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FENDT 900 Vario Workshop Service Manual

FENDT 900 Vario Workshop Service Manual

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Workshop Service Manual

FENDT 900 Vario - COM III

919 .. 0101-1000

919 .. 1001-

922 .. 0101-1000

922 .. 1001-

925 .. 0101-1000

FENDT is a worldwide brand of AGCO

925 .. 1001-

928 .. 0101-1000

928 .. 1001-

931 .. 0101-1000

931 .. 1001-

934 .. 0101-1000

934 .. 1001-

FENDT 900 Vario COM III - EAME

20

No. X990.005.057 .01

3

G - en

English

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Page 1 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 .. 1001- FENDT is a worldwide brand of AGCO No. X990.005.057 .01 G - en FENDT 900 Vario COM III - EAME English...
Page 2 All relevant accident prevention regulations and all generally accepted safety, health and road traffic regulations must be strictly observed. The manufacturer does not accept liability for damage resulting from unauthorised modifications. Changes and additions reserved!
Page 3 FENDT 900 Vario - COM III Table of contents FENDT 900 Vario - COM III 0000 Overall system/tractor 1005 Overall system/transmission 1010 Transmission/differential 1015 Transmission/axle drive 1050 Transmission/housing 1070 Transmission / Brake system 1080 Transmission/drive train 1200 Transmission/front PTO 1220...
Page 4 FENDT 900 Vario - COM III Table of contents 9410 Hydraulic pump installation/LS pump 9430 Hydraulic pump installation/steering pump 9534 Hydraulic piping/"Rüfa"reverse operation 9600 Overall system/hydraulic equipment 9605 Hydraulic equipment/hydraulic connections 9610 Hydraulic equipment/central control block (ZSB) 9620 Hydraulic equipment/valve fitting...
Page 5 0000 General Faults Overall system/tractor Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 7 0000 - Overall system/tractor Table of contents 0000 Overall system/tractor General........5 Faults .
Page 8 0000 - Overall system/tractor Table of contents...
Page 9: Table Of Contents
Tightening torques for bolts in Nm (kpm)........18 History of the FENDT 900 VARIO (COM III) farm tractor ......19 Position of sign plates .
Page 10 0000 - Overall system/tractor Table of contents...
Page 11: Component Overview
0000 - Overall system/tractor A - General Component overview 0000 Tractor – overall system 1000 Transmission 1005 Transmission control system 1010 Differential gear 1015 Axle drive 1030 Hand brake 1050 Housing 1070 Brake system 1080 Drive train 1090 Emergency actuation 1100 Clutch actuation 1150...
Page 12 0000 - Overall system/tractor A - General 3000 Front axle 3060 Suspension valve installation 3070 Suspension piping 3100 Track rod 3120 Steering cylinder 3170 Frame 3180 Cardan shaft 3190 Differential lock actuation 4000 Steering 4070 Steering wheel 4090 Hydraulic steering unit 5000 Vehicle layout 5010...
Page 13 0000 - Overall system/tractor A - General 8800 Compressed air system 8810 Air compressor 8820 Brake fittings 8830 Cables 8850 Electric actuation 8890 Air vessel 8900 Front loader 8910 Mounting frame 8915 Hydraulic equipment actuation 8955 3. Hydraulic circuit 8958 Multi coupling 5970 Piping...
Page 14 0000 - Overall system/tractor A - General 9600 Hydraulic equipment 9605 Hydraulic connections 9610 Central control block (ZSB) 9620 Valve installation 9666 External pressure supply 9690 Auxiliary valves 9700 Electronics 9710 Instrument panel 9715 Terminal 9717 LBS – agricultural bus system 9720 Sensor 9730...
Page 15: Documentation Layout
0000 - Overall system/tractor A - General Documentation layout In this technical documentation, the different tractor types are basically divided according to components that, with a few technical exceptions, reflect the structure of replacement parts. For example, these components may be "0000 – overall system"; "1005 – transmission control system"; "2000 – engine" etc.
Page 16: Notes On Documentation
The tractor must be maintained according to its proper use. Always replace parts with genuine FENDT spare parts! When ordering parts, please provide the chassis number as per the most up-to-date spare parts documentation. The layout of components in this workshop manual matches Epsilon.
Page 17: Safety Briefing And Measures
Attach the earth terminal of the welding appliance as close to the welding spot as possible. – Caution is required when dealing with brake fluid and battery acid as these are toxic and corrosive! – Only use genuine FENDT spare parts. 2. Working on the front axle suspension T003309 Version 1 20-10-2009...
Page 18 0000 - Overall system/tractor A - General ANGER – The front axle suspension pressure lines between the central control block (ZSB) and the suspension cylinders, and – the pressure accumulator on central control block ASP1 and – the piped pressure accumulator ZSP are under 200 bar pressure, even when the engine is switched off and the suspension is lowered (= locked).
Page 19 0000 - Overall system/tractor A - General – Always switch off the engine before fitting or removing the drive shaft. PTO in "0" position! – When working on the PTO, allow no one in the vicinity of the rotating PTO or drive shaft. –...
Page 20: Biodiesel
0000 - Overall system/tractor A - General Biodiesel Fuel quality RME=Rapeseed oil Methyl Ester, VME=Vegetable oil Methyl Ester fuel Use in accordance with DIN EN 14214. Cold-pressed rapeseed oil is not approved for use with standard tractors. Only cold-pressed fuel in accordance with DIN V 51605 is approved for Greentec tractors. The following notes apply to the use of RME and VME Instructions for use Biodiesel is suitable for winter temperatures down to approx.
Page 21: Biodegradable Hydraulic Oil
0000 - Overall system/tractor A - General Biodegradable hydraulic oil Oil quality Use rapeseed-oil and synthetic-based HEES biodegradable hydraulic oil with a viscosity in accordance with ISO VG 32- ISO VG 46. Polyglycol-based synthetic oils cannot be used. Instructions for use Biodegradable hydraulic oil is suitable for winter temperatures down to approx.
Page 22: Tightening Torques For Bolts In Nm (Kpm)
0000 - Overall system/tractor A - General Tightening torques for bolts in Nm (kpm) Friction value: μ total 0.14 for screws and nuts without after-treatment and phosphated nuts. Tighten by hand. When tightening torques are not specified, they can be found in the following diagram. Fig.
Page 23: History Of The Fendt 900 Vario (Com Iii) Farm Tractor
History of the FENDT 900 VARIO (COM III) farm tractor Fig. 4. FENDT 900 Vario I001484...
Page 24 Tractor type Vario Vario Vario Vario Vario Vario Chassis number 919 /…/ 922 /…/ 925 /…/ 928 /…/ 931 /…/ 934 /…/ 0101 and up 0101 and up 0101 and up 0101 and up 0101 and up 0101 and up Technical specification extract: diesel engine Engine type (Deutz) TCD 2013 L6 4V...
Page 25 Heater flange, additional electrical engine heater (optional) Fuel supply (l) Water pre-cleaner in fuel system Standard Technical specification extract: transmission Transmission type (FENDT) ML 260 Transmission oil (see also: fuels and lubricants in Operating Manual) STOU 10 W 40 Housing coupler...
Page 26 Hydraulic Servo-assisted via Pentosin X902.011.622 Transmission oil cooler (transmission oil/air) Standard Technical specification extract: rear axle Rear axle type (FENDT) HA 260 Transmission oil (see also: fuels and lubricants in Operating Manual) STOU 10 W 40 Rear wheel brake Wet multiple-disc brake/pneumatically actuated...
Page 27 Flange/stub shaft 60 km/h variant (16 t permissible overall weight) Flange Technical specification extract: front axle Front axle type (FENDT) Front axle with individual wheel suspension Permissible axle load Transmission oil (see also: fuels and lubricants in Operating Manual) Fendt Extra Trans 10W-40...
Page 28 Tractor type Vario Vario Vario Vario Vario Vario Variant: 1-circuit brake + 4WD engagement with front PTO Forced feed lubrication Hydraulic pump: 8cc/r with 25 bar at pressure-limiting valve Drive transmission: 0.896 Hydraulic pump delivery rate: 9 l/min (at an engine speed of 1000 rpm) 18 l/min (at an engine speed of 2000 rpm) Variant: 1-circuit brake + 4WD engagement without front PTO Injection lubrication...
Page 29 Tractor type Vario Vario Vario Vario Vario Vario Wheel-driven emergency pump steering (PNL) (gear pump, Bosch 8 cc/r); 36 l/min (at 60 km/h)/pressure: max. 190 bar 6 l/min (at 10 km/h)/pressure: max. 190 bar Drive via 4WD shaft Pumping in forwards direction Short-circuit to tank on reversing Auxiliary control valve (Bosch SB 23 LS-EHS 2) Elec.
Page 30 – Active weight adjustment for fully-automatic setting and adjustment of driver weight Version 3: Fendt super deluxe seat, Maximo Evolution active (MSG 97 EAC/741) – Active seat air conditioning for seat cooling or heating to ensure comfortable seat climate –...
Page 31 Tractor type Vario Vario Vario Vario Vario Vario A039 multifunction armrest (MFA) Operation of: – Vario transmission – Working hydraulics – Rear and front power lift – Rear and front PTO – 4WD and diff. lock – Front axle suspension –...
Page 32 Tractor type Vario Vario Vario Vario Vario Vario A050 ECU, basic control unit (32-bit processor) Contents: – Transmission – 4WD and diff. lock – Working hydraulics – Rear power lift (rear EPC) – Front power lift (standard/enhanced control) – PTO (front, rear) –...
Page 33: Position Of Sign Plates
0000 - Overall system/tractor A - General Position of sign plates Position of sign plates Vehicle sign plate right side, on front axle casing Fig. 5. I002592 Chassis number (engraved) right side, on front axle casing Fig. 6. I002593 Front axle sign plate right side, on front axle casing Fig.
Page 34 0000 - Overall system/tractor A - General Diesel engine sign plate right side, on crankcase Fig. 8. I002591 Transmission sign plate right side on transmission housing Fig. 9. I002596 Vario transmission insert sign plate on top of Vario transmission insert Remove cab, remove transmission cover Fig.
Page 35 0000 - Overall system/tractor A - General Cab sign plate in rear of cab Fig. 12. I002597 Trailer frame sign plate See also: Operating manual right side, on trailer frame Fig. 13. I002604 Automatic trailer hitch sign plate See also: Operating manual on trailer hitch Fig.
Page 36 0000 - Overall system/tractor A - General Ball-type coupling sign plate See also: Operating manual on ball-type coupling Fig. 16. I002599 Draw bar sign plate See also: Operating manual on draw bar Fig. 17. I002602 Piton Fix sign plate See also: Operating manual on Piton Fix Fig.
Page 37: Tractor Diagnostics With Terminal
0000 - Overall system/tractor A - General Tractor diagnostics with terminal Ignition on Press F6. Fig. 20. I002368 The second menu level is displayed. Press F6. Fig. 21. I002369 The third menu level is displayed. Press F5. Fig. 22. I002370 The diagnostics menu is displayed.
Page 38 0000 - Overall system/tractor A - General Diagnose 1 (diagnostics 1) menu is displayed. IDEAL value specified by the A050 ECU, basic control unit Adjustment angle of the A009 transmis- sion control unit REAL Transmission ratio actually set in the trans- mission Forwards direction of travel: IDEAL...
Page 39 0000 - Overall system/tractor A - General Press F3 to return to Diagnostics 1 menu. The diagnostics terminal is no substitute for transmission pressure measurements or electrical readings; it only provides a reference value for the Vario transmission functions and the status of the CAN system. Possible applications: –...
Page 40 0000 - Overall system/tractor A - General T002584 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 2 922 .. 0101-1000 928 .. 1001- 03-08-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 41 General Faults Faults Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 43 0000 - Overall system/tractor Table of contents B Faults Confirming, calling up, deleting fault codes ........41 Fault code 00.0.00 - .
Page 44 0000 - Overall system/tractor Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 45: Confirming, Calling Up, Deleting Fault Codes
0000 - Overall system/tractor B - Faults Confirming, calling up, deleting fault codes Confirm fault code Cancelling a fault code does not remove the fault; it is simply no longer displayed. Press button repeatedly until no more fault codes are indicated on the display. Each stored fault code must be cleared individually.
Page 46 0000 - Overall system/tractor B - Faults Press buttons A, B and C simultaneously. All fault codes in the fault memory of A007 - Instrument panel are deleted. Fault codes are also stored in the A050 - ECU, basic control unit and, where necessary, in the A051 - ECU, engine control unit (EDC 7)..
Page 47: Fault Code 00.0.00
Fault code 00.0.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 00.0.01 A050 - ECU, basic control unit Bus fault EDC, no speed setting Engine malfunction to EDC programming 00.0.02 A073 - Terminal (A4) Terminal bus fault, does not report to bus programming 00.0.03...
Page 48 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 00.0.17 A050 - ECU, basic control unit Bus fault, Vario control unit programming 00.0.18 A050 - ECU, basic control unit Bus fault, electro-hydraulic steer- ing (EHL) programming 00.0.19 A050 - ECU, basic control unit Bus fault, ISO task programming 00.0.1E...
Page 49 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 00.1.71 A036 - Control panel, dashboard right/left Enter button Button non-operable 00.1.72 A036 - Control panel, dashboard right/left ESC button Button non-operable 00.1.73 A036 - Control panel, dashboard right/left Up button Button non-operable 00.1.74 A036 - Control panel, dashboard right/left...
Page 50: Fault Code 02.1.00
Fault code 01.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 01.1.01 B055 - Sensor, foot throttle Signal too high, TMS is switched off Circuit diagram Signal to low, EDC engine control No signal for longer than 2000 ms 01.1.03 B055 - Sensor, foot throttle (red side) to A050 ECU, basic con-...
Page 51 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 01.1.3A A077 - Immobiliser ECU Aerial faulty, signal line faulty U001 - Immobiliser aerial 01.1.3B A051 - ECU, engine control unit (EDC 7). Vehicle serial number not the A077 - Immobiliser ECU same in A051 and A077 or B083 B083 - Immobiliser control 01.1.3C...
Page 52 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 01.1.A1 A050 - ECU, basic control unit CAN connection fault Engine does not start Circuit diagram SERDIA diagnostics A051 - ECU, engine control unit (EDC 7). EDC fails to report CAN bus/EDC engine control 01.1.B0 A050 - ECU, basic control unit...
Page 53: Fault Code 04.1.00
Fault code 02.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 02.1.E0 A050 - ECU, basic control unit Faulty CAN communication A039 - MFA, multifunction armrest between e-box and CAN joystick 02.1.EE A050 - ECU, basic control unit Error message on ISO job com- puter, 02.1.EF...
Page 54: Fault Code 06.1.00
Fault code 03.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 03.1.00 A039 - MFA, multifunction armrest unknown MFA fault 03.1.01 A039 - MFA, multifunction armrest Faulty hardware (e.g. RAM with- Function non-operable out flash) programming 03.1.02 A039 - MFA, multifunction armrest Incorrect checksum for the first Function non-operable 128 bytes in the EEPROM...
Page 55: Fault Code 08.1.00
Fault code 04.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.04 B017 - Sensor, clutch pedal Sensor faulty, Loss of enhanced con- Circuit diagram Signal fault trol/function in final Transmission control speed control; system No cruise control func- tion, TMS is switched off Faulty 8.5 V supply...
Page 56 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.22 A039 - MFA, multifunction armrest Throttle pedal resolution potenti- TMS is switched off ometer faulty, Signal fault 04.1.23 A039 - MFA, multifunction armrest Joystick signal "Tempomat cruise Continuation in emer- Circuit diagram control ON"...
Page 57 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.31 B014 - Sensor, collecting shaft Sensor faulty, Continuation in emer- Circuit diagram Direction signal faulty gency mode possible Transmission control system 04.1.32 A039 - MFA, multifunction armrest Faulty button, signal fault Continuation in emer- Circuit diagram Joystick activation button...
Page 58 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.52 B009 - Discharge temperature sensor "Transmission oil temperature Continuing to drive will over 105°". cause transmission damage 04.1.53 B009 - Discharge temperature sensor "Transmission oil temperature transmission damage if Circuit diagram more than 110°C"...
Page 59 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.66 A050 - ECU, basic control unit Actuation of + side of solenoid Fault on + side to sole- Circuit diagram Y053 - Active hold function solenoid valve valve faulty noid valve Transmission control system 04.1.67...
