Keypad

168 Diagnostics connection

F1 Dual Command (2 Speed Power Shift) circuit fuse.

F18 EDC, ADIC, handbrake circuit fuse.

Y See diagrams E1 -- E2.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 115

MPH2007A

87623187 - 05 - 2007
116 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

TAIL/SIDE LIGHTS, FULL BEAM, DIPPED BEAM,

NUMBER PLATE AND HORN CIRCUIT
(Diagram B)

6 Front LH headlamp

7 Front RH headlamp

8 Horn

14 Front lights connection

17 RH front direction indicator and side light

22 Dashboard (ADIC)

41 LH number plate light

48 RH tail light

55 LH front direction indicator and side light

56 RH number plate light

56 RH number plate light

57 LH tail light

89 External lights control switch

155 Front main connection (51 PIN -- PURPLE)

F7 Front right--hand and rear left--hand side lights fuse, seven--pole connector

F8 Front left--hand and rear right--hand side lights fuse, control instrument panel light

F16 Full beam headlights fuse

F17 Dipped beam headlights fuse

F20 Fuse for horn, 8A power socket

R1 Full beam headlights circuit relay

R2 Dipped beam headlights circuit relay

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 117

MPH2009A

87623187 - 05 - 2007
118 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT

(Diagram D)

17 RH front direction indicator and side light

22 Dashboard (ADIC)

48 RH tail light

55 LH front direction indicator and side light

57 LH tail light

89 External lights control switch

91 Flashing hazard warning lights switch

F19 Direction indicator and hazard lights fuse

F24 Direction indicator fuse

R50 Electronic flasher relay

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 121

MPH2014A

87623187 - 05 - 2007
122 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

POWER SHUTTLE CIRCUIT

(Diagram D/2)

22 Dashboard (ADIC)

90 Instrument CAL/SEL control switch

97 Seat safety switch

126 Clutch pedal switch

129 Clutch pedal sensor

130 Power Shuttle control lever

156 Transmission system connection (51 PIN -- GREEN)

169 Transmission control unit (TCM)

182 Dual Command (2 Speed Power Shift) clutch cut--in and clutch cut--out switches

F25 Starter safety circuit fuse

Y See diagrams E1 -- E2.

z First part of the node, diagram D1.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 123

MPH2015A
z

87623187 - 05 - 2007
124 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SENSORS AND TRANSMITTERS CIRCUIT, TRANSMISSION SIDE

(Diagram E/1)

62 PTO speed sensor

66 Differential lock indicator switch

67 Fuel level transmitter

69 Differential lock solenoid valve

70 Four--wheel drive indicator pressure switch

72 Four--wheel drive solenoid valve

138 Transmission oil temperature sensor

156 Transmission system connection (51 PIN -- GREEN)

Y See diagrams D1 -- D2.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 139

MPH2007A

87623187 - 05 - 2007
140 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

TAIL/SIDE LIGHTS, FULL BEAM, DIPPED BEAM

AND HORN CIRCUIT
(Diagram B)

6 Front LH headlamp

7 Front RH headlamp

8 Horn

14 Front lights connection

22 Dashboard (ADIC)

89 External lights control switch

153 LH two--faced headlight

154 RH two--faced headlight

155 Front main connection (51 PIN -- PURPLE)

F7 Left--hand side lights fuse, seven--pole connector

F8 Right--hand side lights fuse, control instrument panel light

F16 Full beam headlights fuse

F17 Dipped beam headlights fuse

F20 Fuse for horn, 8A power socket

R1 Full beam headlights circuit relay

R2 Dipped beam headlights circuit relay

R7 Side/tail lights circuit relay

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 141

MPH2009A

87623187 - 05 - 2007
142 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

DIRECTION INDICATOR AND HAZARD LIGHTS CIRCUIT

(Diagram D)

22 Dashboard (ADIC)

89 External lights control switch

91 Flashing hazard warning lights switch

125 Electronic flasher

153 LH two--faced headlight

154 RH two--faced headlight

F19 Direction indicator and hazard lights fuse

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 143

MPH2010A

87623187 - 05 - 2007
144 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

POWER SHUTTLE CIRCUIT

(Diagram D/1)

22 Dashboard (ADIC)

156 Transmission system connection (51 PIN -- GREEN)

165 Keypad

168 Diagnostics connection

169 Transmission control unit (TCM)

F1 TCM circuit fuse

F18 TCM, ADIC, handbrake circuit fuse

Y See diagrams E1 -- E2.

z Second part of the node, diagram D2.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 145

MPH2014A

87623187 - 05 - 2007
146 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

POWER SHUTTLE CIRCUIT

(Diagram D/2)

22 Dashboard (ADIC)

90 Instrument CAL/SEL control switch

97 Seat safety switch

126 Clutch pedal switch

129 Clutch pedal sensor

130 Power Shuttle control lever

156 Transmission system connection (51 PIN -- GREEN)

169 Transmission control unit (TCM)

182 Dual Command (2 Speed Power Shift) clutch cut--in and clutch cut--out switches

F25 Starter safety circuit fuse

Y See diagrams E1 -- E2.

z First part of the node, diagram D1.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 147

MPH2015A z

87623187 - 05 - 2007
148 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SENSORS AND TRANSMITTERS CIRCUIT, TRANSMISSION SIDE

(Diagram E/1)

62 PTO speed sensor

66 Differential lock indicator switch

67 Fuel level transmitter

69 Differential lock solenoid valve

70 Four--wheel drive indicator pressure switch

72 Four--wheel drive solenoid valve

138 Transmission oil temperature sensor

156 Transmission system connection (51 PIN -- GREEN)

Y See diagrams D1 -- D2.

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 191

MPH2010A

87623187 - 05 - 2007
192 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

KEYPAD, FAULT DIAGNOSIS SOCKET CIRCUIT

(Diagram D/1)

22 Dashboard (ADIC)

156 Transmission system connection (51 PIN -- GREEN)

165 Keypad

168 Diagnostics connection

F1 Dual Command (2 Speed Power Shift) circuit fuse

F18 ADIC, handbrake circuit fuse

Y See diagrams E1 -- E2.