Page 60 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.85 B010 - Sensor, engine speed Engine speed sensor does not Continuation in emer- Circuit diagram supply plausible speed curves. gency mode possible Transmission control Output speed increase or system decrease is outside limits. 04.1.86 B008 - Sensor, high-pressure 1 Plausibility error in both pressure...
Page 61 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.A2 A009 - Actuator unit CAN bus actuation fault Continuation in emer- Check CAN bus A050 - ECU, basic control unit gency mode possible Chapter 9000 Reg. E 04.1.A3 A009 - Actuator unit Fault or logic error in incremental Continuation in emer- Circuit diagram...
Page 62 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.E0 A050 - ECU, basic control unit Turbo-clutch characteristic read Continuation in emer- Y004 - Solenoid valve, turbo-clutch incorrectly gency mode possible programming 04.1.E1 A050 - ECU, basic control unit Traction control regulator parame- Emergency mode EOL programming ters (ML transmission adjust-...
Page 63 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 04.1.F0 A050 - ECU, basic control unit Checksum parameter for trans- Transmission cannot be mission calibration incorrect calibrated programming 04.1.F1 A050 - ECU, basic control unit Checksum parameter for station- Emergency mode ary control incorrect programming 04.1.F2...
Page 64 Fault code 05.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 05.1.00 A050 - ECU, basic control unit EEPROM fault in basic control unit programming 05.1.31 A039 - MFA, multifunction armrest Faulty button, 4WD 100% button Signal fault 05.1.32 A039 - MFA, multifunction armrest Faulty button,...
Page 65 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 05.1.59 S086 - Switch, brake wearing, right Faulty switch, Circuit diagram Signal fault trailer brake 05.1.5A S087 - Switch, brake wearing, left Brake pad worn Circuit diagram trailer brake 05.1.5B S086 - Switch, brake wearing, right Brake pad worn Circuit diagram trailer brake...
Page 66 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 05.1.B0 A050 - ECU, basic control unit Initialisation error on communica- tion driver, programming CAN bus communication restricted, checksum error, EEPROM GD routing data 05.1.B1 S026 - Switch, steering pump flow controller Plausibility check on When engine is OFF , u Circuit diagram...
Page 67 Fault code 06.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 06.1.01 A039 - MFA, multifunction armrest Faulty button, PTO disengages Rear PTO button in cab ON/OFF Signal fault Faulty bus 06.1.02 S020 - Button, rear PTO, external right Faulty button, PTO can be engaged by Circuit diagram...
Page 68 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 06.1.19 A039 - MFA, multifunction armrest Faulty button, PTO speed cannot be 1000E button, REAR PTO Signal fault modified or selected 06.1.1A Y026 - Solenoid valve, rear PTO, stage I Actuation fault PTO cannot be engaged Circuit diagram Speed rate 540...
Page 69 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 06.1.50 B020 - Sensor, rear PTO speed (stub shaft) PTO stub shaft speed > 1300 Electr. speed selection Circuit diagram rpm, signal fault in Hall sensor possible, actuate PTO (B020 or B021) clutch ON/OFF button for at least 5 seconds (emer- gency mode)
Page 70 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 06.1.81 A039 - MFA, multifunction armrest Counter error REAR PTO ON/OFF button 06.1.95 A039 - MFA, multifunction armrest Counter error Button neutral, REAR PTO programming 06.1.96 A039 - MFA, multifunction armrest Counter error Button 540, REAR PTO programming...
Page 71 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 06.1.E3 A050 - ECU, basic control unit Checksum error, for PW of PTO Use default values programming 06.1.E4 A050 - ECU, basic control unit Checksum error, over/under step Use default values counter of PTO programming 06.1.E5...
Page 72 Fault code 07.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 07 .1.01 A039 - MFA, multifunction armrest Faulty button Button, front PTO ON/OFF Signal fault Faulty bus 07 .1.04 Y011 - Front PTO solenoid valve (clutch) Actuation fault Circuit diagram trailer brake 07 .1.05...
Page 73 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 07 .1.E2 A050 - ECU, basic control unit Error in checksum PW rise of Use default values front PTO programming 07 .1.E3 A050 - ECU, basic control unit Checksum error, PW of front PTO Use default values programming 07 .1.E4 A050 - ECU, basic control unit...
Page 74 Fault code 08.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 08.1.00 Y077 [HKH] - Cut-off valve, rear EPC Unknown rear EPC fault 08.1.22 B030 - Sensor, rear power lift position Sensor faulty, No control possible, Circuit diagram Signal fault operable via external but- Hydraulics...
Page 75 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 08.1.43 S028 - Button, rear power lift, right-hand external Faulty button, Button inoperable until Circuit diagram lower Signal fault next trouble-free cold Hydraulics start 08.1.44 A039 - MFA, multifunction armrest Faulty button, Button inoperable until Button, stop rear power lift Signal fault...
Page 76 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 08.1.B0 B030 - Sensor, rear power lift position Position sensor not calibrated No control possible, Calibration code "8002" operable only via external button 08.1.B2 A039 - MFA, multifunction armrest Setpoint value potentiometer not Setpoint values cannot Calibration code "8001"...
Page 77 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 08.1.F9 Y077 [HKH] - Cut-off valve, rear EPC Valve actuator not in neutral posi- Valve remains deflected tion when switched on; frequent when engine is on, valve cause: valve actuator mechani- locks, pilot pressure OFF cally jams (pilot control or main actuator) due to contamination in...
Page 78 Fault code 09.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 09.1.00 Y070 [FKH] - Cut-off valve, front power lift Unknown error, front EPC enhanced control 09.1.22 B040 - Sensor, front power lift position Sensor faulty, No control possible, Circuit diagram Faulty signal line operable only via external...
Page 79 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 09.1.4B A039 - MFA, multifunction armrest Auto front power lift button faulty Button, auto front power lift (output via TeachIn) 09.1.A2 Y070 [FKH] - Cut-off valve, front power lift EEPROM error (valve) Valve moves to neutral enhanced control and locks...
Page 80 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 09.1.E5 Y070 [FKH] - Cut-off valve, front power lift High overvoltage (> 45V) Valve moves to neutral enhanced control and locks 09.1.E6 Y070 [FKH] - Cut-off valve, front power lift Final stage error (pilot control Valve moves to neutral enhanced control solenoid valve)
Page 81: Fault Code 0A.1.00
Fault code 0A.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code X stands for the valve number, e.g. 0A.1.10 = position 1 valve does not report to CAN or 0A.1.37 = position pickup sensor error in position 3 valve 0A.1.X0 Y071 [2.1] - Auxiliary control valve (olive) Position Valve does not report to CAN bus...
Page 82 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.X2 Y071 [2.1] - Auxiliary control valve (olive) Position Undervoltage (where U < 8V) Valve moves to neutral Circuit diagram and locks Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position Y074 [1.1] - Auxiliary control valve (yellow) Posi- tion 1 Y075 [1.2] - Auxiliary control valve (blue) Position...
Page 83 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.X4 Y071 [2.1] - Auxiliary control valve (olive) Position Valve actuator falls short (frequent Valve moves to neutral Circuit diagram cause: brief control pressure dips and locks Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position or oil too viscous at very low tem- peratures) Y074 [1.1] - Auxiliary control valve (yellow) Posi-...
Page 84 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.X6 Y071 [2.1] - Auxiliary control valve (olive) Position Final stage error (pilot control Valve moves to neutral Circuit diagram solenoid valve) and locks Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position Y074 [1.1] - Auxiliary control valve (yellow) Posi- tion 1 Y075 [1.2] - Auxiliary control valve (blue) Position...
Page 85 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.X8 Y071 [2.1] - Auxiliary control valve (olive) Position Valve actuator does not return to Valve remains deflected Circuit diagram neutral position (frequent cause: when engine is on; valve Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position valve actuator mechanically jams locks, (pilot control or main actuator)
Page 86 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.XA Y071 [2.1] - Auxiliary control valve (olive) Position Valve actuator deflected too far Valve moves to neutral Circuit diagram and locks Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position Y074 [1.1] - Auxiliary control valve (yellow) Posi- tion 1 Y075 [1.2] - Auxiliary control valve (blue) Position...
Page 87 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.XC Y071 [2.1] - Auxiliary control valve (olive) Position Manual actuation (occurs when a All valve positions, no Circuit diagram valve is deflected from its neutral function; Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position position) Valve locked, Pilot pressure OFF...
Page 88 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.XE Y071 [2.1] - Auxiliary control valve (olive) Position RAM or FLASH test fault Valve moves to neutral Circuit diagram and locks, pilot pressure Hydraulics/Auto-Guide Y072 [2.2] - Auxiliary control valve (grey) Position Y074 [1.1] - Auxiliary control valve (yellow) Posi- tion 1 Y075 [1.2] - Auxiliary control valve (blue) Position...
Page 89 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.A2 Y071 [2.1] - Auxiliary control valve (olive) Position More valves connected than reg- istered via EOL programming Y072 [2.2] - Auxiliary control valve (grey) Position Y074 [1.1] - Auxiliary control valve (yellow) Posi- tion 1 Y075 [1.2] - Auxiliary control valve (blue) Position Y076 [1.3] - Auxiliary control valve (red) Position 3...
Page 90 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.B9 A039 - MFA, multifunction armrest Linear module 2 (rocker) faulty or Valve position not func- engaged when ignition switched tioning, lock valve 0A.1.BA A039 - MFA, multifunction armrest Linear module 3 (rocker) not cali- Valve position not func- Calibration code "1005"...
Page 91 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.D1 A039 - MFA, multifunction armrest Faulty button, Button inoperable until Button, hydraulic circuit 4 Signal fault next trouble-free cold start 0A.1.D2 A039 - MFA, multifunction armrest Faulty button, Valve position not func- Red raise/lower/floating position button on joy- Signal fault tioning,...
Page 92 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.DD B063 - Pressure switch, filter contamination Filter clogged Warning display only (hydraulic circuit) 0A.1.DE B063 - Pressure switch, filter contamination Faulty switch, Warning display only (hydraulic circuit) Signal fault 0A.1.DF Y071 [2.1] - Auxiliary control valve (olive) Position Prio volume greater than pump volume...
Page 93 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0A.1.F8 Y084 - Solenoid valve, Power BeyondIn Power Actuation fault No control pressure Circuit diagram Beyond mode increase possible Hydraulics 0A.1.FA S067 - Button, valve actuation, external raise Faulty button, Button inoperable until Circuit diagram Signal fault next trouble-free cold...
Page 94: Fault Code 0B.1.00
Fault code 0B.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0B.1.11 A050 - ECU, basic control unit Electrical fault, internal communi- TeachIn cation 0B.1.12 A050 - ECU, basic control unit Electrical fault, terminal TeachIn 0B.1.21 A050 - ECU, basic control unit Internal communication error TeachIn 0B.1.22...
Page 95 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0B.1.B3 A050 - ECU, basic control unit "No memory available for sequence data or configura- tion/sequence data do not match" 0B.1.B4 A050 - ECU, basic control unit Configuration wizard: error with TeachIn writing or reading settings and parameters on tractor start-...
Page 96: Fault Code 0D.1.00
Fault code 0D.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0D.1.01 A073 - Terminal (A4) Vario terminal cannot open ISO Not enough free mem- bus screen ory, delete the existing ISO implement projects from the terminal 0D.1.02 A073 - Terminal (A4) Terminal has not reported to the Check wiring, restart...
Page 97 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0D.1.0F A055 - ECU, data transfer Control bus error on Vario-Doc Possible faulty program- (transmitter buffer) ming, restart tractor 0D.1.10 A055 - ECU, data transfer Control bus error on Vario-Doc Faulty parameterisation, (receiver buffer) restart tractor 0D.1.11...
Page 98 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0D.1.23 A055 - ECU, data transfer EEPROM communication report- System operation not ing fault upon data transmission possible, potentially Replace hardware, restart tractor 0D.1.24 A055 - ECU, data transfer EEPROM communication check- System operation not sum error possible, potentially...
Page 99 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0D.1.31 A055 - ECU, data transfer Vario-Doc circuit board tempera- Data transfer (via Blue- ture higher than 60°C tooth) not possible, allow tractor (roof area) to cool down 0D.1.33 A055 - ECU, data transfer Break in Vario-Doc internal volt- System failure, replace age;...
Page 100: Fault Code 0F.1.00
Fault code 0F.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0F .1.00 A038 - ECU, central electrical system Unknown error in central electri- cal system 0F .1.01 E066 - Brake and tail light left Function non-operable Brake light, left dipped Circuit diagram for night driving Vehicle licensing regu-...
Page 101 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0F .1.0A E088 - Direction direction indicator, front right Function non-operable Circuit diagram Vehicle licensing regu- lations/work lights 0F .1.0B E064 - Rear direction indicator, left Function non-operable Circuit diagram Wiper/work lights 0F .1.0C E065 - Rear direction indicator, right Function non-operable...
Page 102 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0F .1.1D M002 - Front wiper motor Function non-operable Circuit diagram Wiper/work lights 0F .1.1E M004 - Rear wiper motor Function non-operable Circuit diagram Wiper/work lights 0F .1.1F M010 - Fuel pump Function non-operable Circuit diagram Work lights/...
Page 103 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 0F .1.2B A038 - ECU, central electrical system Mirror heater faulty 0F .1.2C A038 - ECU, central electrical system Left reverse operation support valve inoperable 0F .1.2D A038 - ECU, central electrical system Right reverse operation support valve inoperable 0F .1.2E...
Page 104: Fault Code 10.1.00
Fault code 10.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 10.1.31 M015 - Actuator motor, top/middle air flap Function non-operable Circuit diagram Air conditioning/mirror/ 10.1.32 M016 - Servomotor, bottom air valve Function non-operable Circuit diagram Air conditioning/mirror/ 10.1.33 B074 - Sensor, internal temperature Function non-operable...
Page 105: Fault Code 18.1.00
Fault code 15.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 15.1.62 Y065 - Raise suspension solenoid valve Function non-operable Circuit diagram Suspension/Auto- Guide 15.1.63 Y064 - Suspension load pressure/lowering sole- Function non-operable Circuit diagram noid valve Suspension/Auto- Guide 15.1.64 A039 - MFA, multifunction armrest...
Page 106 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 15.1.6C B066 - Sensor, wheel position (left) Position sensor not calibrated Calibration code "7666" B068 - Sensor, wheel position (right) 15.1.6D A050 - ECU, basic control unit Checksum error, suspension programming 15.1.6E B066 - Sensor, wheel position (left) Plausibility error...
Page 107 Fault code 18.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 18.1.01 A039 - MFA, multifunction armrest Partial activation button in MFA Auto-Guide partial activation button faulty, Signal fault 18.1.02 A039 - MFA, multifunction armrest Full activation button in MFA Auto-Guide full activation button faulty, Signal fault...
Page 108 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 18.1.34 Y087 - Steering valve block, Auto-Guide Error with steering valve actuation 18.1.35 Y087 - Steering valve block, Auto-Guide Error with steering valve hard- ware 18.1.36 Y087 - Steering valve block, Auto-Guide Warning regarding FLASH, EEPROM and software for steer- ing valve...
Page 109 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 18.2.05 A039 - MFA, multifunction armrest Seat not "loaded" when steering is Seat switch activated 18.2.40 A050 - ECU, basic control unit Warning message when attempt- ing full activation — no connec- tion 18.2.70 Y087 - Steering valve block, Auto-Guide...
Page 110: Fault Code 1E.1.00
Fault code 1E.1.00 - Fault DIN brief description Cause Consequences Reference FENDIAS/Note code If the following errors occur (1E.1…), they must be deleted in the engine control unit following error correction with SERDIA! 1E.1.00 A051 - ECU, engine control unit (EDC 7). Original error, Deutz SERDIA (delete error) 1E.1.01...
Page 111 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.12 S002 - Switch, ignition Pin 50, Circuit diagram SERDIA Ignition starter switch sticking EDC engine control (delete error) 00E3, 00E4 1E.1.14 B055 - Sensor, foot throttle Cable break or short circuit Speed maintained, can Circuit diagram SERDIA...
Page 112 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.34 S034 - Switch, coolant level Coolant outside of setpoint level Check coolant level Circuit diagram SERDIA EDC engine control (delete error) FC:0025 1E.1.37 A051 - ECU, engine control unit (EDC 7). Fan speed exceeds target range SERDIA (delete error)
Page 113 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.63 A051 - ECU, engine control unit (EDC 7). Misfiring on cylinder 3 SERDIA (delete error) FC:0028 1E.1.64 A051 - ECU, engine control unit (EDC 7). Misfiring on cylinder 4 SERDIA (delete error) FC:0029 1E.1.65...
Page 114 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.7A A051 - ECU, engine control unit (EDC 7). Short circuit in cylinder bank 2 Cylinder switch-off SERDIA (delete injector valves error) FC:009B 1E.1.7B A051 - ECU, engine control unit (EDC 7). Break in wiring of cylinder bank 2 Cylinder switch-off SERDIA...
Page 115 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.B2 A051 - ECU, engine control unit (EDC 7). CAN message, no engine protec- Circuit diagram SERDIA tion mechanism EDC engine control (delete error) FC:006A 1E.1.B3 A051 - ECU, engine control unit (EDC 7). CAN message, no pre-heater or Circuit diagram SERDIA...
Page 116 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.C0 A051 - ECU, engine control unit (EDC 7). CAN-message missing Circuit diagram SERDIA EDC engine control (delete error) FC:0080 1E.1.C1 A051 - ECU, engine control unit (EDC 7). CAN bus times out with at least Circuit diagram SERDIA one sent message...
Page 117 Fault DIN brief description Cause Consequences Reference FENDIAS/Note code 1E.1.D6 A051 - ECU, engine control unit (EDC 7). Engine monitoring system over- SERDIA loaded (delete error) FC:00DA 1E.1.D7 A051 - ECU, engine control unit (EDC 7). Incorrect voltage for internal 5 V Check the supply and SERDIA reference source 1...
Page 118: Calibration Fault Codes
0000 - Overall system/tractor B - Faults Calibration fault codes Fault code during calibration on FENDT 900 Vario COM III Calibration code 1001 (A039 - MFA, multifunction armrest crossgate lever) Fault code Cause Preliminary conditions for calibration not satisfied Calibrated values are faulty...
Page 119 0000 - Overall system/tractor B - Faults Calibration code 2401 (B067 - Sensor, steering angle) Fault code Cause Preliminary conditions for calibration not satisfied Calibration taking too long (more than 30 seconds) User terminated calibration with "ESC" Plausibility of "centre position" calibration value Plausibility of "left stop"...
Page 120 0000 - Overall system/tractor B - Faults Calibration code 4003 (B016 - Sensor, travel range detection) Fault code Cause User terminated calibration with "ESC" Speed above 0,1 Km/h Engine speed below 600 rpm Engine speed above 900 rpm Transmission not in neutral Clutch not depressed B015 - Sensor, bevel pinion faulty B014 - Sensor, collecting shaft faulty...
Page 121 0000 - Overall system/tractor B - Faults Calibration code 4007 (A009 - Actuator unit) Fault code Cause A009 - Actuator unit reporting a fault Frequent cause of fault: During previous fault-generated calibration exit, no "Key reset (ignition OFF/ON)" was carried out A009 - Actuator unit fails to control the specified value exactly.
Page 122 0000 - Overall system/tractor B - Faults Fault code Cause Travel range II button faulty Range control I/II is not in neutral - Range selector in neutral (normal after calibration of the travel range selector (code 4003)) - Manually set the transmission to neutral via the emergency operation if necessary Electrical fault in Y005 - Solenoid valve, speed governor Calibration code 4009 (Y004 - Solenoid valve, turbo-clutch) Fault code Cause...
Page 123 0000 - Overall system/tractor B - Faults Calibration code 7666 (B066 - Sensor, wheel position (left) B068 - Sensor, wheel position (right)) Fault code Cause User terminated calibration with ESC Raising the suspension takes too long (longer than 40 seconds) Lowering the suspension takes too long (longer than 40 seconds) Calibrated min.
Page 124 0000 - Overall system/tractor B - Faults T006640 919 .. 1001- 934 .. 1001- 922 .. 1001- Version 2 925 .. 1001- 09-10-2009 928 .. 1001- 931 .. 1001-...
Page 125 General Faults Component position Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 127 0000 - Overall system/tractor Table of contents D Component position Electrical/electronic components - A ........125 Electrical/electronic components - B .
Page 128 0000 - Overall system/tractor Table of contents 919 .. 1001- 934 .. 1001- 922 .. 1001- 925 .. 1001- 928 .. 1001- 931 .. 1001-...
Page 129: Electrical/Electronic Components - A
0000 - Overall system/tractor D - Component position Electrical/electronic components - A A007 - Instrument panel Cab, at top in steering column unit Fig. 1. I001023 A009 - Actuator unit Right side of tractor, on gearbox Detach right rear wheel and panel Fig.
Page 130 0000 - Overall system/tractor D - Component position A015 - Radio Cab, right in roof Fig. 5. I001025 A036 - Control panel, dashboard right/left Cab, on steering column Fig. 6. I007383 A038 - ECU, central electrical system Cab, right mudguard at bottom Detach panel Fig.
Page 131 0000 - Overall system/tractor D - Component position A050 - ECU, basic control unit Cab, right mudguard at bottom Detach panel Fig. 9. I001030 A051 - ECU, engine control unit (EDC 7). Bulkhead between engine and cab Open bonnet. Fig. 10. I001150 A053 - ECU, air conditioning control Below cab...
Page 132 0000 - Overall system/tractor D - Component position A058 - TopDock (Auto-Guide) Cab roof compartment Fig. 13. I002345 A059 - Terminal (Auto-Guide) In cab, right-hand side Fig. 14. I001366 A060 - Hands-free device Cab, right in roof Fig. 15. I008139 A073 - Terminal (A4) Cab, on right driver seat Fig.
Page 133 0000 - Overall system/tractor D - Component position A075 - ECU, tail light LED, right A076 - ECU, tail light LED, left Fig. 17. I000001 A077 - Immobiliser ECU Standard from chassis number: – 919/../1847 – 922/../2004 – 925/../2054 – 928/../2291 –...
Page 134: Electrical/Electronic Components - B
0000 - Overall system/tractor D - Component position Electrical/electronic components - B B002 - Sensor, front PTO speed X151 - Separation point on B002 Face end of front PTO housing, next to PTO stub shaft Detach protective funnel Fig. 20. I001053 B004 - Vacuum switch (air filter) X153 - Separation point on B004...
Page 135 0000 - Overall system/tractor D - Component position B010 - Sensor, engine speed X159 - Separation point on B010 Right side of engine, on flywheel Open bonnet. Fig. 24. I001060 B013 - Sensor, hydraulic oil temperature X162 - Separation point on B013 Right side of engine, on suction line to auxiliary pump Detach cover panel...
Page 136 0000 - Overall system/tractor D - Component position B016 - Sensor, travel range detection X165 - Separation point on B016 Left side of transmission, behind fuel tank Remove rear left wheel, detach left fuel tank and pull forward Fig. 28. I001065 B017 - Sensor, clutch pedal X166 - Separation point on B017...
Page 137 0000 - Overall system/tractor D - Component position B030 - Sensor, rear power lift position X178 - Separation point on B030 On left lift arm Detach cover Fig. 32. I001069 B031 - Sensor, draft sensing pin, right B032 - Sensor, draft sensing pin, left X179 - Separation point on B031 X180 - Separation point on B032 Lower link bearing (right and left)
Page 138 0000 - Overall system/tractor D - Component position B040 - Sensor, front power lift position X188 - Separation point on B040 Left side of front PTO Detach cover Fig. 36. I001072 B050 - Loudspeaker, left B051 - Loudspeaker, right X289 - Separation point on B051 X311 - Separation point on B050 Cab, in roof lining, front left and right Fig.
Page 139 0000 - Overall system/tractor D - Component position B061 - Loudspeaker X1620 - Separation point on B061 Cab, in roof lining, rear right Fig. 40. I001076 B062 - Loudspeaker X1622 - Separation point on B062 Cab, in roof lining, rear left Fig.
Page 140 0000 - Overall system/tractor D - Component position B067 - Sensor, steering angle X1508 - Separation point on B067 Front axle, right Detach cover Fig. 44. I001081 B068 - Sensor, wheel position (right) X1507 - Separation point on B068 Right front axle on top axle suspension, front Detach steering cylinder protective cover, right...
Page 141 0000 - Overall system/tractor D - Component position B074 - Sensor, internal temperature X1545 - Separation point on B074 Cab, left mudguard in ventilating shaft. Remove the cab circulation air filter. Fig. 48. I001258 B076 - Sensor, external temperature X1538 - Separation point on B076 Air conditioning cooler, reverse side of panel Open bonnet.
Page 142 0000 - Overall system/tractor D - Component position B083 - Immobiliser control X1494 - Separation point on B083 Cab, left side on the steering column. Remove panel. Fig. 52. I001999 B084 - Sensor, hydraulic oil level X214 - Separation point on B084 Left side of tractor, clutch housing top, below cab Fig.
Page 143 0000 - Overall system/tractor D - Component position B087 - Fuel low pressure sensor X1656 - Separation point on B087 Right side of engine, on fuel filter Open bonnet, detach panel Fig. 56. I001087 B088 - Crankshaft speed sensor X1657 - Separation point on B088 Right side of engine, on flywheel Open bonnet.
Page 144 0000 - Overall system/tractor D - Component position Version A B091 - Sensor, water in fuel X1660 - Separation point on B091 sensor, water in fuel Version A is fitted up to chassis numbers: 919/../1011; 922/../1006; 925/../1010; 928/../1013; 931/../1009; 934/../1083 Right side of tractor, behind the right fuel tank.
Page 145 0000 - Overall system/tractor D - Component position B101 - KITAS sensor Rear axle, rear right Fig. 64. I008240 T000404 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 4 922 ..
Page 146: Electrical/Electronic Components - E
0000 - Overall system/tractor D - Component position Electrical/electronic components - E E003 - H4 additional headlight, right E004 - H4 additional headlight, left Fig. 65. I000479 E009 - Licence plate lighting, right E010 - Licence plate lighting, left Fig. 66. I000480 E019 - Lighting, cab Top left in cab roof...
Page 147 0000 - Overall system/tractor D - Component position E021 - Rotating beacon, right E022 - Rotating beacon, left Fig. 69. I000483 E023 - Rear window heater Fig. 70. I000484 E050 - Work lights, front left roof, internal E051 - Work lights, front right roof, internal Fig.
Page 148 0000 - Overall system/tractor D - Component position E063 - Heater element, air dryer (temperature-controlled) Behind right rear axle Fig. 73. I000486 E064 - Rear direction indicator, left E065 - Rear direction indicator, right Fig. 74. I000487 E066 - Brake and tail light left E067 - Brake and tail light right Fig.
Page 149 0000 - Overall system/tractor D - Component position E074 - Work light, right (cornerlight) E075 - Work light, left (cornerlight) Fig. 77. I000490 E078 - Work light, rear right mudguard (optional Xenon) E079 - Work light, rear left mudguard (optional Xenon) Fig.
Page 150 0000 - Overall system/tractor D - Component position E098 - Drive headlight (main beam), right E099 - Drive headlight (dipped beam), right E100 - Drive headlight (main beam), left E101 - Drive headlight (dipped beam), left Fig. 81. I000493 E106 - Exterior mirror (adjustment/heater), right E107 - Exterior mirror (adjustment/heater), left Fig.
Page 151 0000 - Overall system/tractor D - Component position E130 - LED for rear direction indicator, left E131 - LED for rear direction indicator, right Fig. 85. I000001 T000261 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 ..
Page 152: Electrical/Electronic Components - G
0000 - Overall system/tractor D - Component position Electrical/electronic components - G G001 - Battery 1 X058 - Battery terminal (+ UB 30) X059 - Separation point on G001 X060 - Separation point on G001 X066 - Separation point on G001 Right side of tractor, on entrance step Detach cover Fig.
Page 153: Electrical/Electronic Components - H
0000 - Overall system/tractor D - Component position Electrical/electronic components - H H005 - Horn X998 - Separation point on H005 X999 - Separation point on H005 Front of tractor, before radiator assembly Opening the bonnet Fig. 89. I001107 H006 - Audio warning signal X204 - Separation point on H006 Cab, right mudguard, top Detach cover...
Page 154: Electrical/Electronic Components - K
0000 - Overall system/tractor D - Component position Electrical/electronic components – K K061 - ISO bus disconnect relay Right side of tractor, on the right tank. Detach panel Fig. 92. I001609 K063 - Heater flange relay Above the engine. Open bonnet. Fig.
Page 155 0000 - Overall system/tractor D - Component position K069 - Relay, safety function (battery disconnect) Cab, right mudguard at bottom Detach panel Fig. 96. I003170 T000532 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 ..
Page 156: Electrical/Electronic Components - M
0000 - Overall system/tractor D - Component position Electrical/electronic components - M M001 - starter. X057 - Separation point on M001 X061 - Separation point on M001 On left side of engine Open bonnet. Fig. 97. I001143 M002 - Front wiper motor X347 - Separation point on M002 Cab, top of steering column Detach panel...
Page 157 0000 - Overall system/tractor D - Component position M005 - Wiper pump, rear X303 - Separation point on M005 Tractor rear, left mudguard, on washer sys- tem reservoir Remove washer system reservoir Fig. 101. I001147 M010 - Fuel pump X300 - Separation point on M010 Left-hand fuel tank, top Fig.
Page 158 0000 - Overall system/tractor D - Component position M017 - Primary fan X1555 - Separation point on M017 Left side of tractor, on entrance step under Remove entrance step Fig. 105. I001149 T000419 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 159: Electrical/Electronic Components - S
0000 - Overall system/tractor D - Component position Electrical/electronic components - S S002 - Switch, ignition X072 - Separation point on S002 X246 - Separation point on S002 In cab, steering column right. Fig. 106. I001113 S005 - Switch, right brake X217 - Separation point on S005 S005 - Switch, right brake only installed in tractors with 1-circuit brake system...
Page 160 0000 - Overall system/tractor D - Component position S013 - Emergency mode button X224 - Separation point on S013 Cab, top of right mudguard, next to A013 Detach cover Fig. 110. I001116 S017 - Filter contamination switch X228 - Separation point on S017 Right side of transmission, on transmis- sion oil filter Detach right rear wheel and panel...
Page 161 0000 - Overall system/tractor D - Component position S021 - Button, front power lift, external raise S022 - Button, front power lift, external lower X231 - Separation point on S021 X232 - Separation point on S022 Front of tractor, left Fig.
Page 162 0000 - Overall system/tractor D - Component position S029 - Button, rear power lift, left-hand external raise S030 - Button, rear power lift, left-hand external lower X239 - Separation point on S029 X240 - Separation point on S030 Rear of tractor, on left mudguard Fig.
Page 163 0000 - Overall system/tractor D - Component position S045 - Switch, reversing driver stand X213 - Separation point on S045 Cab, below rear window Fig. 122. I003191 S047 - Switch, engine brake X140 - Separation point on S047 Cab, on floor, left Fig.
Page 164 0000 - Overall system/tractor D - Component position S076 - Switch, clutch fluid X1542 - Separation point on S076 X1543 - Separation point on S076 Cab, top of steering column Detach cover Fig. 126. I001136 S079 - Switch, steering column X1590 - Separation point on S079 X1591 - Separation point on S079 Cab, steering column left...
Page 165 0000 - Overall system/tractor D - Component position S086 - Switch, brake wearing, right S087 - Switch, brake wearing, left X1651 - Separation point on S086 X1652 - Separation point on S087 Rear axle left and right, on Tristop cylinder Fig.
Page 166: Electrical/Electronic Components - U
0000 - Overall system/tractor D - Component position Electrical/electronic components – U U001 - Immobiliser aerial Cab, steering column at the ignition switch. Remove panel. Fig. 132. I002006 U002 - Radio aerial Cab, in cab roof. Remove the roof lining. Fig.