87623187 - 05 - 2007
 CONTENT 1

CONTENT VOLUME 3
Page Date Page Date
14001--15000 (Analog--
55 -- ELECTRICAL SYSTEM (*) digital control panel) . . . . . 336 to 404 03--06
Electronic draft control
CHAPTER 8 -- Connectors (EDC) . . . . . . . . . . . . . . . . . . 405 to 472 03--06
2001--3000
Summary . . . . . . . . . . . . . . 1 05--07 (New transmission codes) 473 to 484 05--07
Electrical circuits compo-
nents . . . . . . . . . . . . . . . . . . 2 to 6 03--06 CHAPTER 11 -- HH menu and calibrations
Wirings (pre--modification) 7 to 26 03--06 Summary . . . . . . . . . . . . . . . 1 03--06
Wirings Calibrations . . . . . . . . . . . . . 2 03--06
(post--modification) . . . . . . 27 to 46 03--06
HH MENU access . . . . . . . 3--4 03--06
List of connectors . . . . . . . . 47 to 94 03--06
HH MENU of the control
panel . . . . . . . . . . . . . . . . . . 5 to 11 03--06
CHAPTER 9 -- Components Testing
HH MENU of the transmis-
Summary . . . . . . . . . . . . . . . 1 05--07 sion . . . . . . . . . . . . . . . . . . . 12 to 25 03--06
Tests on switches, sensors HH MENU of the advan-
and pressure switches . . . 02 to 18 03--06 ced keypad . . . . . . . . . . . . . 25--26 03--06
Removal--Installation win-
dscreen wiper motor . . . . . 19 03--06 90 -- BODYWORK AND DRIVING POSITION
Summary . . . . . . . . . . . . . . . 1 03--06
CHAPTER 10 -- Error codes
Removal--Installation --
Summary . . . . . . . . . . . . . . . 1 05--07 bonnet . . . . . . . . . . . . . . . . . 2--3 03--06
Introduction . . . . . . . . . . . . . 2 05--07 Removal--Installation --
platform . . . . . . . . . . . . . . . . 4 to 11 03--06
Special tools . . . . . . . . . . . . 3 03--06
Removal--Installation --
Repairing the wiring . . . . . . 3 03--06 driver’s seat . . . . . . . . . . . . 12 03--06
Digital multimeter . . . . . . . . 6 to 8 03--06 Cab Removal--Installation . 13 to 25 03--06
Electrical test procedures . 9--11 03--06 Removal--Installation --
Circuit components . . . . . . 11 to 20 03--06 door . . . . . . . . . . . . . . . . . . . 26 03--06
CAN system . . . . . . . . . . . . 21 03--06 Replacement of glued cab
windows . . . . . . . . . . . . . . . 27--28 03--06
Control unit location . . . . . . 21 03--06
Replacement of cab rear
Error code display . . . . . . . 22 to 24 03--06 window . . . . . . . . . . . . . . . . 29 to 31 03--06
“H” menu diagnostic mode 24 03--06 Replacement of seal on
Error codes lists . . . . . . . . . 25 to 30 03--06 left--hand upright . . . . . . . . 32 03--06
Replacement of seal on
Error codes charts right--hand upright . . . . . . . 33--34 03--06
Replacement of fixed pad-
Calibration U--Codes . . . . . 31 to 34 03--06 ding on right--hand wall . . . 35 to 37 03--06
2001--3000 Replacement of fixed pad-
(Transmission) . . . . . . . . . . 35 to 280 03--06 ding on left--hand wall . . . . 38--39 03--06
5001--6000 Replacing hydraulic con-
(Rear PTO) . . . . . . . . . . . . 281 to 308 03--06 trol lever guard . . . . . . . . . . 40--41 03--06
6001--7000 Replacing cab ceiling fit-
(4WD) . . . . . . . . . . . . . . . . . 309 to 319 03--06 tings . . . . . . . . . . . . . . . . . . . 42--43 03--06
7001--8000
(Differential lock) . . . . . . . . 320 to 335 03--06 (*) Chapters prior to section 55 are in volume 2.

87623186 -- 05 -- 2007
2 CONTENT

87623186 -- 05 -- 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 8 -- WIRINGS AND CONNECTORS

TL- A Series

CONTENT

Description Page
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Wirings valid until chassis frame no. HJS062849 (cab versions),

HJS064464 (deck versions) and (EKS004891) production St. Valentin . . . . . . . . . . . . . . . . 7

Wiring diagram A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wiring diagram B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Wiring diagram C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring diagrams D/1 -- D/2 -- E/1 -- E/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring diagrams F -- G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Wiring diagram H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Wiring diagrams I -- L -- M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Wiring diagrams N/1 -- N/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Wiring diagram O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wirings valid from chassis frame no. HJS062849 (cab versions),

HJS064464 (deck versions) and (EKS004891) production St. Valentin . . . . . . . . . . . . . . . 27

Wiring diagram A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Wiring diagrams B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Wiring diagrams C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Wiring diagrams D/1 -- D/2 -- E/1 -- E/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Wiring diagrams F -- G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wiring diagram H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wiring diagrams I -- L -- M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Wiring diagrams N/1 -- N/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Wiring diagram O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