Page 167 0000 - Overall system/tractor D - Component position Electrical/electronic components - X X007 - Implement socket X008 - Socket, on-board computer counter input Cab, C-pillar, top right Fig. 134. I001191 X015 - External control socket Rear of tractor, right Fig. 135. I001300 X017 - Front socket Front of tractor, left...
Page 168 0000 - Overall system/tractor D - Component position X028 - ISO socket (cab) Cab, C-pillar, top right Fig. 138. I001191 X037 - Separation point on A009 Right side of transmission. Detach right rear wheel and panel Fig. 139. I001227 X100 [blau] - Separation point on A007 X101 [gelb] - Separation point on A007 Rear of instrument panel Swivel instrument panel forwards...
Page 169 0000 - Overall system/tractor D - Component position X254 - 10 amp socket X255 - 25 A socket (+ UB 30) X256 - 25 amp socket (earth) Cab, C-pillar, top right Fig. 142. I001191 X259 - Separation point on E023 X260 - Separation point on E023 Cab, rear wiper motor Detach cover...
Page 170 0000 - Overall system/tractor D - Component position X346 - Separation point on E021 Cab roof, left Detach cover Fig. 146. I001229 X400 - Rear ISO implement socket Rear of tractor, right Fig. 147. I001279 X454 - Separation point on A038 X455 - Separation point on A038 X456 - Separation point on A038 Cab, right mudguard, bottom...
Page 171 0000 - Overall system/tractor D - Component position X497 - Separation point, ISO preparation Right side of tractor, next to fuel tank, right Detach cover Fig. 150. I001268 X510 - Earth pin, engine left X511 - Earth pin, engine X512 - Earth pin, engine X513 - Earth pin, engine X520 - Earth pin, oil sump right X521 - Earth pin, engine...
Page 172 0000 - Overall system/tractor D - Component position X551 - Earth pin, operator platform right X552 - Earth pin, operator platform X553 - Earth pin, operator platform X554 - Earth pin, operator platform Cab, right mudguard, bottom Detach panel Fig. 154. I001248 X558 - Earth pin, transmission X559 - Earth pin, transmission...
Page 173 0000 - Overall system/tractor D - Component position X608 - Connector, + UB 15 Cab, right mudguard, bottom Detach panel Fig. 158. I001195 X619 - Connector, electronics earth X620 - Connector, sensor system earth Cab, right mudguard, top Detach panel Fig.
Page 174 0000 - Overall system/tractor D - Component position X631 - Connector, rear PTO LED ON X635 - Connector, sensor system earth (instrument panel) X643 - Connector, instrument panel earth Cab, right mudguard, top Detach panel Fig. 162. I001197 X650 - Connector, headlight 56b (dipped beam) X651 - Connector, headlight 56a (main beam) Cab, right mudguard, top Detach panel...
Page 175 0000 - Overall system/tractor D - Component position X672 - Connector, sensor system earth X673 - Connector, sensor system earth X674 - Connector, sensor system earth Right side of tractor, next to transmission oil filter Detach protective guard and cap Fig.
Page 176 0000 - Overall system/tractor D - Component position X694 - Connector, +UB 30 (A038) Cab, right mudguard, bottom Detach panel Fig. 170. I001195 X698 - Connector, sensor system earth Right side of tractor, next to transmission oil filter Detach protective guard and cap Fig.
Page 177 0000 - Overall system/tractor D - Component position X725 - Connector, K bus_High X726 - Connector, K bus_Low Cab, right mudguard, top Detach panel Fig. 174. I001205 X727 - Connector, ISO bus_High X728 - Connector, ISO bus_Low Cab, right mudguard, top Detach panel Fig.
Page 178 0000 - Overall system/tractor D - Component position X760 - Connector, earth Rear mudguard, left Detach cover panel Fig. 178. I001270 X761 - Connector, earth Rear mudguard, right Detach cover panel Fig. 179. I001269 X762 - Connector, + UB 15 Cab, left side of steering column Detach panel Fig.
Page 179 0000 - Overall system/tractor D - Component position X769 - Connector, signal (E021/E022) X789 - Connector, signal (E083/E084) X793 - Connector, signal (E082/E085) Right C-pillar, top Detach cover plate with connectors Fig. 182. I001262 X794 - Connector, earth (A051) Right side of tractor, next to fuel tank, right Detach right rear wheel and panel, protec- tive guard and cap Fig.
Page 180 0000 - Overall system/tractor D - Component position X810 - EDC diagnostics socket (engine control unit) Cab, right mudguard, top Detach cover Fig. 186. I001207 X814 - Connector, +UB30 (X1048 socket, ABS) Tractor rear, back of ABS socket. Fig. 187. I001842 X834 - Separation point on E070 Cab roof right, underneath roof lining...
Page 181 0000 - Overall system/tractor D - Component position X836 - Separation point on E0116 / E117 Fig. 190. I000001 X837 - Separation point on X1048 socket, ABS Top of rear axle housing, back of valve block. Fig. 191. I001289 X838 - Separation point on X015 socket, external control Top of rear axle housing, back of valve block.
Page 182 0000 - Overall system/tractor D - Component position X868 - Separation point on E106 Mirror holder, right Detach cover Fig. 194. I001253 X869 - Separation point on E107 Mirror holder, left Detach cover Fig. 195. I001254 X896 - Separation point on E054 Cab, left mudguard, bottom Detach panel Fig.
Page 183 0000 - Overall system/tractor D - Component position X899 - Connector, earth Engine, next to engine control unit Open bonnet. Fig. 198. I001273 X916 - Separation point on E064 X916 - Separation point on E118 X917 - Separation point on E065 X917 - Separation point on E119 Fig.
Page 184 0000 - Overall system/tractor D - Component position X1315 - Separation point on radio (compact plug) X1316 - Separation point on radio (compact plug) Cab, in roof lining, top right Detach cover or radio Fig. 202. I001282 X1343 - Connector, G bus_High X1344 - Connector, G bus_Low Cab, left side of steering column Detach panel...
Page 185 0000 - Overall system/tractor D - Component position X1404 [A] - Separation point on A038 X1405 [B] - Separation point on A038 X1406 [C] - Separation point on A038 X1407 [D] - Separation point on A038 X1408 [E] - Separation point on A038 X1409 [F] - Separation point on A038 Cab, right mudguard, bottom Detach panel...
Page 186 0000 - Overall system/tractor D - Component position X1421 - Cable coupling, operator platform Cab, right mudguard, bottom rear Detach panel Fig. 210. I001255 X1422 - Cable coupling, mudguard Cab, left mudguard, bottom rear Detach panel Fig. 211. I001257 X1423 - Cable coupling, operator platform/transmission X1424 - Cable coupling, operator platform X1425 - Cable coupling, operator platform Right entrance step...
Page 187 0000 - Overall system/tractor D - Component position X1440 - Fuse holder Cab, right mudguard, top Detach cover Fig. 214. I001208 X1461 - Connector, sensor system earth (left mudguard) Rear mudguard, right Detach cover panel Fig. 215. I001269 X1462 - Connector, sensor system earth (right mud- guard) Rear mudguard, left Detach cover panel...
Page 188 0000 - Overall system/tractor D - Component position X1466 - Separation point on A051 Engine control unit Open bonnet. Fig. 218. I001259 X1525 - Connector, sensor + UB (from instrument panel) Right side of tractor, next to transmission oil filter Detach protective guard and cap Fig.
Page 189 0000 - Overall system/tractor D - Component position X1539 - ISO bus diagnostics socket Cab, right mudguard, top Detach cover Fig. 222. I001209 X1565 - Connector, position light X1578 - Connector, + UB 15 Cab, right mudguard, top Detach panel Fig.
Page 190 0000 - Overall system/tractor D - Component position X1597 - Cable coupling A059 Cab, right mudguard, top Detach panel Fig. 226. I001220 X1600 - Cable coupling, to rear work lights (roof) Below cab, on left Detach housing from cab air filter Fig.
Page 191 0000 - Overall system/tractor D - Component position X1633 - Separation point, Auto-Guide TopDock Tractor without Auto-Guide Cab, front right loudspeaker Detach front right loudspeaker Fig. 230. I001293 X1633 - Separation point, Auto-Guide TopDock Tractor with Auto-Guide The connector X1633 - Separation point, Auto-Guide Top- Dock is disconnected and both X4000 - Separation point on X1633_ P and X4001 - Separation point on X1633_ S connectors are connected accordingly...
Page 192 0000 - Overall system/tractor D - Component position X1636 - Vario-Doc cable coupling Cab, right mudguard, bottom Detach panel Fig. 234. I001302 X1637 - Connector, ISO bus_Low (A055 Vario-Doc) X1638 - Connector, ISO bus_High (A055 Vario-Doc) X1639 - Connector, K bus_High X1640 - Connector, K bus_Low Cab, right mudguard, bottom Detach panel...
Page 193 0000 - Overall system/tractor D - Component position X1669 - Separation point on U002 X1670 - Separation point on U002 Cab, glued to inside of roof. Remove roof lining. Fig. 238. I002490 X1673 - Cylinder head cable coupling (injectors) On left side of engine Open bonnet.
Page 194 0000 - Overall system/tractor D - Component position X1677 cable coupling EDC On left side of engine Open bonnet. Fig. 242. I004022 X1678 - Connector, front work light Cab, right mudguard, bottom Detach panel Fig. 243. I001294 X1681 - Cable coupling, E051 Cab, front right loudspeaker Detach front right loudspeaker Fig.
Page 195 0000 - Overall system/tractor D - Component position X1683 - Cable coupling, camera socket Cab, right mudguard, top Detach panel Fig. 246. I001297 X1729 - Connector, ISO bus_Low X1730 - Connector, ISO bus_Low X1731 - Connector, ISO bus_High X1734 - Connector, ISO bus_High X1735 - Connector, earth (Auto-Guide) X1740 - Connector, Auto-Guide (+UB 15) X1742 - Connector, Auto-Guide (+UB 30)
Page 196 0000 - Overall system/tractor D - Component position X1787 - Connector, + UB 15 Cab, steering column Detach panel Fig. 250. I001297 X1802 - Separation point on E116 / E117 Fig. 251. I000001 X1806 - +UB 30 distributor Right side of tractor, on the right tank. Detach panel Fig.
Page 197 0000 - Overall system/tractor D - Component position X4003 - Connector, ISO bus_Low X4004 - Connector, ISO bus_High X4005 - Connector, V bus_Low X4006 - Connector, V bus_High The connectors are not routed outwards, but are cast in the plastic casing Cab roof compartment Fig.
Page 198 0000 - Overall system/tractor D - Component position X5028 - Connector, cab earth pin Fig. 258. I000001 T000425 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 4 922 .. 0101-1000 928 ..
Page 199: Electrical/Electronic Components - Y
0000 - Overall system/tractor D - Component position Electrical/electronic components - Y Y002 - Solenoid valve, travel range I Y003 - Solenoid valve, travel range II Y004 - Solenoid valve, turbo-clutch Y005 - Solenoid valve, speed governor Right side of transmission, transmission valve block Detach right rear wheel and panel Fig.
Page 200 0000 - Overall system/tractor D - Component position Y012 - Oil pre-heater/load suspension solenoid valve Right side of tractor, central valve block Detach panel Fig. 263. I001173 Y021 - Lifting solenoid valve (standard front power lift) Y022 - Lowering solenoid valve (standard front power lift) Right side of tractor, central valve block Detach panel Fig.
Page 201 0000 - Overall system/tractor D - Component position Y024 - Magnetic clutch, air conditioning compressor On left side of engine Open bonnet. Fig. 267. I001163 Y026 - Solenoid valve, rear PTO, stage I Y027 - Solenoid valve, rear PTO, stage II Rear axle housing at top, below cab Detach left rear wheel Fig.
Page 202 0000 - Overall system/tractor D - Component position Y055 - Rear pressure compensator lock valve Rear of tractor, rear valve block Detach cover panel Fig. 271. I001175 Y060 - Hydraulic oil pre-heater solenoid valve (rear) Rear of tractor, rear valve block Fig.
Page 203 0000 - Overall system/tractor D - Component position Y063 - Wobble stabiliser solenoid valve Left side of tractor, behind left fuel tank. Fig. 275. I001177 Y064 - Suspension load pressure/lowering solenoid valve Right side of tractor, central valve block Detach panel Fig.
Page 204 0000 - Overall system/tractor D - Component position Y070 [FKH] - Cut-off valve, front power lift enhanced con- trol Y071 [2.1] - Auxiliary control valve (olive) Y072 [2.2] - Auxiliary control valve (grey) Right side of tractor, central valve block Detach panel Fig.
Page 205 0000 - Overall system/tractor D - Component position Y088 - Solenoid valve, release trailer brake Right side of transmission Detach right rear wheel and panel Fig. 283. I001303 Y091 - Dispensing unit (fuel) Right side of engine Open bonnet. Fig. 284. I001172 Y092 - Solenoid valve, reverse operation (RÜFA), rotate to left...
Page 206 0000 - Overall system/tractor D - Component position Y095 - Injector valve 1 (injector) Y096 - Injector valve 2 (injector) Y097 - Injector valve 3 (injector) Y098 - Injector valve 4 (injector) Y100 - Injector valve 5 (injector) Y101 - Injector valve 6 (injector) Fig.
Page 207: Hydraulic Components
0000 - Overall system/tractor D - Component position Hydraulic components APE - Entry plate with ext. Pressure supply Rear valve block Fig. 288. I000823 ASP1 - Accumulator, suspension 1 ASP2 - Accumulator, suspension 2 Left side of tractor, in VBF Fig.
Page 208 0000 - Overall system/tractor D - Component position DBV1 - Main pressure-limiting valve Right side of tractor, in ZSB Detach panel Fig. 292. I000794 DBVF1 - Pressure-limiting valve, suspension 1 Right side of tractor, in ZSB Detach panel Fig. 293. I000800 DBVF2 - Pressure-limiting valve, suspension 2 Left side of tractor, in VBF...
Page 209 0000 - Overall system/tractor D - Component position DBVKH [Y062] - Field pressure valve, DA rear power lift Rear valve block Fig. 296. I000839 DBV-L - Pressure-limiting valve, 175 bar steering Right side of tractor, in ZSB Detach panel Fig. 297. I000805 DFE - Pressure filter, external LS Rear valve block, in APE...
Page 210 0000 - Overall system/tractor D - Component position DFWH - Flow monitor, auxiliary pump Right side of tractor, central valve block Detach panel Fig. 300. I000848 DFWN - Flow monitor, emergency steering pump Right side of tractor, central valve block Detach panel and right fuel tank Fig.
Page 211 0000 - Overall system/tractor D - Component position DRVP - Pressure cut-off valve, pilot pressure Right side of tractor, in VBP Detach panel and right fuel tank Fig. 304. I000816 DS1 - Pressure switch, LS pump monitor Right side of tractor, ZSB top Detach panel Fig.
Page 212 0000 - Overall system/tractor D - Component position DWL - Pressure compensator, steering Right side of tractor, in VBL Detach panel Fig. 308. I000821 DWP - Pressure compensator, pilot pressure Right side of tractor, in VBP Detach panel and right fuel tank Fig.
Page 213 0000 - Overall system/tractor D - Component position FSP - Front power lift accumulator Left side of tractor, on the front axle Fig. 312. I000842 FSS [B084] - Level switch Top clutch housing, left Fig. 313. I000786 GDR - Silencer, LS pump In clutch housing Remove right rear wheel, right fuel tank and clutch housing hatch cover...
Page 214 0000 - Overall system/tractor D - Component position Hy.ABV - Hydraulic trailer brake Right side of tractor, central valve block Detach panel Fig. 316. I000822 K - Hydraulic oil cooler Front, below bonnet Fig. 317. I000790 LE - Steering unit Left side of tractor, by entrance step below Detach cab air filter Fig.
Page 215 0000 - Overall system/tractor D - Component position MVFF [Y067] - Solenoid valve, lock suspension Left side of tractor, in VBF Pull forward left fuel tank Fig. 320. I000807 MVFH [Y065] - Solenoid valve, raise suspension Right side of tractor, in ZSB Detach panel Fig.
Page 216 0000 - Overall system/tractor D - Component position MVKFH [Y021] - Lifting solenoid valve (standard front power lift) Right side of tractor, central valve block (standard front power lift). Detach panel Fig. 324. I001647 MVKFS [Y022] - Lowering solenoid valve (standard front power lift) Right side of tractor, central valve block (standard front power lift).
Page 217 0000 - Overall system/tractor D - Component position MVP [Y032] - Solenoid valve, pilot pressure Right side of tractor, in VBP Detach panel and right fuel tank Fig. 328. I000818 MVUL [Y082] - Solenoid valve, lower link stabiliser lock Rear valve block Detach cover panel Fig.
Page 218 0000 - Overall system/tractor D - Component position OETR - Oil temperature regulator Right side of tractor, central valve block Detach panel Fig. 332. I000789 PH - Auxiliary pump Flange-mounted to right side of engine Fig. 333. I000779 PNL - Emergency steering pump In clutch housing, flange-mounted to 4WD shaft Remove right rear wheel, right fuel tank...
Page 219 0000 - Overall system/tractor D - Component position PVL - Priority valve, steering Right side of tractor, in VBL Detach panel Fig. 336. I000820 RLF - Return line filter Left side of clutch housing Detach closing plate from clutch housing, bottom left Fig.
Page 220 0000 - Overall system/tractor D - Component position RVFS - Non-return valve, lower suspension Right side of tractor, in ZSB Detach panel Fig. 340. I000799 RVL1-3 - Non-return valve, steering 1-3 Right side of tractor, in ZSB Detach panel Fig. 341. I000925 RVN - Non-return valve, emergency steering pump In clutch housing...
Page 221 0000 - Overall system/tractor D - Component position SFN1+2 - Suction filter, emergency steering pump 1+2 In clutch housing Remove right rear wheel, right fuel tank and clutch housing hatch cover Fig. 344. I000782 SFR - Suction filter, LS pump In clutch housing Remove right rear wheel, right fuel tank and clutch housing hatch cover...
Page 222 0000 - Overall system/tractor D - Component position TG [B013] - Temperature sensor Right side of engine, suction line to auxil- iary pump Fig. 348. I000781 VBF - Valve block, suspension Left side of tractor, behind fuel tank Pull forward left fuel tank Fig.
Page 223 0000 - Overall system/tractor D - Component position WV1 - LS shuttle valve 1 Right side of tractor, in ZSB Detach panel Fig. 352. I000923 WV2 - LS shuttle valve 2 Right side of tractor, in ZSB Remove right rear wheel, remove right tank, remove VBP , shuttle valve 2 is located behind the VBP .
Page 224 0000 - Overall system/tractor D - Component position ZF2 - Federungszylinder 2 Front axle, right Fig. 356. I003951 ZL - Steering cylinder Front axle Fig. 357. I000897 ZSB - Central control block Right side of tractor, central valve block Detach panel Fig.
Page 225 0000 - Overall system/tractor D - Component position Electro-hydraulic steering system (Autoguide) APLE - Connection plate for el.-hyd. steering system Right side of transmission. Remove right rear wheel. Fig. 360. I001892 DRVLE - Pilot pressure cut-off valve, el.-hyd. steering system Right side of transmission.
Page 226 0000 - Overall system/tractor D - Component position PVLE - Proportional valve, el.-hyd. steering system Right side of transmission. Remove right rear wheel. Fig. 364. I003983 VBLE1 - Valve block, el.-hyd. steering system 1 Right side of transmission. Remove right rear wheel. Fig.
Page 227 0000 - Overall system/tractor D - Component position VLE2+3 - LE switch off 1 + 2 valves Right side of tractor, behind the right fuel tank. Remove the right fuel tank. Fig. 368. I001894 WVLE - LS shuttle valve, el.-hyd. steering system Right side of transmission.
Page 228 0000 - Overall system/tractor D - Component position T000335 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 4 922 .. 0101-1000 928 .. 1001- 10-09-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 229 General Faults Setting and calibrating Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 231 0000 - Overall system/tractor Table of contents F Setting and calibrating General information on calibration ......... . 229 Calibration code 8001, 8002 (EPC rear) .
Page 232 0000 - Overall system/tractor Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 233: General Information On Calibration
0000 - Overall system/tractor F - Setting and calibrating General information on calibration To compensate for mechanical and electrical tolerances in sensors, the sensors concerned must be calibrated. If a sensor is replaced, it must be calibrated. The following sensors and functions require calibration Rear EPC calibration (depth control code 8001 and rear power lift position code 8002) Calibration, EPC front (code 9001 and code 9002) Calibration, crossgate lever (hydr.
Page 234 0000 - Overall system/tractor F - Setting and calibrating Second main menu in the A007 instrument panel Fig. 2. I001079 Transmission menu Front PTO menu (for front PTO only) Front power lift menu (for EPC front power lift only) Front axle suspension menu Rear PTO menu Rear power lift menu T000330...
Page 235 0000 - Overall system/tractor F - Setting and calibrating Hydraulics menu Steering menu Heater valve menu Transmission menu Transmission menu Fig. 3. I001091 Transmission calibration, Display (A) Change wheel circumference, Display (B) Calibrate speed display, Display (C) Change acceleration ramp I, Display (D) (Note: adjustment range from 0.02-0.5 km/h possible) T000330 919 ..
Page 236 0000 - Overall system/tractor F - Setting and calibrating Rear PTO menu Rear PTO menu Fig. 4. I001101 Rear PTO calibration, Display (A) Select factory setting for auto mode switch-on point, Display (B) (see also: Operating Manual) Change auto mode switch-on point, Display (C) (see also: Operating Manual) T000330 919 ..
Page 237: Calibration Code 8001, 8002 (Epc Rear)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 8001, 8002 (EPC rear) 1. Calibration of the EPC rear Calibration of depth control (8001) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON –...
Page 238 0000 - Overall system/tractor F - Setting and calibrating The rear power lift menu level appears on the multi-dis- play. Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 8. I000899 Input code 8001 Press one of the buttons until the required number is displayed Press "Return"...
Page 239 0000 - Overall system/tractor F - Setting and calibrating Slowly rotate depth control to the right Fig. 12. I000888 Slowly rotate depth control to the right Fig. 13. I000889 If the depth control is rotated too quickly, an im- age will appear. Rotate depth control back slightly Fig.
Page 240 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 241 0000 - Overall system/tractor F - Setting and calibrating Press "Return", the first main menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return", the second main menu appears in the multiple display Fig.
Page 242 0000 - Overall system/tractor F - Setting and calibrating Set quick lift switch to "Raise". The lifting gear rises up and remains in its uppermost position Press "Return" to confirm Fig. 23. I000893 Set quick lift switch to "Lower". The linkage lowers and re- mains in its lowermost position Press "Return"...
Page 243: Calibration Code 9001, 9002 (Front Epc)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 9001, 9002 (front EPC) 2. Calibrating the front EPC Calibrating the depth control (9001) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON –...
Page 244 0000 - Overall system/tractor F - Setting and calibrating The front power lift menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 30. I000911 Input code 9001 Press one of the buttons until the required number is displayed Press "Return"...
Page 245 0000 - Overall system/tractor F - Setting and calibrating Slowly rotate depth control to the right Fig. 34. I000888 Slowly rotate depth control to the right Fig. 35. I000889 If the depth control is rotated too quickly, an im- age will appear. Rotate depth control back slightly Fig.
Page 246 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 247 0000 - Overall system/tractor F - Setting and calibrating Press "Return", the first main menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return", the second main menu appears in the multiple display Fig.
Page 248 0000 - Overall system/tractor F - Setting and calibrating Set quick lift switch to "Raise". Front power lift will raise and stop at the top Press "Return" to confirm Fig. 45. I000918 Set quick lift switch to "Lower". Front power lift will lower and stop at the bottom Press "Return"...
Page 249: Calibration Code 1001 (Crossgate Lever)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 1001 (crossgate lever) 3. Calibrating the crossgate lever (1001) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON – If fault messages are displayed, the faults must be confirmed one by one. Press "ESC"...
Page 250 0000 - Overall system/tractor F - Setting and calibrating The auxiliary control valve menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 52. I000939 Input code 1001 Press one of the buttons until the required number is displayed Press "Return"...
Page 251 0000 - Overall system/tractor F - Setting and calibrating Push crossgate lever to left (exert excessive pressure against spring) Hold crossgate lever Press "Return" to confirm this position Fig. 56. I000943 Push crossgate lever forward (exert excessive pressure against spring) Hold crossgate lever Press "Return"...
Page 252 0000 - Overall system/tractor F - Setting and calibrating Push crossgate lever at rear right into the corner (exert ex- cessive pressure against spring) Hold crossgate lever Press "Return" to confirm this position Fig. 60. I000947 Push crossgate lever at rear left into the corner (exert ex- cessive pressure against spring) Hold crossgate lever Press "Return"...
Page 253 0000 - Overall system/tractor F - Setting and calibrating Push crossgate lever to left (do not exert excessive pres- sure against spring Hold crossgate lever Press "Return" to confirm this position Fig. 64. I000951 Push crossgate lever forwards (do not exert excessive pressure against spring) Hold crossgate lever Press "Return"...
Page 254 0000 - Overall system/tractor F - Setting and calibrating If incorrect values are detected or the conditions are not met, an message appearsERROR 1001 = calibration code FXX = fault code The fault code is displayed from end-of-line pro- gram (EOL) 7.60 onward (Autumn 2007) Fig.
Page 255: Calibration Code (1003
0000 - Overall system/tractor F - Setting and calibrating Calibration code (1003 ... 1006) (linear module) 4. – 7. Calibrating linear module (1003 … 1006) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON –...
Page 256 0000 - Overall system/tractor F - Setting and calibrating The auxiliary control valve menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 72. I000939 Linear module 1 = code 1003 Linear module 2 = code 1004 Linear module 3 = code 1005 Linear module 4 = code 1006...
Page 257 0000 - Overall system/tractor F - Setting and calibrating Release linear module (centres automatically) Press "Return" to confirm this position Fig. 76. I000970 Push linear module forwards (do not exert excessive pressure against spring) Hold linear module Press "Return" to confirm Fig.
Page 258 0000 - Overall system/tractor F - Setting and calibrating If incorrect values are detected or the conditions are not met, an message appearsERROR 1003 = calibration code, linear module 1 1004 = calibration code, linear module 2 1005 = calibration code, linear module 3 1006 = calibration code, linear module 4 FXX = fault code The fault code is displayed from end-of-line pro-...
Page 259: Calibration Code 7666 (Front Axle Suspension)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 7666 (front axle suspension) 8. Calibrating the front axle suspension (7666) Calibration operation: ARNING Once the input code has been confirmed, the tractor will raise and lower automatically! Important: The following preparatory steps must be carried out. –...
Page 260 0000 - Overall system/tractor F - Setting and calibrating Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 84. I000977 Once the input code has been con- ARNING firmed, the tractor will raise and lower auto- matically! Input code 7666 Press one of the buttons until the required...
Page 261 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ignition again!) T000368 919 ..
Page 262: Calibration Code 2401 (Steering Angle Sensor)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 2401 (steering angle sensor) (calibration only possible for tractors with Auto-Guide) 9. Calibrating the steering angle sensor (2401) Important: The following preparatory steps must be carried out. Calibration procedure from end-of-line program EOL 7.60 or higher –...
Page 263 0000 - Overall system/tractor F - Setting and calibrating Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 91. I000984 Input code 2401 Press one of the buttons until the required number is displayed Press "Return"...
Page 264 0000 - Overall system/tractor F - Setting and calibrating Move the steering wheel to its centre position and make sure the front wheels are completely straight Release hand brake and advance the tractor slowly, keeping the wheels straight. Press "Return" to confirm Fig.
Page 265: Calibration Code 2403 (Auto-Guide Control Valve)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 2403 (Auto-Guide control valve) (calibration only possible for tractors with Auto-Guide) 9. Calibrating Auto-Guide control valve If a new A050 - ECU, basic control unit has been installed, carry out transmission calibration 4001–4010. Important: The following preparatory steps must be carried out Calibration procedure from end-of-line program EOL 7.60 or higher –...
Page 266 0000 - Overall system/tractor F - Setting and calibrating The second main menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 101. I000980 Press one of the buttons repeatedly until the symbol (A) flashes Press "Return"...
Page 267 0000 - Overall system/tractor F - Setting and calibrating The following image is displayed Fig. 105. I002516 If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 268: Calibration Code 6034 (Rear Pto Clutch)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 6034 (rear PTO clutch) 10. Calibration of rear PTO coupling time The load-dependent start-up of the rear PTO is stored in the A050 - ECU, basic control unit. The rear PTO clutch is calibrated to adapt the coupling operation to the implement concerned. The A050 - ECU, basic control unit can be taught, i.e.
Page 269 0000 - Overall system/tractor F - Setting and calibrating The second main menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 110. I000765 The rear PTO menu appears on the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return"...
Page 270 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ignition again!) T000332 919 ..
Page 271: Calibration Code 7034 (Front Pto Clutch)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 7034 (front PTO clutch) 11. Calibration – front PTO coupling time The load-dependent start-up of the front PTO is stored in the A050 - ECU, basic control unit. The rear PTO clutch is calibrated to adapt the coupling operation to the implement concerned. The A050 - ECU, basic control unit can be taught, i.e.
Page 272 0000 - Overall system/tractor F - Setting and calibrating The second main menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 116. I000802 The rear PTO menu appears on the multiple display Press "Return"...
Page 273 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ignition again!) T000334 919 ..
Page 274: Calibration Code 4001 (Drive Clutch Pedal)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4001 (drive clutch pedal) 12. Calibrating the drive clutch pedal Important: The following preparatory steps must be carried out. – Ignition ON – Hand brake applied – If fault messages are displayed, the faults must be confirmed one by one. Press "ESC"...
Page 275 0000 - Overall system/tractor F - Setting and calibrating The transmission menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 123. I000989 Input code 4001 Press one of the buttons until the required number is displayed Press "Return"...
Page 276 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been switched to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 277: Calibration Code 4002 (Hand Throttle)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4002 (hand throttle) 13. Calibrating the hand throttle (4002) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON – If fault messages are displayed, the faults must be confirmed one by one. Press "ESC"...
Page 278 0000 - Overall system/tractor F - Setting and calibrating The transmission menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 132. I000989 Input code 4002 Press one of the buttons until the required number is displayed Press "Return"...
Page 279 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been switched to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 280: Calibration Code 4003 (Travel Range Selector)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4003 (travel range selector) 14. Calibrating the travel range selector (4003) Important: The following preparatory steps must be carried out. – Transmission oil temperature approx. 40°C – Hand brake applied –...
Page 281 0000 - Overall system/tractor F - Setting and calibrating The transmission menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 141. I000989 Input code 4003 Press one of buttons until desired number is displayed Press "Return"...
Page 282 0000 - Overall system/tractor F - Setting and calibrating The centre position is displayed and enabled automati- cally If incorrect values are detected or the conditions are not met, an message appearsERROR Fig. 145. I001008 If calibration is completed without errors, the screen ap- pears and the new settings are saved.
Page 283 0000 - Overall system/tractor F - Setting and calibrating Fault code Cause Terminated by user Speed above 0.1 km/h Engine speed below 600 rpm Engine speed above 900 rpm Transmission not in neutral Clutch not depressed B015 bevel pinion sensor faulty B014 hydrostatic collecting shaft sensor faulty B010 engine speed sensor faulty Neutral button, driving switch faulty (A039 multifunction armrest)