87623187 - 05 - 2007
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

ELECTRICAL CIRCUIT COMPONENTS

1 Battery
2 Engine coolant temperature sensor
4 Sediment filter sensor
5 Filter/dryer sensor
6 Front LH headlamp
7 Front RH headlamp
8 Horn
9 Air conditioning system compressor
10 Engine cut--out electromagnet
12 Air filter clogged sensor
13 Grid heater
14 Front lights connection
15 Fuses and relay control unit
16 Left brake pedal switches
17 RH front direction indicator and side light
18 Brake fluid level sensor
19 Dual Command (2 Speed Power Shift) control switch
22 Measuring device (ADIC)
23 Safety switch / mechanical power take--off indicator light
25 Parking brake switch
26 RH front auxiliary work light
27 Cigar lighter
28 Rear windscreen wiper/washer switch
29 Rotating beacon control switch
30 Right--hand brake pedal switch
31 Radio connections
33 RH speaker
34 Air conditioner switch / potentiometer
35 Ventilation and air--conditioning system connection
36 LH rotating beacon socket
37 Windscreen wiper motor
38 Ventilation and air--conditioning system electric fan switch
39 Connection for auxiliary work light and RH rear extra direction indicator
40 Auxiliary power socket (internal)
41 LH number plate light
42 LH speaker
43 Rear windscreen wiper motor
Continued

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 7

WIRINGS VALID UNTIL CHASSIS FRAME

No. HJS062849 (CAB VERSIONS), HJS064464 (DECK VERSIONS)
EXCLUDED
AND EKS004891 (PRODUCTION ST. VALENTIN)

87623187 - 05 - 2007
8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

WIRING DIAGRAM A -- POWER SHUTTLE CAB VERSION

MPH2073A

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 27

WIRINGS VALID FROM CHASSIS FRAME

No. HJS062849 (CAB VERSIONS), HJS064464 (DECK VERSIONS)
INCLUDED
AND EKS004891 (PRODUCTION ST. VALENTIN)

87623187 - 05 - 2007
28 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

WIRING DIAGRAM A -- POWER SHUTTLE CAB VERSION

MPH2044A

19

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 47

LIST OF CONNECTORS

NOTE: Unless specified otherwise, the connectors in the following list are valid for both pre modification sy-
stems [ones fitted on tractors up to chassis frame HJS062849 (cab version), HJS064464 (deck version) and
EKS004891 (production St. Valentin) excluded] and post modification systems [ones fitted on tractors from
chassis frame HJS062849 (cab version), HJS064464 (deck version) and EKS004891 (production St. Va-
lentin) included].

87623187 - 05 - 2007
48 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

1HR
1NG 1AB

37 38

1ZB

39 40

41 42

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8 87

1MN (5)

* Power Shuttle version post--modification

192

87623187 - 05 - 2007
88 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

1AR (3)
*

1GN (32)
1G (33)

* Power Shuttle version pre--modification

193

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 9 -- COMPONENTS TESTING

CONTENT

Operation Description Page

Differential lock indicator switch (66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Brake fluid level switch (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low transmission oil pressure switch (83) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air filter clogged switch (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lift status switch (127) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel sediment filter switch (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine coolant temperature sensor (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake light switch (16--30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Italia version trailer brake valve pressure switches (54--110) . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handbrake status switch (25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dual Command (2 Speed Power Shift) switch (52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dual Command (2 Speed Power Shift) switches and clutch cut--out (182) . . . . . . . . . . . . . 8
Air brake air pressure switch (190) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gear/Range lever position sensors (139--140--141) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator (87) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pressure sensor (82) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Speed sensors (68--162) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Switch (126) and clutch pedal potentiometer (129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch pressure switches A and B (132--133) and oil temperature sensor (138) . . . . . . . 14
Power Shuttle lever (130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Radar (123) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel level gauge (67) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4WD pressure switch (70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PTO speed sensor (62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Seat safety switch (97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electronic lift arm position potentiometer (145) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Draft pin sensors (119--120) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
55 518 52 Front windscreen wiper motor. R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

NOTE: Unless specified otherwise, all the data in [_] refers to tractors fitted with new systems (post modifica-
tion) from chassis frame no. HJS062849 (cab versions) and no. HJS064464 (deck versions) and
EKS004891 (production of S. Valentin) included, the other data are pre modification.

87623187 - 05 - 2007
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

COMPONENTS
(Power shuttle models with cab)

1
1. Low transmission oil pressure switch (83). 4. Differential lock indicator switch (66).
2. Brake fluid level switch (18). 5. Lift status switch (127).
3. Air filter clogged switch (12).

Differential lock indicator switch (66)

Switch normally off (PIN 1--4).
Fuse F15 (10A) [F6 (10)] delivers 12V to PIN 1 of the
switch via PIN 41 of the connection (156), when the
differential lock is engaged PIN 1 -- 4 are closed via
PIN 9 of the connection (156) the voltage reaches
PIN 4 of the connection (22C) of the dashboard.
The amber light of the differential lock comes on.
1ZB (1)

1H (1)

87623187 - 05 - 2007
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 3

Brake fluid level switch (18)

Switch normally on.
When the fluid level is regular, the switch is off.
Fuse F15 (10A) [F6 (10A)] delivers 12V to a PIN of
the reservoir float via PIN 6 of the connection (155).
When the fluid level is below the minimum, the float
PINs close and the voltage reaches PIN 4 of the con-
nection (22A) via PIN 3 of the connection (155), the
low brake fluid pressure icon appears on the display
accompanied by the related amber warning light and
the red warning light on the panel comes on. 1ZB
1ZB
MDG0154A

3
Low transmission oil pressure switch (83)
Switch normally on.
Opens with pressure above 159.5 psi (11 bar).
With lower pressure the switch turns on and PIN 12
connection (22C) is grounded via PIN 37 of connec-
tion (155); the dashboard displays the low gearbox
oil pressure icon, with the red warning light coming
on, the red warning light on the panel comes on.
Whereas the other cable goes to PIN 7 of the con-
nection (169B) of the gearbox control unit. 1VG

MDG0155A

4
Air filter clogged switch (12)
Switch normally off.
When the pressure goes down to 62 mbar, the switch
turns on and grounds PIN 11 of connection (22A)
through PIN 18 of connection (155), the clogged filter
symbol appears on the display and the amber warn-
ing light comes on.

5
Lift status switch (127)
Powered through fuse F14 (5A) [F5 (5A)].
On raising the lift arms with the Lift--O--Matic button,
a signal is sent to PIN 1 of connection (22C) to stop
the count of the worked area, and a signal is sent to
PIN 4 of connection (111) EDC to turn off slip control;
whereas, the other cable is connected to the diag-
nosis connector.
NOTE: On tractors with chassis frame greater than
no. HJS062849 (cab versions) and
no. HJS064464 (deck versions) and EKS004891 0.5LR
(production of S. Valentin) the above--described
diagnostics socket is no longer present. MDG0156A

87623187 - 05 - 2007
4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

COMPONENTS
(Power shuttle models with cab)

7
1. Italia version trailer brake valve pressure 3. Engine coolant temperature sensor (2).
switches (54). 4. Fuel sediment filter switch (4).
2. Brake light switch (16).

Fuel sediment filter switch (4)

Via fuse F15 (10) [F6 (10A)] through PIN 6 of the con-
nection (155) 12V to PIN 3.
PIN 2 to ground.
When water is detected in the circuit, PIN 1 sends a
signal to PIN 13 of connection (22A) via PIN 19 of
connection (155), the water--in--fuel icon appears on
the monitor with the related amber warning light ac-
companied by the warning light on the panel.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 5

Engine coolant temperature sensor (2)

The sensor contains two resistors that vary as the
coolant temperature varies. It receives a ground sig-
nal from PIN 22 of connection (22A) of the dash-
board, via PIN 16 of connection (155) engine side. A
resistor sends a signal to PIN 10 of connection (164)
of the GRID HEATER via PIN 14 of connection (155)
engine side.
The other resistor sends a signal to connection (22C)
of PIN 20, via PIN 13 of connection (155).

Brake light switch (16--30)

30
Switches normally on, they turn off under pressure.
Powered through fuse F1 (10A) via PIN 11 connec-
tion (155).
16
A -- Delivers 12V to PIN 86 relay IV [4] via PIN 7 of
the connector (155).
A -- Delivers 12V to PIN 20 of the connection (169B)
of the gearbox control unit via PIN 7 of the connector
(155).
B -- Delivers 12V to PIN 21 of the connection (169B)
of the gearbox control unit via PIN 10 of the con- HN HG
nector (155). MN MN
MDG0160A
When they are both off, the lock disengages and
10
4WD engages.
When switch A is off, the brake lights come on.
When just one is off, the differential lock disengages.
Function test of program H5 of the HH MENU of the
transmission control unit (MCM) press the right and
left pedal on the display and codes d74 and d73 will
appear respectively.

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6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Safety pressure switches / Italia trailer brake

valve circuit indicator (54--110)

11

Pressure switches normally on, they turn off under

pressure.

A -- Turns off at 10 bar.

When the pressure is lower, it grounds PIN 6 of con- 54
nection (22C) via PIN 10 of connection (156) [(188)]
110
and the red warning light on the panel comes on.

NOTE: On tractors with chassis frame greater than

no. HJS062849 (cab versions) and
no. HJS064464 (deck versions) and EKS004891
(production of S. Valentin) push--button A is
grounded via PIN 7 of the connection (188).
ZB
1SB
B -- Turns off at 3.5 bar.
Powered via fuse F15 (10A) [F6 (10A)] through PIN MDG0161A

41 [3] of the connector (156) [(188)], when the pres- 12

sure is lower, the pressure switch delivers a voltage
of 12V to PIN 86 of relay H [6] via PIN 24 [4] of the
connection (156) [(188)] energizing the two solenoid
valves that discharge the 10 bar circuit pressure
making it possible to engage the mechanical emerg-
ency brake.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 7

COMPONENTS
(Power shuttle models with cab)

13
1. Handbrake status switch (25). 3. Gear/Range lever position sensors (139--140--141).
2. Dual Command (2 Speed Power Shift) switch (76). 4. Air brake circuit pressure switch (190).

Handbrake status switch (25)

Switch normally on with brake disengaged (PIN 1
and PIN 2).
When the switch is on, it receives 12V from the fuse
F9 (5A) [F18 (5A)] and sends them to PIN 7 of con-
nection (22C), the red handbrake indicator light
comes on.
ITALIA VERSION
Switch normally on with brake disengaged (PIN 3
and PIN 4).
Powered via fuse F15 (10A) [F6 (10A)], when it is on
it delivers 12V to PIN 86 of relay E [5], energizing the
two solenoid valves to discharge the 10 bar circuit
thereby mechanically engaging the emergency
brake.
14
Functional test of program H5 of the HH MENU of the
dashboard (ADIC) on operating the brake the display
shows code d65.

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8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Interruttori HI--LO (52)

Switches normally off.
On when a clutch is selected, powered 12V via fuse
52
F1 (10A).
When LOW is pressed, it sends 12V to PIN 41 of con-
nection (169B).
When HIGH is pressed, it sends 12V to PIN 38 of
connection (169B). MN

The control unit engages the selected clutch and if

the HIGH clutch is selected it sends a signal to the CA

dashboard to switch on the relevant green indicator L

light (hare).
Function test of program H5 of the HH MENU of the
transmission control unit (MCM) press the HI and LO MDG0164A
button and codes d25 and d24 will appear on the dis- 15
play.

NOTE: On tractors with chassis frame greater than

no. HJS062849 (cab versions) and
no. HJS064464 (deck versions) and EKS004891
(production of S. Valentin) the gear lever has three
buttons, two for engaging the dual command (2
speed power shift) clutches and a third button to cut
off the clutches (see fig. 16).