Page 284: Calibration Code 4005 (Foot Throttle/Throttle Pedal)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4005 (foot throttle/throttle pedal) 15. Calibrating the foot throttle/throttle pedal (4005) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON – If fault messages are displayed, the faults must be confirmed one by one. Press "ESC"...
Page 285 0000 - Overall system/tractor F - Setting and calibrating The transmission menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 152. I000989 Input code 4005 Press one of buttons until desired number is displayed Press "Return"...
Page 286 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 287: Calibration Code 4007 (Transmission Ratio Characteristic)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4007 (transmission ratio characteristic) 16. Calibrating the transmission ratio characteristic Important: The following preparatory steps must be carried out. – Transmission oil temperature approx. 40°C – Hand brake applied –...
Page 288 0000 - Overall system/tractor F - Setting and calibrating "Transmission in neutral" display Press "ESC" to confirm Fig. 160. I001009 Press "Return", the first main menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return", the second main menu appears in the multiple display Fig.
Page 289 0000 - Overall system/tractor F - Setting and calibrating Input code 4007 Press one of the buttons until the required number is displayed Press "Return" to confirm Fig. 164. I000773 Step1 (test step 1) to … Fig. 165. I000555 … Step7 (test step 7) run automatically Fig.
Page 290 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 291 0000 - Overall system/tractor F - Setting and calibrating Fault code Cause Transmission ratio characteristic not logical, e.g. shifted forward and reverse detected. F 10 Repeat calibration. See also error message F 2. Check rotational direction signal from B014 hydrostatic sensor (collecting shaft) Step 7: check Step 1 to Step 6 values.
Page 292 0000 - Overall system/tractor F - Setting and calibrating Fault code Cause Step 3: forward actuator shaft adjustment greater than 155°, but transmission adjustment reacts less than 155°. Step 4: reverse actuator shaft adjustment greater than 135°, but transmission adjustment reacts less than 135°.
Page 293 0000 - Overall system/tractor F - Setting and calibrating Graphic overview of transmission ratio calibration Fig. 171. I001031 T000399 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 3 922 .. 0101-1000 928 ..
Page 294: Calibration Code 4009 (Turbo-Clutch Function)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4009 (turbo-clutch function) 17. Calibrating the turbo-clutch function (4009) Important: The following preparatory steps must be carried out. – Transmission oil temperature approx. 40°C – Start engine – Engage transmission travel range II via the switch in the A039 multifunction armrest –...
Page 295 0000 - Overall system/tractor F - Setting and calibrating The transmission menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 175. I000989 Input code 4009 Press one of the buttons until the required number is displayed Press "Return"...
Page 296 0000 - Overall system/tractor F - Setting and calibrating Fig. 179. I001034 Fig. 180. I001033 Fig. 181. I001034 If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when the ignition key has been turned to "0"...
Page 297 0000 - Overall system/tractor F - Setting and calibrating If incorrect values are detected or the conditions are not met, an message appearsERROR 4009 = calibration code FXX = fault code The fault code is displayed from end-of-line pro- gram (EOL) 7.60 onward (Autumn 2007) Fig.
Page 298: Calibration Code 4010 (Throttle Pedal Resolution)
0000 - Overall system/tractor F - Setting and calibrating Calibration code 4010 (throttle pedal resolution) 18. Calibrating the throttle pedal resolution (4010) Important: The following preparatory steps must be carried out. – Hand brake applied – Ignition ON – If fault messages are displayed, the faults must be confirmed one by one. Press "ESC"...
Page 299 0000 - Overall system/tractor F - Setting and calibrating The transmission menu appears in the multiple display Press one of the buttons repeatedly until the symbol (A) flashes Press "Return" to confirm Fig. 187. I000989 Input code 4010 Press one of buttons until desired number is displayed Press "Return"...
Page 300 0000 - Overall system/tractor F - Setting and calibrating If calibration is completed without errors, O.K. appears and the new sensor settings are saved. Settings are only transferred when ignition key has been turned to "0" position. (Wait for at least 15 seconds before switching on the ig- nition again!) Fig.
Page 301: Calibrating The Heater Valve (No Code)
0000 - Overall system/tractor F - Setting and calibrating Calibrating the heater valve (no code) 19. Calibrating the heater valve (no code) Important: The following preparatory steps must be carried out. – Ignition ON – Diesel engine running Press "ESC" to confirm the warning and fault messages displayed on the A007 instrument panel Fig.
Page 302 0000 - Overall system/tractor F - Setting and calibrating The calibration process is automatic (approx. 30 sec- onds) The heater valve stepper motor is opened and closed slowly The display flashes during the calibration process Fig. 196. I001047 If incorrect values are detected or the conditions are not met, an message appearsERROR If calibration is completed without errors, O.K.
Page 303: Calibrating The Speed Display (A007 Instrument Panel And A011 Radar Sensor)
0000 - Overall system/tractor F - Setting and calibrating Calibrating the speed display (A007 instrument panel and A011 radar sensor) Calibrating speed display – Transmission signals (actual tyre circumference) "theoretical speed" – A011 radar sensor "actual speed" (from EOL 7.60/Nov. 07) Preliminary conditions: –...
Page 304 0000 - Overall system/tractor F - Setting and calibrating Using the "ESC" key, work back until Time and Operating Hours are displayed Fig. 200. I002926 Transfer of tyre circumference and radar impulses only takes place when the ignition key is set to the "0" position. (Wait for at least 15 seconds before switching on the ignition again!) ERROR Cause...
Page 305: Auto-Guide System: Calibration Of Roll Bias (Dmu)
0000 - Overall system/tractor F - Setting and calibrating Auto-Guide system: calibration of roll bias (DMU) (only with OmniStar HP or basic station) When operating the Auto-Guide system with the patch: – OmniStar HP – Basic station (local base) the DMU (gyro compass) roll bias must be calibrated. When operating the Auto-Guide system with the OmniStar VBS patch, calibration of the roll bias is not nec- essary.
Page 306 0000 - Overall system/tractor F - Setting and calibrating Conditions for roll bias calibration – Scroll with the arrow key Fig. 203. I003307 – Switch to the status indicator with the measuring gauges Fig. 204. I003308 Press DETAILS in the "Status" screen Fig.
Page 307 0000 - Overall system/tractor F - Setting and calibrating Set the following parameters on the A059 Auto-Guide terminal: Implement width = 10 m Implement offset = 0 m Way line offset = 0 m On flat, reasonably level ground, align the tractor at the start of the wayline. Move the tractor forwards and switch on the automatic track guide.
Page 308 0000 - Overall system/tractor F - Setting and calibrating System information from the DMU (gyro compass) In the Details status screen Overview with system information "General Informa- tion" Roll Bias If the calibration of the DMU "gyro compass" shows Value = 0 (DMU not calibrated) Value = 0 +/-5°...
Page 309 1005 General Faults Overall system/transmission Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 311 1005 - Overall system/transmission Table of contents 1005 Overall system/transmission General........5 Documents and diagrams .
Page 312 1005 - Overall system/transmission Table of contents...
Page 313 1005 - Overall system/transmission Table of contents A General Transmission control system functional sequence ....... 7 Transmission function diagram .
Page 314 1005 - Overall system/transmission Table of contents...
Page 315 The ML transmission unit is flexibly mounted in the transmission housing. The transmission housing is also the oil reser- voir for the hydrostatic drive. Oil fill: Fendt Extra Trans 10W-40 or STOU oil, viscosity SAE 10W-40 or 15W-40 Initial fill: approx. 87 l Refill: approx.
Page 316 1005 - Overall system/transmission A - General The CAN bus is a data line and connects various components (also called users) with each other. If a large amount of data is transmitted, the voltage in the CAN bus (+ and - cables) rises. In the Vario 900, data is transmitted via 4 CAN buses.
Page 317 1005 - Overall system/transmission A - General Travel range detection sensor (B016) electronically monitors range control travel. Temperature sensor (B009) monitors the temperature of the transmission oil. Temperatures above 110°C are logged with a fault code. Rotary position sensor (B055) electronically monitors the pedal travel of the foot throttle pedal. Solenoid valve, transmission neutral/turbo-clutch valve (Y004) controls the turbo-clutch function.
Page 318 1005 - Overall system/transmission A - General Transmission function diagram Planetary carrier (drive from combustion engine) Ring gear (drive to pump) Planet gear Sun gear (drive to collecting shaft) Fig. 1. I001380 Fig. 2. I001381 A Mechanical power flow 1 Planetary gear B Hydrostatic power flow 2 Hydraulic pump C PTO drive...
Page 319 1005 - Overall system/transmission A - General Active stationary Engine running, tractor stationary Fig. 3. I001382 A Mechanical power flow B Hydrostatic power flow T000466 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 ..
Page 320 1005 - Overall system/transmission A - General Pulling away 99% hydrostatic power transmission 1% mechanical power transmission Fig. 4. I001383 A Mechanical power flow B Hydrostatic power flow T000466 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 ..
Page 321 1005 - Overall system/transmission A - General Driving, average speed 50% hydrostatic power transmission 50% mechanical power transmission Fig. 5. I001384 A Mechanical power flow B Hydrostatic power flow T000466 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 ..
Page 322 1005 - Overall system/transmission A - General Transport 40 km/h, 50 km/h or 60 km/h approx. 100% mechanical power transmission Fig. 6. I001385 A Mechanical power flow B Hydrostatic power flow T000466 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 323 1005 - Overall system/transmission A - General Reversing Average speed 100% hydrostatic power transmission Ring gear rotates faster than the combustion engine Fig. 7. I001386 A Mechanical power flow B Hydrostatic power flow T000466 919 .. 0101-1000 925 .. 1001- 934 ..
Page 324 1005 - Overall system/transmission A - General T000466 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 3 922 .. 0101-1000 928 .. 1001- 04-02-2010 922 .. 1001- 931 .. 0101-1000 925 ..
Page 325 1005 - Overall system/transmission Table of contents C Documents and diagrams Transmission hydraulic system diagram - 931.100.000.002 ..... . . 19 919 ..
Page 326 1005 - Overall system/transmission Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 327 1005 - Overall system/transmission C - Documents and diagrams Transmission hydraulic system diagram - 931.100.000.002 Item Designation Item Designation Switching circuits: Valves: Valve block, feed/lubrication Radiator bypass valve Main circuit Pressure-limiting valve, discharge Displacement Pressure-limiting valve, feed Valve block, enhanced hydraulics Pressure-limiting valve, lubrication Brake and rear axle Pressure-limiting valve, servo pump...
Page 328 1005 - Overall system/transmission C - Documents and diagrams Lubrication, rear PTO Switching pressure, PTO level 2 Lubrication pressure, rear axle Clutch and turbo-clutch valve leakage Depending on the version, level 1 operates at the following PTO speeds: 540/540 E or 1000 E (1000 E is available from chassis number 9XX/2X/3501 onwards on request).
Page 330 1005 - Overall system/transmission C - Documents and diagrams T000467 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 4 922 .. 0101-1000 928 .. 1001- 15-12-2008 922 .. 1001- 931 ..
Page 331 1005 - Overall system/transmission Table of contents E Measuring and testing Pressure measuring points on transmission and control hydraulics ....25 Measuring transmission pressure ......... . . 28 Transmission pressure measurement (fax template).
Page 332 1005 - Overall system/transmission Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 333: Pressure Measuring Points On Transmission And Control Hydraulics
1005 - Overall system/transmission E - Measuring and testing Pressure measuring points on transmission and control hydraulics Fig. 1. I001390 Mounted at rear on the rear axle housing Fig. 2. I001391 T000470 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 334 1005 - Overall system/transmission E - Measuring and testing Fig. 3. I011587 Pressure, 4WD clutch Switching pressure, PTO 1000 Pressure, differential lock The measuring connections at the rear right and left of the cover plate on the rear axle housing may also be used for checking the rear PTO.
Page 335 1005 - Overall system/transmission E - Measuring and testing Measur- Mark on Designation Measur- Mark on Designation ing point the com- ing point the com- ponent ponent Pressure, servo pump Pressure, differential lock System pressure, transmission 1000 Switching pressure, PTO 1000 Switching pressure, travel Lubrication pressure, rear axle range I...
Page 336: Measuring Transmission Pressure
1005 - Overall system/transmission E - Measuring and testing Measuring transmission pressure In the event of complaints regarding Vario tractors that indicate malfunctions in the transmission or are gener- ally captured under the heading "Power", proceed as follows. It must be determined whether the complaint is attributable to inadequate engine power or inadequate power from the drive train (transmission).
Page 337: Transmission Pressure Measurement (Fax Template)
1005 - Overall system/transmission E - Measuring and testing Transmission pressure measurement (fax template) Workshop (Address): Workshop (Customer number): Chassis number: Operating hours: Complaint (if available: specify the fault code) Date, Signature For all transmission pressure measurements, all 4 tractor wheels must be jacked up to prevent ANGER the risk of accident! I.
Page 338 1005 - Overall system/transmission E - Measuring and testing Load PH high-pressure circuit for max. 5 seconds, performing the following measurements at the same time. Measuring point Engine speed Setpoint value in bar Actual value in bar 1600 26±2 1600 22±2 1600 15±2...
Page 339: Enhanced Control Pressure Measurement: Transmission (Fax Template)
1005 - Overall system/transmission E - Measuring and testing Enhanced control pressure measurement: transmission (fax template) Workshop (Address): Workshop (Customer number): Chassis number: Operating hours: Complaint (if available: specify the fault code) Date, Signature Check switch function pressures Measuring point Engine speed rpm Setpoint value in bar Actual value in bar...
Page 340: Inspecting The Clutch Or Turbo-Clutch Pressure-Limiting Valve
1005 - Overall system/transmission E - Measuring and testing Inspecting the clutch or turbo-clutch pressure-limiting valve Turbo-clutch pressure-limiting valve 4V4/Y004 If the max. pressure is not reached during a high pressure measurement, the cause may originate from the drive train or may lie outside in the valve block.
Page 341 1005 - Overall system/transmission E - Measuring and testing Screw in the hex. socket head screw Fig. 8. I002100 Clutch pressure-limiting valve 4V5 The clutch pressure-limiting valve is fitted to the valve block, which also comprises the connection from the PH high pres- sure to the tank.
Page 342 1005 - Overall system/transmission E - Measuring and testing Checking the high-pressure circuit in the valve block The following tasks must be carried out: Support the tractor safely on four support trestles (high pressure measurement) ANGER – Remove the right rear wheel as well as the cover panels –...
Page 343: Enhanced Control Hydraulics Valve Block (Rear Axle)
1005 - Overall system/transmission E - Measuring and testing Enhanced control hydraulics valve block (rear axle) Fig. 10. I001568 Fig. 11. I001391 T000506 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 344: Valve Block, Inlet/Lubrication
1005 - Overall system/transmission E - Measuring and testing Valve block, inlet/lubrication Fig. 12. I001389 Radiator bypass valve (3.5 bar) Pressure-limiting valve, servo-pump (50 Pressure-limiting valve, outlet (6.5 bar) bar) Pressure-limiting valve, inlet (6.5 bar) Pressure-limiting valve, servo-circuit (25 bar) T000469 919 ..
Page 345 1010 General Faults Transmission/differential Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 347 1010 - Transmission/differential Table of contents 1010 Transmission/differential Repair........5...
Page 348 1010 - Transmission/differential Table of contents...
Page 349 1010 - Transmission/differential Table of contents G Repair Remove differential gear ........... 7 Installing the differential .
Page 350 1010 - Transmission/differential Table of contents...
Page 351: Remove Differential Gear
1010 - Transmission/differential G - Repair Remove differential gear Preliminary work: – see §1 The work was carried out on a model for greater clarity. Carry out the following tasks on both sides. Unscrew the hand brake release screw on the Tristop cyl- inder by turning counterclockwise until it becomes notice- ably more difficult to turn, then tighten as far as it will go with a spanner (SW24)
Page 352 1010 - Transmission/differential G - Repair Remove lower part of brake cylinder Fig. 4. I010440 Remove brake plate hex bolts Fig. 5. I002637 Remove brake plate using a slide hammer puller Fig. 6. I002638 Remove brake plate Fig. 7. I002639 T000820 919 ..
Page 353 1010 - Transmission/differential G - Repair Remove shaft Fig. 8. I002643 Remove front disc pack Fig. 9. I002644 Remove actuator plate and rear disc pack Fig. 10. I002645 Attach hoisting gear to differential gear Fig. 11. I002649 T000820 919 .. 0101-1000 925 ..
Page 354 1010 - Transmission/differential G - Repair Press off bearing flange with jack screws Fig. 12. I002646 Remove bearing flange Fig. 13. I002647 Remove differential gear using the hoisting gear Fig. 14. I002648 T000820 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 355: Installing The Differential
1010 - Transmission/differential G - Repair Installing the differential The work was carried out on a model for greater clarity. Fit the differential in the transmission housing using the hoisting gear Fig. 15. I002668 The following tasks must be carried out on both sides. Starting on the right side. Fit stud bolts (M12x180) as a mounting aid Fig.
Page 356 1010 - Transmission/differential G - Repair Fit the spacer Fig. 18. I002676 Fit the thrust ring with collar facing inwards Fig. 19. I002677 Fit the circlip Fig. 20. I002686 Fit 3 pairs of discs. Starting with the externally toothed discs Fit the externally toothed discs 90°...
Page 357 1010 - Transmission/differential G - Repair Fit the actuator plate Attach the 3rd and 4th externally toothed discs to the actuator plate Fig. 22. I002679 Fit remaining discs and thread in wheel axle Fig. 23. I002680 Fit brake plate with new shaft seal ring Fig.
Page 358 1010 - Transmission/differential G - Repair Using a rotating device and torque gauge, check the roll resistance to be 4–6Nm. If necessary, use an adjusting shim Fig. 26. I002735 Tighten hex bolts to 120 Nm Fig. 27. I002685 Fit lower part of brake cylinder Tightening torque for bolts: 69 Nm Adjust the rear wheel brake see §1...
Page 359 1010 - Transmission/differential G - Repair Connect air hoses and sensors Fig. 30. I002469 Screw in the hand brake release screw on the Tristop cyl- inder in a clockwise direction Fig. 31. I002468 T000823 919 .. 0101-1000 925 .. 1001- 934 ..
Page 360: Dismantling Differential Gear
1010 - Transmission/differential G - Repair Dismantling differential gear Preliminary work: – see §1 Loosen hex bolts Fig. 32. I002650 Loosen hex socket head screws Fig. 33. I002651 Press off the housing flange Fig. 34. I002652 T000821 919 .. 0101-1000 925 ..
Page 361 1010 - Transmission/differential G - Repair Remove the housing flange Fig. 35. I002653 Remove the disc package with axle bevel gear Fig. 36. I002654 Remove the ring gear Fig. 37. I002655 Remove the shaft hollow dowel pins Fig. 38. I002656 T000821 919 ..
Page 362 1010 - Transmission/differential G - Repair Remove the long shaft Fig. 39. I002657 Remove the short shaft Fig. 40. I002658 Remove the cross bearing Fig. 41. I002659 Remove the pinion gears and thrust rings Fig. 42. I002660 T000821 919 .. 0101-1000 925 ..
Page 363 1010 - Transmission/differential G - Repair Remove the axle bevel gear Fig. 43. I002661 Remove the ring disk Fig. 44. I002662 Remove the piston from the housing flange Fig. 45. I002663 Remove the taper roller bearing Fig. 46. I002669 T000821 919 ..
Page 364: Assembling The Differential Gear
1010 - Transmission/differential G - Repair Assembling the differential gear Fig. 47. I002670 Circlip Bevel gear set Shim Cylinder roller bearing Washer Spacer Taper roller bearing Ring Differential housing External disc Parallel pin Internal disc Ring Piston Dowel pin Lip seal Dowel pin Lip seal Axle...
Page 365 1010 - Transmission/differential G - Repair Heat the taper roller bearing (5) to approx. 90°C and fit it onto the housing flange (33) and differential housing (8) Risk of burns! AUTION Fig. 48. I002673 Fit the piston (28) with new lip sealing rings (29, 30) into the housing flange (33) Fig.
Page 366 1010 - Transmission/differential G - Repair Lay the axle bevel gear (18) in the differential housing (8) Fig. 52. I002661 Fit the cylinder roller ring (22) into the differential bevel gears Emplace the cylinder rollers with heavy grease Fig. 53. I002672 Fit the differential bevel gears (19) with the thrust ring (17) Fig.
Page 367 1010 - Transmission/differential G - Repair Fit the long axle (14) and then the two short axles (15) and secure the axles (14, 15) with the dowel pins (12, 13) Fig. 56. I002664 Fit the axle bevel gear (20) Fig. 57. I002665 Fit the ring (25) along with the outer and inner discs (26, Fig.
Page 368 1010 - Transmission/differential G - Repair Fit the hex. bolts (35) and the two hex. socket head bolts (36) Torque value for the hex. bolt (35): 120 Nm Fig. 60. I002667 Fit the rectangular-section rings (38) Fig. 61. I002734 T000822 919 ..
Page 369: Dismantling The Pinion Shaft
1010 - Transmission/differential G - Repair Dismantling the pinion shaft Preliminary work: – see §1 – Separate the rear axle from the transmission housing The work was carried out on a model for greater clarity. Remove the pinion shaft lubricating line Fig.
Page 370 1010 - Transmission/differential G - Repair Remove the pinion shaft Fig. 65. I002691 Remove the bevel roller bearings from the pinion shaft Fig. 66. I002712 Remove the securing ring and toothed gear Fig. 67. I002692 Remove the bevel roller bearing Fig.
Page 371 1010 - Transmission/differential G - Repair Remove the adjustment spacer Fig. 69. I002689 T000824 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 ..
Page 372: Adjusting And Fitting The Pinion Shaft
1010 - Transmission/differential G - Repair Adjusting and fitting the pinion shaft Fig. 70. I002713 Spigot bush Circlip Locating ring Spur gear Circlip Taper roller bearing Ring Oil tray Ring Shim pack Shim pack Pinion shaft Oil tray Ring gear Taper roller bearing The work was carried out on a model for greater clarity.
Page 373 1010 - Transmission/differential G - Repair Determining dimension A: Determine bore depth from outer flange face. +0.1 Nominal dimension = 20 Fig. 71. I002694 Determining dimension E: Carefully roll in the tapered roller bearing before taking the measurement Carry out the measurement on a level surface (surface plate) +0.2 Nominal dimension = 20...
Page 374 1010 - Transmission/differential G - Repair Spacer thickness (16) S = G + A - E - F Dimension G = 190.02 Dimension A = 20.03 Dimension E = 20.2 Dimension F = 187 .00 2.85 Fig. 75. I002689 Fitting the pinion shaft Fit a spacer of the determined thickness onto the pinion shaft Fig.
Page 375 1010 - Transmission/differential G - Repair Press the oiled bearing outer ring of the taper roller bear- ing (14) into the transmission housing as far as it will go Fig. 79. I002697 Press the oiled bearing outer ring of the taper roller bear- ing (11) into the transmission housing as far as it will go Fig.
Page 376 1010 - Transmission/differential G - Repair Heat the taper roller bearing (11) to approx. 90°C and fit it to the pinion shaft, liberally oil the taper roller bearing Risk of burns! AUTION Fig. 83. I002701 Pre-tension the bearing with a drawing tool and threaded spindle Fig.
Page 377 1010 - Transmission/differential G - Repair Fit the circlip (5) Fig. 87. I002705 Fit the oil trays (10, 15) Fig. 88. I002706 T000825 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 378: Pinion Shaft - Ring Gear Backlash Adjustment
1010 - Transmission/differential G - Repair Pinion shaft - ring gear backlash adjustment Backlash adjustment calculation: Calculation: Target dimension A = X - E - 0.2 mm – X = Actual dimension, middle of pinion shaft to measurement surface of the rear axle housing (156) –...
Page 379 1010 - Transmission/differential G - Repair Checking the wear pattern Coat the sides of six to eight of the ring gear teeth with gear marking compound Fig. 92. I002682 Clean the sealing surfaces, apply sealing compound X903.050.074.000, mate the rear axle housing and the transmission housing, and screw together Tightening torque: 295 Nm for M16 Tightening torque: 580 Nm for M20...
Page 380 1010 - Transmission/differential G - Repair Screw the measuring device (self-made) into the pinion shaft and fit the measuring scale Set the measuring scale 34 mm from the middle of the pinion shaft Determine backlash in four positions. Target value = 0.2 mm + 0.05 Fig.
Page 381 1015 General Faults Transmission/axle drive Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 383 1015 - Transmission/axle drive Table of contents 1015 Transmission/axle drive Repair........5...
Page 384 1015 - Transmission/axle drive Table of contents...
Page 385 1015 - Transmission/axle drive Table of contents G Repair Dismantling and reassembling axle drive ........7...
Page 386 1015 - Transmission/axle drive Table of contents...
Page 388 1015 - Transmission/axle drive G - Repair Fig. 2. I003577 Item Designation Item Designation Internal gear Stud bolt M12 x 165 - 10.9 Spur gear Hex. nut M12-10 Axle Screw plug M30 x 1.5 Circlip Seal ring Cylinder roller ring Ring Hex screw Shim...
Page 390 1015 - Transmission/axle drive G - Repair Fig. 4. I003604 Item Designation Item Designation Internal gear Hex. nut M12-10 Spur gear Screw plug M30 x 1.5 Axle Seal ring Circlip Ring Cylinder roller ring Shim Hex screw Taper roller bearing Plate Taper roller bearing Dowel pin...
Page 391 1015 - Transmission/axle drive G - Repair Dismantling axle drive The task is carried out on the axle drive (flange). Logical repair of axle drive (stub shaft). Preliminary work: Remove the axle drive concerned Screw out socket head cap screws (19) by approx. 10 mm and lightly tap the ring gear (1) back Fig.
Page 392 1015 - Transmission/axle drive G - Repair Pre-tension the rear axle shaft bearing with the hex screw (10). Remove the planetary carrier (14) once more. Do not turn the rear axle shaft (31)! Fig. 9. I003612 Press the sectioned ring (25) out of the rear axle shaft (31) groove Remove shims Withdraw the dowel pin (12)
Page 393 1015 - Transmission/axle drive G - Repair Withdraw the inner ring from the taper roller bearing (28) using X899.980.159.000 extraction tool. Then push the shaft seal ring (30) off. Fig. 13. I003616 Assembling axle drive Assembly: Where removed: Press the outer ring of the taper roller bearing (28) in as far as it will go.
Page 394 1015 - Transmission/axle drive G - Repair Turn the axle housing (15) round. Heat the inner ring of the taper roller bearing (27) to ap- prox. 80°C and press it on as far as it will go. Lubricate the rear axle shaft bearing with transmission oil. Fig.
Page 395 1015 - Transmission/axle drive G - Repair Lightly tap the bearing in both directions, thus releasing its tension. Remove the planetary carrier once more. Select a shim (26) thickness that enables the sectioned ring (25) to be pushed in by light tapping with a hammer. Insert the dowel pin (12) into the rear axle shaft (31).
Page 396 1015 - Transmission/axle drive G - Repair If dismantled, attach the planet wheels. Emplace the snap ring onto the groove of the bush and press the bush (arrow) into the spur gear (2) (planet wheel) until the snap ring engages. The bush (arrow) cannot be dismantled.
Page 397 1015 - Transmission/axle drive G - Repair Clean the flange surface and then coat it with flange seal- ant X903.050.074. Fig. 29. I003632 Attach the ring gear (1). Tighten the socket head cap screws (19) to a torque of 86 Fig.
Page 398 1015 - Transmission/axle drive G - Repair T001212 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 .. 1001- 931 .. 0101-1000 925 ..
Page 399 1050 General Faults Transmission/housing Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 401 1050 - Transmission/housing Table of contents 1050 Transmission/housing Repair........5...
Page 402 1050 - Transmission/housing Table of contents...
Page 403 1050 - Transmission/housing Table of contents G Repair Separating tractor – engine and clutch housing ........7 Assembling tractor - engine and clutch housing .
Page 404 1050 - Transmission/housing Table of contents...
Page 405 1050 - Transmission/housing G - Repair Separating tractor – engine and clutch housing Preliminary work: – Lower the tractor completely at the front – Safely jack up the tractor and remove the wheels – Drain the coolant. – Drain hydraulic oil. –...
Page 406 1050 - Transmission/housing G - Repair Loosen the shaped brackets and remove the exhaust si- lencer Fig. 4. I001408 Loosen both shaped brackets Fig. 5. I003483 Remove the intermediate pipe Fig. 6. I003482 Loosen the bolts and remove the exhaust pipe Fig.
Page 407 1050 - Transmission/housing G - Repair Remove the earth cable on the right hand side of the en- gine Fig. 8. I003481 Unplug all connections on the right hand side of the en- gine and secure the cable set to the central control block Fig.
Page 408 1050 - Transmission/housing G - Repair Remove the auxiliary pump suction line Fig. 12. I003475 Loosen the hydraulic piping to the auxiliary pump Fig. 13. I003474 Loosen the hydraulic piping to the auxiliary pump flow monitor and remove the hydraulic piping Fig.
Page 409 1050 - Transmission/housing G - Repair Loosen the air piping at the screw coupling and remove the piping Fig. 16. I003470 Loosen the fuel pipe to the Sepra filter Fig. 17. I003478 Loosen the fuel pipe to the engine and remove the pipe Fig.
Page 410 1050 - Transmission/housing G - Repair Loosen the hydraulic piping to the oil temperature regula- tor and remove the piping Fig. 20. I003469 Loosen the hydraulic piping to the transmission oil cooler Fig. 21. I003468 Loosen the hydraulic piping to the transmission oil cooler Fig.
Page 411 1050 - Transmission/housing G - Repair Loosen the hydraulic piping to the oil temperature regula- tor and remove the piping Fig. 24. I003465 Remove the banjo bolt on the front EPC valve May vary according to the tractor equipment con- figuration Fig.
Page 412 1050 - Transmission/housing G - Repair Separate the hydraulic piping at the screw coupling Fig. 28. I003462 Separate the front axle hydraulic piping at the screw cou- pling Fig. 29. I003461 Remove the compressed air tank on the left rear axle Fig.
Page 413 1050 - Transmission/housing G - Repair Remove the left fuel tank Fig. 32. I003454 Remove the starter cable Fig. 33. I003453 Unplug all connections on the left side of the engine and secure the cable set to the transmission Fig. 34. I003452 Remove the panel between the clutch housing and the transmission housing...
Page 414 1050 - Transmission/housing G - Repair Loosen all hydraulic piping to the front axle suspension valve block Fig. 36. I003447 Loosen the front axle valve block bolts Fig. 37. I003446 Remove the front axle valve block Fig. 38. I003445 Loosen the hydraulic piping to the radiator plate Fig.
Page 415 1050 - Transmission/housing G - Repair Loosen the return line from the hydraulic oil cooler to the screw coupling and remove the piping Fig. 40. I003503 Separate the hydraulic piping from the steering and front hydraulics to the screw coupling Fig.
Page 416 1050 - Transmission/housing G - Repair Loosen hose clamps and remove the heating hoses. Fig. 44. I001423 Remove the hex. bolts from the left and right of the cab suspension Fig. 45. I001430 Remove the hydraulic oil filler neck Fig. 46. I003443 Remove the fuel pipe Fig.
Page 417 1050 - Transmission/housing G - Repair Fit the front wheels, place an assembly trolley under the engine and an assembly trestle under the clutch housing or the transmission housing Loosen the flange bolts between the engine and clutch housing at the left, right and top Do not remove the M20 hex.
Page 418 1050 - Transmission/housing G - Repair Assembling tractor - engine and clutch housing Present the engine to the tractor frame Fig. 50. I003439 Face the engine onto the clutch housing, ensuring that no hydraulic piping is snagged Ensure that the teeth of the drive shaft and the 4WD shaft fit the bushes.
Page 419 1050 - Transmission/housing G - Repair Fit the fuel pipe from right to left Fig. 54. I003442 Fit the hydraulic oil filler neck, replace the O-ring if neces- sary Fig. 55. I003443 Lower the front of the cab, fit one hex. bolt to both the left and right front cab bearing Tightening torque: 206 Nm Fig.