Dual Command (2 Speed Power Shift) switches

and clutch cut--out (182)
Switches normally off.
On when a clutch or the clutch cut--out is selected, 182 HI

powered directly from the control unit via PIN 5 of the LO

connection (169A). DUMP CLUTCH

When LOW is pressed, it sends a signal to PIN 41 of

connection (169B).
4

When HIGH is pressed, it sends a signal to PIN 38 1L (2) 3

of connection (169B). 1SB (4)

2
1

The control unit engages the selected clutch and if

the HIGH clutch is selected it sends a signal to the
dashboard to switch on the relevant green indicator 1MN (3)
light (hare). 1CA (1)
When the clutch cut--out button is pressed, it sends 16
a signal to PIN 44 of the connection (169B).
Function test of program H5 of the HH MENU of the
transmission control unit (MCM) press the HI button
code d25, press the LO button code d24, press the
clutch cut--out button code d55 will appear on the dis-
play.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 9

Air brake circuit pressure switch (190)

NOTE: This pressure switch exists only on tractors

with chassis frame greater than no. HJS062849
(cab versions) and no. HJS064464 (deck ver-
sions) and EKS004891 (production of S. Valen-
tin).

It receives ground directly from the dashboard via 190

G WK
PIN 1 connection (22A) via PIN 1 connection (188).

It sends a variable signal to the dashboard PIN 15

connection (22C) via PIN 2 connection (188), the
dashboard displays the air brake air pressure gauge
and if the pressure drops under 65.25 to 72.5 psi
M( )
(4.5 to 5,0 bar) the amber warning light blinks, the
low brake pressure icon appears on the display and V (G)
the related red warning light on the panel comes on.

17
The following table gives the resistances, which are
found by measuring the values in Ohm with a tester
putting one rod on pin G and the other on ground, as
the pressure varies.
Functional test of program H9 of the HH MENU of the
dashboard (ADIC) channel Ch24, the value to read
off the display as the pressure varies goes from 40 to
500.

bar 0 2 4
Ohms 5 to 13 52 ± 4 88 ± 4
bar 6 8 10
Ohms 124 ± 5 145 to 170 184 ± 30

Gear/Range lever position sensors

(139--140--141)

Switches normally off.

5V from PIN 30 of connection (169B), via PIN 23 of
connection (156) (powered directly from the control
unit).
G -- sends a signal to PIN 39 of connection (169B),
via PIN 48 of connection (156).
R1 -- sends a signal to PIN 40 of connection 169B,
via PIN 49 of connection 156.
R2 -- sends a signal to PIN 43 of connection 169B,
via PIN 51 of connection 156.

18

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10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Functional test Gearbox sensor G

With a tester switched onto ohmmeter putting the With
rods at the ends of the various switches we will have lever Switch Ω Analog--digital
the values in the tables under the column of Ω, with in......... status conversion H9
the various gears engaged. (Channel 16)
In program H9 of the diagnostics HH MENU of the Neutral Closed 560 650
control unit of the gearbox (MCM) the values in the
table are the values that will be read on the display 1st Open 2760 270
as the engaged gear varies. 2nd Open 2760 270
In program H7 channel Ch 1 move the gear lever if
3rd Open 2760 270
the gearbox lever status switches have no trouble,
the display will show the selected gear. 4th Open 2760 270

VB

1 NO--N
MDG0165A

19

Range sensor R1 Range sensor R2

With lever Switch Ω Analog--digital Switch Ω Analog--digital
in......... status conversion H9 status conversion H9
(Channel 17) (Channel 18)

Neutral Open 2760 270 Open 2760 270

Medium Open 2760 270 Closed 560 650

Fast Closed 560 650 Closed 560 650

Slow Closed 560 650 Open 2760 270

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 17

COMPONENTS
(Power shuttle models with cab)

37
1. Electronic lift arm position potentiometer (145). 3. Draft pin sensors (119--120).
2. Seat safety switch (97). 4. PTO speed sensor (62).

PTO speed sensor (62)

It receives a ground signal from PIN 22 of connection
22A of the dashboard, via PIN 8 of connection 156
of the transmission.
It sends a signal to PIN 2 of connection 22A, via PIN
21 of connection 156 so that the advanced dash-
board displays the speed of the power take--off.
Functional test HE of the dashboard (ADIC) channel
Ch96 the monitor will show the speed of the PTO.

1NG

HN
MDG0218A

38

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18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Seat safety switch (97)

Switch normally off, on with operator seated.
12V via fuse F1 (10A).
When on, it sends 12V to PIN 18 of connection (22A).
Functional test H5 of the dashboard (ADIC) sitting
down and getting up the display will show code d10.

1MN (2)

1VN (1)

39

Electronic lift arm position potentiometer (145)

-- PIN 1 ground from PIN 38 of the EDC control unit
connection (124) via PIN E [6] of connection
(118).
-- PIN 2 signal to PIN 6 of the EDC control unit con-
nection (124) via PIN B [6] of connection (118).
-- PIN 3 8.5V via PIN 39 of the EDC control unit
connection (124), via PIN J [3] of connection
(118).

40

Draft pin sensors (119 -- 120)

-- PIN 1: ground from PIN 1 of the EDC control unit
connection (124) via PIN A [2] of connection
(118).
-- PIN 2: signal.
-- DX (119) to PIN 26 of the EDC control unit con-
nection (124) via PIN G [8] of connection (118).
-- SX (120) to PIN 7 of the EDC control unit connec- F
tion (124) via PIN C [4] of the connection (118).
-- PIN 3 8.5V via PIN 39 of the EDC control unit
connection (124), via PIN J [10] of connection
(118).
MDG0219A

41
-- Component test procedure
-- With the pin connected, turn the key ON.
-- Use a voltmeter to check the supply of the pin be-
tween pin 1 and pin 3 is 8 Volt (power supply of
the control unit to the pin.
-- Now, again using the voltmeter, test between pin
2 and pin 1 and the signal of the pin to the control
unit, it must be 50 ± 2.5% of the power supply

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 1

SECTION 55 -- ELECTRICAL SYSTEMS

Chapter 10 -- FAULT CODES

CONTENT

Section Description Page

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring Harness Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Digital Multi--Meter -- Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Circuit Components -- Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Controller Area Network (CAN) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Locations of the control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Error code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
“H” menu diagnostic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault code lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fault code charts

Calibration U--Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2001--3000 (Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5001--6000 (Rear PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
6001--7000 (Four wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
7001--8000 (Differential lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
14001--15000 (Analog--digital control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Electronic draft control (EDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
2001--3000 (new transmission codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473

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2 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

INTRODUCTION
Fault Codes and Fault Finding Where two colours are specified, the first letter indi-
cates the base colour and the second letter indicates
a straight stripe.
The tractors have an inbuilt self diagnostic facility.
This facility utilises the digital display of the Analog-- All tests are carried out on the harness side of the
Digital Instrument Cluster (ADIC) and the electronic connector, unless otherwise stated.
draft control panel, to indicate, in coded format, mal- Refer to the relevant chapter for complete wiring dia-
functions in the electrical and electronic circuitry and grams and how to use them.
in the micro--processor. It should be noted that even
though the self diagnostic capability is generally li- Where the fault finding procedure requires checks for
mited to diagnosis of the electrical and electronic cir- continuity a visual inspection of the wiring should be
cuitry and related components, however, there are made prior to conducting tests to ensure that obvious
some codes, which can be generated if pressure “mechanical’ damage has not occurred to the har-
switch circuits are opened because of an actual lack ness or the connectors.
of hydraulic pressure. Any malfunction of the mech-
anical and hydraulic components must be diagnosed A good quality multi--meter is an essential item to per-
using conventional techniques, performance char- form fault finding. It should be capable of measuring
acteristics and tooling, such as pressure testing resistance of at least 20,000 ohms and measuring
equipment. voltage and current. When using the multi--meter it is
good practice to select a high range and work down-
Troubleshooting and fault finding should always be wards to avoid damaging the instrument. Refer to the
carried out in a logical and planned sequence, many ‘Basic Multi--Meter use’ section of this chapter for
apparent faults associated with electronic compo- further details.
nents are often hastily diagnosed and result in the re-
placement of expensive components. An extra few IMPORTANT: Care should be used when using the
minutes confirming the apparent fault will result in a multi--meter, only use the instrument as instructed to
more positive and cost effective repair. avoid damage to the internal elements of the micro--
processor. When checking the continuity of wiring,
With the use of micro--processors it is often that this sensors or switches it is necessary to isolate the elec-
item is blamed for any malfunction but the real truth tronic micro--processor and ensure the keystart is
is that this item is usually sound and that the fault is turned off to prevent possible further damage. The
due to poor contacts in the associated connectors. keystart should only be switched on and the pro-
cessor connected where specifically instructed in the
The connection references indicate: connector fault finding procedure.
number, pin number, wire dimension and wire colour.
If it is found necessary to clean the connectors a con-
Example: C124 pin 10, cable 0.5 (MV) tact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
C124 = Connector number Do not use a cleaner that contains Trichloro--ethy-
10 = Connector pin number lene, this solvent will damage the plastic body of the
0.5 = Wire dimension connector. It is preferable to use a cleaner with a
(MV) = Wire colour Freon T.F. base.

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 25

TRANSMISSION FAULT CODE LISTING

Fault
code Description of Fault
2011 Clutch pedal potentiometer signal too low
2012 Clutch pedal potentiometer signal too high
2014 Voltage from the gear neutral position switch is high
2015 Voltage from the gear neutral position switch is low
2016 Voltage from the range position switch (R1) is high
2017 Voltage from the range position switch (R1) is low
2018 Voltage from the range position switch (R2) is high
2019 Voltage from the range position switch (R2) is low
2021 Drive line harness disconnected
2022 Clutch A solenoid valve short circuit
2023 Clutch B solenoid valve short circuit
2024 All the clutches must be calibrated
2025 Engine speed (rpm) high
2026 Clutch D not calibrated
2027 Clutch C not calibrated
2028 Clutch B not calibrated
2029 Clutch A not calibrated
2031 Clutch C solenoid valve short circuit
2032 Clutch D solenoid valve short circuit
2033 Pressure on clutch A would not decrease
2034 Wheel speed too low
2035 Wheel speed too high
2036 Engine speed (rpm) low
2037 Clutch disconnect switch open circuit
2038 Clutch B solenoid valve short to + 12 volts
2039 Clutch B solenoid valve open circuit or short to ground
2040* Inconsistent gear lever status switches
2041 Clutch A solenoid valve open circuit or short to ground
2042 Clutch A solenoid valve short to + 12 volts
2043 Pressure on clutch B would not decrease
2047 Clutch disconnect switch set too high
2048 Clutch disconnect switch set too low
2049 Wheel speed sensor too high
2051 Oil temperature sensor open circuit
2052 Oil temperature sensor short circuit
2053 5 volt reference voltage too high

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26 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

2054 5 volt reference voltage too low

2055 Shuttle lever forward switch voltage high
2056 Shuttle lever forward switch voltage low
2057 Shuttle lever reverse switch voltage high
2058 Shuttle lever reverse switch voltage low
2059 Shuttle Lever sw. disagree
2061 No seat safety switch transition in the last 25 hours of work
2065 Clutch C solenoid valve open circuit or short to ground
2066 Clutch D solenoid valve open circuit or short to ground
2067 Clutch D solenoid valve short to + 12 volts
2068 Clutch C solenoid valve short to + 12 volts
2069 Wheel speed sensor voltage too low
2073 12 VF supply voltage too high
2074 12 VF supply voltage too low
2076 Control unit (MCM) trouble
2077 8 volt reference voltage too high
2078 8 volt reference voltage too low
2081 Clutch A safety pressure switch open circuit or short to ground
2082 Clutch A safety pressure switch short circuit
2083 Clutch B safety pressure switch open circuit or short to ground
2084 Clutch B safety pressure switch short circuit
2085* No supply to pressure switches for clutches A and B
2090 Break in CAN communication between the ADIC and the MCM transmission
control unit
2092 Short circuit to +12V from the clutch cut--out switch
2093 Short circuit to +12VF to the gear lever switch feed signal
2094 Short circuit to ground to the gear lever switch feed signal
2095* Clutch cut--out button jammed closed

* For resolution of these error codes,

refer to page 473 of this section.

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 35

TRANSMISSION FAULT CODE LISTING

Fault
code Description of Fault
2011 Clutch pedal potentiometer signal too low
2012 Clutch pedal potentiometer signal too high
2014 Voltage from the gear neutral position switch is high
2015 Voltage from the gear neutral position switch is low
2016 Voltage from the range position switch (R1) is high
2017 Voltage from the range position switch (R1) is low
2018 Voltage from the range position switch (R2) is high
2019 Voltage from the range position switch (R2) is low
2021 Drive line harness disconnected
2022 Clutch A solenoid valve short circuit
2023 Clutch B solenoid valve short circuit
2024 All the clutches must be calibrated
2025 Engine speed (rpm) high
2026 Clutch D not calibrated
2027 Clutch C not calibrated
2028 Clutch B not calibrated
2029 Clutch A not calibrated
2031 Clutch C solenoid valve short circuit
2032 Clutch D solenoid valve short circuit
2033 Pressure on clutch A would not decrease
2034 Wheel speed too low
2035 Wheel speed too high
2036 Engine speed (rpm) low
2037 Clutch disconnect switch open circuit
2038 Clutch B solenoid valve short to + 12 volts
2039 Clutch B solenoid valve open circuit or short to ground
2040* Inconsistent gear lever status switches
2041 Clutch A solenoid valve open circuit or short to ground
2042 Clutch A solenoid valve short to + 12 volts
2043 Pressure on clutch B would not decrease
2047 Clutch disconnect switch set too high
2048 Clutch disconnect switch set too low
2049 Wheel speed sensor too high
2051 Oil temperature sensor open circuit
2052 Oil temperature sensor short circuit
2053 5 volt reference voltage too high

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36 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

2054 5 volt reference voltage too low

2055 Shuttle lever forward switch voltage high
2056 Shuttle lever forward switch voltage low
2057 Shuttle lever reverse switch voltage high
2058 Shuttle lever reverse switch voltage low
2059 Shuttle Lever sw. disagree
2061 No seat safety switch transition in the last 25 hours of work
2065 Clutch C solenoid valve open circuit or short to ground
2066 Clutch D solenoid valve open circuit or short to ground
2067 Clutch D solenoid valve short to + 12 volts
2068 Clutch C solenoid valve short to + 12 volts
2069 Wheel speed sensor voltage too low
2073 12 VF supply voltage too high
2074 12 VF supply voltage too low
2076 Control unit (MCM) trouble
2077 8 volt reference voltage too high
2078 8 volt reference voltage too low
2081 Clutch A safety pressure switch open circuit or short to ground
2082 Clutch A safety pressure switch short circuit
2083 Clutch B safety pressure switch open circuit or short to ground
2084 Clutch B safety pressure switch short circuit
2085* No supply to pressure switches for clutches A and B
2090 Break in CAN communication between the ADIC and the MCM transmission
control unit
2092 Short circuit to +12V from the clutch cut--out switch
2093 Short circuit to +12VF to the gear lever switch feed signal
2094 Short circuit to ground to the gear lever switch feed signal
2095* Clutch cut--out button jammed closed

* For resolution of these error codes, refer to page 473 of this section.

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 271

182

1L (2)

1SB (4)

1MN (3)
1CA (1)

* Power Shuttle version post--modification

** Version without cab, this pin is spare

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272 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

MPH2015A
z

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 275

182

1L (2)

1SB (4)

1MN (3)
1CA (1)

* Power Shuttle version post--modification

** Version without cab, this pin is spare

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276 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

MPH2015A
z

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 279

182

1L (2)

1SB (4)

1MN (3)
1CA (1)

* Power Shuttle version post--modification

** Version without cab, this pin is spare

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280 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

MPH2015A
z

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 473

TRANSMISSION FAULT CODE LISTING

2040 Inconsistent gear lever status switches.

2085 No supply to pressure switches for clutches A and B.
2095 Clutch cut--out button jammed closed.

NOTE: For any missing codes, refer to pages 25 and 35 of this section.

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474 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

ERROR CODE 2040 -- INCONSISTENT RANGE LEVER STATUS SWITCHES

(R1 AND R2)

Cause:
With the machine moving, both switches R1 and R2 off for longer than 3 sec.

Effects:
The control unit detects lever neutral even if it has a range engaged, it displays code 2040 and does not disable
transmission.

Possible fault modes and causes:

3. Faulty switches
4. Faulty controller (MCM)

Solution:
NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal
operation.
1. Check that the switches are connected and not damaged, the pins are in the right position and the connection
to the connector is secure. Repair or replace as required.
A. Check the switches:
(R1) C140
Pin 1 wire 1 (AB) ! 156 pin 23 wire 1 (AB) ! 169B -- CN2 pin 30 wire 1 (AB).
Pin 2 wire 1 (M) ! 156 pin 49 wire 1 (M) ! 169B -- CN2 pin 40 wire 1 (M).
(R2) C141
Pin 1 wire 1 (AB) ! 156 pin 23 wire 1 (AB) ! 169B -- CN2 pin 30 wire 1 (AB).
Pin 2 wire 1 (NO_N) ! 156 pin 51 wire 1 (NO_N) ! 169B -- CN2 pin 43 wire 1 (NO_N).
with the tests described in sect. 21 chap. 5 page 18 and 19 and, if necessary, repeat the adjustment described
on the same pages; or with the diagnostics program:
H5 ! code d34 for R1 and code d50 for R2
H7 ! channel ch1
H9 ! channel 17 for R1 and channel 18 for R2.

NOTE: With some diagnostics programs it is possible to move the tractor. It is wise to test in motion and on
ground that is not level but rather broken. The jolting produced and the vibration of the gear levers must not be
enough to accidentally switch over the switches, even for a short time, thus causing this fault code.

B. If the switches are okay, download the correct level of software.

NOTE: Before replacing the control unit (MCM) with this fault code, which moreover does not disable the trans-
mission, repeat the adjustment in sect. 21 Chap. 5, certainly the fact that the switches change status during mo-
tion is eliminated. Breakage of the switches will display codes 2016 and 2017 for R1, 2017 and 2018 for R2 at
the next start, when (especially if the transmission will be disabled) they will be replaced or, if there is nothing
wrong with them, the control unit will be replaced.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 475

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476 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

1NO -- N (51)

* Power Shuttle version post--modification

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 477

1AB(1)

1NO--N(2)

**

* Power Shuttle version post--modification

** Version without cab, this pin is spare

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478 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

MPH2017A

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 479

ERROR CODE 2085 -- BLOWN FUSE

Cause:
The supply voltage +12 V of the control unit (MCM) is less than + 6 Volt at C169 B -- CN2 pin 55.
Clutch A and B safety pressure switches not powered.
Effects:
The control unit detects no current from clutch A and B pressure switches and as a result considers clutches
A and B closed; it ignores this unlikely situation and generates a code that can also be displayed in a situation
of fault code reduction.

Possible fault modes and causes:

1. Fuse F3 (10A) blown.

Solution:
NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal
operation.
1. Check fuse F3.
A Make the replacement.

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480 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

ERROR CODE 2095 -- CLUTCH CUT--OUT SWITCH (NORMALLY OPEN) JAMMED SHUT

Cause:
The control unit (MCM) detects closure of the clutch cut--out switch for a period of 15 sec.

Effects:
The clutch disabling function stays inactive until the next “key OFF” (switching off the machine), the display
shows CP and the amber warning light is on.

Possible fault modes and causes:

1. Switch faulty.
2. Clutch cut--out switch wiring short circuit.
3. Faulty controller (MCM).

Solution:
NOTE: When the cause of the error code has been rectified, clear the error code and test the system for normal
operation.
1. Check the clutch cut--out switch:
A. Disconnect the clutch cut--out switch connector C182. Operating the switch, check between:
C182 pin 4, cable 1.0 (SB) and C182 pin 3, cable 1.0 (MN). It must indicate a closed circuit when the button
is pressed, an open circuit when the button is released.
If the switch operation is not as indicated, remove and replace the clutch cut--out switch.
B. If the switch is okay, pass on to phase 2.
2. Check for a short circuit.
A. Disconnect the connector of the control unit (MCM) C169B -- CN2 and C169a -- CN1. Check between
connector C169B -- CN2 pin 44, cable 1.0 (SB) and C169A -- CN1 pin 5, cable 1.0 (MN). If a short circuit
is indicated, repair or replace the harness as required.
B. If the harness has no problems, download the correct level of software. If the error is repeated, remove
and replace the control unit (MCM).

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 481

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482 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

182

1L (2)

1SB (4)

1MN (3)
1CA (1)

* Power Shuttle version post--modification

** Version without cab, this pin is spare

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 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 483

1MN (5)

* Power Shuttle version post--modification

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484 SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

MPH2015A
z

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11 21

H8 MENU TRANSMISSION DELETION OF

DATA SAVED IN MEMORY
Access the PA HH MENU as described on page 2
and proceed as follows.
0
-- Select the H8 MENU with buttons (1) and (2), x100

press key (3) to access the above--mentioned H8

MENU.

1
3
2

58
-- The central display will show EECL.
-- To delete the memory you need to keep the but-
ton (1, fig. 58) pressed down until the procedure PA H8 4
is completed, that is when the display shows EE.
3
NOTE: In these conditions the transmission, four--
wheel drive, differential lock and power take--off me-
mories will be deleted.
2
EECL 1
5 EE
59
-- Turn the switch (1) to A (OFF).

MDB1669A

60
H9 MENU TRANSMISSION VOLTMETER
Access the PA HH MENU as described on page 2
and proceed as follows.
-- Select the H9 MENU with buttons (1) and (2), 0
press key (3) to access the above--mentioned H9 x100

MENU.

1
3
2

61

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22 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 11

-- It is possible to select the various channels by

pressing buttons (1, fig. 61) and (2, fig. 61).
-- The central display will show the selected chan-
nel followed by the relevant measurement.
-- Press button (3, fig. 61) to go back to HH MENU. PA H9 ch1

438

62

ch Description Typical Value

1 Clutch pedal ∼ 85 (pressed)
∼ 430 (released)
2 Transmission oil temperature ∼ 450 (at 30 °C)
7 Clutch A ∼ 450 (clutch pedal released
and Shuttle lever engaged)
8 Clutch B ∼ 450 (clutch pedal released
and Shuttle lever engaged)
9 Forward switch ∼ 650 (Shuttle lever on forward)
∼ 270 (Shuttle lever in neutral)
10 Reverse switch ∼ 650 (Shuttle lever in reverse)
∼ 270 (Shuttle lever in neutral)
11 Wheel speed sensor ∼ 1300 (at 5 km/h)
12 Clutch D ∼ 450 (LO and Shuttle lever engaged)
13 Clutch C ∼ 450 (HI and Shuttle lever engaged)
16 Gear lever switch (G) ∼ 270 (gear engaged)
∼ 650 (gearbox in neutral
17 Range lever switch (R1) ∼ 270 (range gear in neutral and II)
∼ 650 (range I and III engaged)
18 Range lever switch (R2) ∼ 270 (range gear in neutral and I)
∼ 650 (range II and III engaged)
19 12 VF ∼ 840 (engine running)
20 12 VD ∼ 840 (engine running, clutch pedal re-
leased and Shuttle lever engaged)
21 5 Volts sensor supply ∼ 670
22 8 Volts sensor supply ∼ 850
23 Four--wheel drive solenoid valve ∼ 830 (four--wheel drive disengaged)
24 Differential lock solenoid valve ∼ 950 (differential lock engaged)
25 Power take--off solenoid valve ∼ 950 (power take--off engaged)
26 Power supply fuse of pressure switch for clutches A
and B (F3 -- 10A) ∼ 267

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