Page 420 1050 - Transmission/housing G - Repair Fit the shock absorber hex. bolt Tightening torque: 85 Nm Fig. 58. I001431 Fit the front cab suspension hex. bolt. Tightening torque: 85 Nm Fig. 59. I001472 Tighten the hydraulic piping for the steering and front hy- draulics on the left side of the tractor Fig.
Page 421 1050 - Transmission/housing G - Repair Tighten the hydraulic piping to the return screw coupling Fig. 62. I003503 Tighten the hydraulic piping to the radiator plate Fig. 63. I003202 Fit the front axle suspension valve block Fig. 64. I003445 Tighten the front axle valve block bolts Fig.
Page 422 1050 - Transmission/housing G - Repair Fit and tighten all hydraulic piping to the front axle suspen- sion valve block Fig. 66. I003447 Fit the panel between the clutch housing and transmis- sion housing Fig. 67. I003451 Fit the cable set to the left side of the engine and plug in all connections Fig.
Page 423 1050 - Transmission/housing G - Repair Fit the left fuel tank Fig. 70. I003454 Secure the left fuel tank with the retaining strap and bracket Fig. 71. I003455 Secure the compressed air reservoir on the left rear axle with the retaining strap Fig.
Page 424 1050 - Transmission/housing G - Repair Tighten the hydraulic piping to the front axle Fig. 74. I003461 Tighten the hydraulic piping Fig. 75. I003462 Fit and tighten the hydraulic piping for the front connec- tions May vary according to the tractor equipment con- figuration Fig.
Page 425 1050 - Transmission/housing G - Repair Tighten the banjo bolt on the front EPC valve May vary according to the tractor equipment con- figuration Fig. 78. I001656 Fit the hydraulic piping between the oil temperature reg- ulator and the front DA pressure-limiting valve and tighten it to the oil temperature regulator Fig.
Page 426 1050 - Transmission/housing G - Repair Fit and tighten the transmission oil cooler hydraulic piping Fig. 82. I003468 Fit the hydraulic piping between the oil temperature reg- ulator and the radiator plate and tighten it to the oil tem- perature Fig.
Page 427 1050 - Transmission/housing G - Repair Tighten the fuel pipe to the Sepra filter Fig. 86. I003478 Fit the air piping between the compressor and the piping and tighten the connection Fig. 87. I003470 Tighten the air piping to the compressor Fig.
Page 428 1050 - Transmission/housing G - Repair Tighten the hydraulic piping to the auxiliary pump Fig. 90. I003474 Fit and tighten the suction line between the auxiliary pump and the piping Fig. 91. I003475 Fit the cable set to the engine control unit and plug in all connections Fig.
Page 429 1050 - Transmission/housing G - Repair Fit the cable set to the right side of the engine and plug in all connections Fig. 94. I003480 Fit the earthing strip to the right side of the engine Fig. 95. I003481 Fit the exhaust pipe and tighten the screws Fig.
Page 430 1050 - Transmission/housing G - Repair Tighten both shaped brackets Fig. 98. I003483 Fit the exhaust silencer using the shaped brackets and tighten them Fig. 99. I001408 Mount fuel tank on right Fig. 100. I003487 Fit the battery box, cable plate and battery Fig.
Page 431 1050 - Transmission/housing G - Repair Screw in and tighten the front axle suspension lock valves Fig. 102. I003206 Final procedures: – Fit and clamp the battery – Fit all panels – Top up coolant water – Fill up hydraulic oil –...
Page 432 1050 - Transmission/housing G - Repair T001195 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 .. 1001- 931 .. 0101-1000 925 ..
Page 433 1070 General Faults Transmission / Brake system Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 435 1070 - Transmission / Brake system Table of contents 1070 Transmission / Brake system Documents and diagrams ..... .5 Setting and calibrating ..... . .15...
Page 436 1070 - Transmission / Brake system Table of contents...
Page 437 1070 - Transmission / Brake system Table of contents C Documents and diagrams Technical drawing of the rear wheel brake ........7 Technical drawing of actuator cylinder and wheel brake cylinder .
Page 438 1070 - Transmission / Brake system Table of contents...
Page 440 1070 - Transmission / Brake system C - Documents and diagrams Brake discs Fig. 2. I003574 T001210 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 ..
Page 441 1070 - Transmission / Brake system C - Documents and diagrams Actuator plate Fig. 3. I003575 Rear wheel brake adjustment information Chapter 1070 Reg. F - Adjusting the rear wheel brake Chapter 1070 Reg. C - Technical drawing of the wheel brake cylinder T001210 919 ..
Page 442 1070 - Transmission / Brake system C - Documents and diagrams Technical drawing of actuator cylinder and wheel brake cylinder Diagram: Actuator cylinder and wheel brake cylinder Fig. 4. I001911 Item Designation Item Designation Brake release screw Wheel brake cylinder Foot brake connection (Note: The foot brake is Actuation cylinder (tri-stop-cylinder) applied with compressed air)
Page 443 1070 - Transmission / Brake system C - Documents and diagrams Wheel brake cylinder (2-circuit brake) Fig. 5. I001912 Fig. 6. I001913 T002613 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 444 1070 - Transmission / Brake system C - Documents and diagrams Wheel brake cylinder (1-circuit brake) Fig. 7. I001918 Fig. 8. I001919 T002613 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 445 1070 - Transmission / Brake system C - Documents and diagrams Technical drawing of the wheel brake cylinder Wheel brake cylinder, 1-circuit brake (40, 50 km/h) 1-circuit = Rear wheel brake + 4WD engagement when braking Fig. 9. I001919 Wheel brake cylinder, 2-circuit brake (40, 50, 60 km/h) 1-circuit = Rear wheel brake 2-circuit = Front wheel brake T001208...
Page 446 1070 - Transmission / Brake system C - Documents and diagrams Fig. 10. I001913 Testing options and adjustment of the tractor brake For brake actuation, please see: Chapter 8800 Reg. C – 1-circuit brake diagram (compressed air system) Chapter 8800 Reg. C – 2-circuit brake diagram (compressed air system) For checking tractor brake (compressed air system), please see: Chapter 8800 Reg.
Page 447 1070 - Transmission / Brake system Table of contents F Setting and calibrating Adjusting rear wheel brake..........17 Magnet setting for S005/S006 switch, right/left brake .
Page 448 1070 - Transmission / Brake system Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 449 1070 - Transmission / Brake system F - Setting and calibrating Adjusting rear wheel brake Preliminary work: – Position the tractor on a level surface and ensure it cannot move – Apply the hand brake – Remove the rear wheel Unscrew the hand brake release screw on the Tristop cyl- inder by turning counterclockwise until it becomes notice- ably more difficult to turn, then tighten as far as it will go...
Page 450 1070 - Transmission / Brake system F - Setting and calibrating Loosen the fixing bolts on the upper part of the cylinder Fig. 4. I002470 Remove the Tristop cylinder and the cylinder upper part Fig. 5. I002477 Loosen the locknut (SW 36) on the lower part of the cyl- inder, holding the guide piston (SW41) against it.
Page 451 1070 - Transmission / Brake system F - Setting and calibrating Loosen the adjustment screw (approx. 1 turn) Fig. 8. I002472 Tighten the adjustment screw to a torque of 7 Nm (or block rear wheel) Fig. 9. I002474 Unscrew the adjustment screw 6.5 turns Fig.
Page 452 1070 - Transmission / Brake system F - Setting and calibrating Tighten the locknut and guide piston to a torque of 80 Nm + 20 Nm Fig. 12. I002476 Fit the cylinder upper part and Tristop cylinder and tighten the fixing bolts Tightening torque: 86 Nm Fig.
Page 453 1070 - Transmission / Brake system F - Setting and calibrating Magnet setting for S005/S006 switch, right/left brake Setting the S005/S006 switch magnets Fig. 16. I001649 Setting instructions for brake pedal Set the adjustment screw (1) to 256 mm. Adjust piston rod play 0.9 mm (1/2 turn on the push rod (2) equals approx.
Page 454 1070 - Transmission / Brake system F - Setting and calibrating Setting instructions for magnet (4) Fig. 17. I001650 If necessary: unlock brake pedals, set individually. Place shims between buffer (1) and brake pedal (2) to provide a space of 3 mm. This corresponds to a pedal travel of approx.
Page 455 1070 - Transmission / Brake system F - Setting and calibrating S086/S087 switch, adjust brake wear – Release handbrake, ensuring that there is sufficient pressure in the tank – Foot brake not applied Secure the vehicle to prevent it from rolling away! ANGER Disconnect plug from the switch and connect adapter ca- ble X899.980.246.204...
Page 456 1070 - Transmission / Brake system F - Setting and calibrating Mark switch relative to the housing Fig. 21. I007223 Turn switch back 1 4/6 turns When the switch is turned back, the multimeter will switch back to 120 Ohm Fig.
Page 457 1080 General Faults Transmission/drive train Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 459 1080 - Transmission/drive train Table of contents 1080 Transmission/drive train General........5 Repair.
Page 460 1080 - Transmission/drive train Table of contents...
Page 461 1080 - Transmission/drive train Table of contents A General 2V3/2V4 high-pressure limiting valve ......... . 7 2V5 purge valve (function) .
Page 462 1080 - Transmission/drive train Table of contents...
Page 463 1080 - Transmission/drive train A - General 2V3/2V4 high-pressure limiting valve Fig. 1. I002165 If the clutch and turbo-clutch valve is The pressure is limited by the clutch and closed, the pressure is equal in both cham- turbo-clutch valves. bers. The spring holds the piston closed. If the clutch or turbo-clutch valve is open, the pressure drop through the diaphragm (x piston surface area) becomes greater than...
Page 464 1080 - Transmission/drive train A - General 2V5 purge valve (function) Pressure at A, B max. 550 bar Pressure at T max. 50 bar Opening pressure: delta p = 7 bar between A and B Fig. 2. I002166 Transmission in "neutral" pA = pB, delta p <...
Page 465 1080 - Transmission/drive train Table of contents G Repair Dismantling the continuous drive train........11 Fit the continuous drive train .
Page 466 1080 - Transmission/drive train Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 467: Dismantling The Continuous Drive Train
1080 - Transmission/drive train G - Repair Dismantling the continuous drive train Preliminary work: – Remove rear wheels – Remove cover panels – see §1 Drain transmission oil. Fig. 1. I001718 Loosen compressed air bracket Fig. 2. I001811 Remove the left hand fuel tank retaining strap Fig.
Page 468 1080 - Transmission/drive train G - Repair Unscrew the retaining strap bracket Fig. 4. I001813 Push the bracket to the side and remove Fig. 5. I001815 Remove the housing cover screws Fig. 6. I001814 Carefully take the weight of the housing cover and raise it Do not walk or stand under sus- ANGER pended loads!
Page 469 1080 - Transmission/drive train G - Repair Remove the actuator unit Fig. 8. I001818 Remove the plug on the transmission valve block sole- noid valves Fig. 9. I001819 Remove the hydraulic piping between the valve block and the valve housing Fig.
Page 470 1080 - Transmission/drive train G - Repair Loosen the pipe clamps Fig. 12. I001824 Loosen the hydraulic piping to the hydraulic oil cooler on the engine and remove the piping Fig. 13. I001825 Remove the valve block Fig. 14. I001823 Unscrew the emergency actuation unit Fig.
Page 471 1080 - Transmission/drive train G - Repair Loosen the transmission valve block retaining screws Fig. 16. I001827 Remove the transmission valve block Fig. 17. I001828 Unclip the securing rings and press the hydraulic piping in- wards Separate the steel piping Fig.
Page 472 1080 - Transmission/drive train G - Repair Dismantle sensor, collecting shaft Fig. 20. I001830 Dismantle sensor, bevel pinion Fig. 21. I001831 Unscrew the stud bolt and withdraw the actuator shaft Fig. 22. I002826 Remove the hydraulic hose (enhanced switching pres- sure supply) Fig.
Page 473 1080 - Transmission/drive train G - Repair Unclip the drive shaft securing ring and push it to the rear Fig. 24. I002829 Remove three M8 hex. screws from the planetary gear and push the drive shaft to the rear Fig. 25. I002830 Unclip the securing ring on the pinion shaft Push the securing ring, washer and sleeve onto the bevel...
Page 474 1080 - Transmission/drive train G - Repair Remove the hex. nuts from the bearings Fig. 28. I002834 Loosen the upper locking screws M12 Remove the two screw plugs on the under side of the transmission housing Collect any escaping oil. Loosen the two locking screws M12 as above Fig.
Page 475 1080 - Transmission/drive train G - Repair Raise transmission unit carefully out of transmission housing using hoist Ensure clearance of all components! Do not walk or stand under sus- ANGER pended loads! Fig. 32. I002838 T000666 919 .. 0101-1000 925 .. 1001- 934 ..
Page 476: Fit The Continuous Drive Train
1080 - Transmission/drive train G - Repair Fit the continuous drive train Attach transmission unit to hoist, taking appropriate safety precautions. Set travel range control I-II (arrowed) to neutral (middle) Fig. 33. I002893 Clean sealing surfaces on transmission housing to re- move oil and seal residue.
Page 477 1080 - Transmission/drive train G - Repair Check the bushes for wear and, if necessary, use new bushes Insert four bushes into bores as far as they will go Fig. 37. I002880 Fit the rings to the left and right as appropriate to the shaft, with the cut-out towards the bushing Screw on the M20 nuts Fig.
Page 478 1080 - Transmission/drive train G - Repair Tighten all four securing screws (two above, two be- neath) Torque: 86 Nm Using new seals, fit both screw plugs to the underside of the transmission housing Switch through travel range control I-II Fig.
Page 479 1080 - Transmission/drive train G - Repair Slide the sleeve on the pinion shaft forwards until the groove for the circlip is uncovered Clip circlip into groove If the sleeve is not aligned, jack up one of the front wheels and turn it Fig.
Page 480 1080 - Transmission/drive train G - Repair Fit the hydraulic hose (enhanced switching pressure sup- ply) Fig. 49. I002828 High-pressure reverse sensor lines System pressure, rear axle Switching pressure, travel range I Speed governor Switching pressure, travel range II System pressure Control line for high-pressure limiting valves Insert the pressure hoses in the transmission housing...
Page 481 1080 - Transmission/drive train G - Repair Place new O-rings into the valve housing with a small amount of grease and tighten the securing bolts Torque: 25 Nm Fig. 53. I002900 If necessary, fit the new shaft sealing ring and fill 2/3 with grease Fit the actuator shaft Fig.
Page 482 1080 - Transmission/drive train G - Repair Fit the coolant piping and tighten the screw coupling on the engine Fig. 57. I001825 Tighten the coolant piping on the valve housing Fig. 58. I001822 Tighten the piping clamps Fig. 59. I001824 Fit the hydraulic piping between the valve block and the valve housing Fig.
Page 483 1080 - Transmission/drive train G - Repair Tighten the hydraulic piping Fig. 61. I001820 Fit the actuator unit and tighten the hex. socket head screws Torque: 25 Nm Fig. 62. I001818 Fit the screw plugs on the underside of the transmission housing Fig.
Page 484 1080 - Transmission/drive train G - Repair Coat the clean sealing surfaces evenly with X903.050.074 sealing compound Carefully raise the transmission housing cover and fit it Do not walk or stand under sus- ANGER pended loads! Fig. 65. I001816 Tighten the housing cover bolts Torque: 120 Nm Fig.
Page 485 1080 - Transmission/drive train G - Repair Fit the left fuel tank retaining strap and tighten the nut Fig. 69. I001812 Fit the compressed air bracket and tighten the bolts Fig. 70. I001811 Final procedures: – see §6 – see §2 T000671 919 ..
Page 486: Installing A009 Actuator Unit
1080 - Transmission/drive train G - Repair Installing A009 actuator unit A009 actuator unit X037 separation point on actuator unit On the right side of the transmission Remove right rear wheel. Remove metal panel Fig. 71. I001024 Fig. 72. I000691 Item Designation Item...
Page 487 1080 - Transmission/drive train G - Repair Fig. 73. I000690 Item Designation Item Designation Shaft Hex screw Shaft seal ring Deep-groove ball bearing A009 actuator unit Governor Circlip O-ring Locating ring Dowel pin Belleville spring Hex screw Deep-groove ball bearing Parallel pin Shim pack Actuator shaft...
Page 489 1080 - Transmission/drive train G - Repair Connect carrier coupling with the two increases (arrow) pointing towards the actuator unit Fig. 75. I000711 Fit pre-mounted actuator unit to the transmission housing Tighten the M8 socket head cap screws to 25 Nm Connect electrical cables Fig.
Page 490: Replacing High-Pressure Limiting Valve
1080 - Transmission/drive train G - Repair Replacing high-pressure limiting valve Preliminary work: Drain off transmission oil (approx. 87 l), unscrew the two screw plugs on the underside of the transmission. Dismantle 2V3 or 2V4 using socket spanner (SW 27) 2V3 = high-pressure limiting valve, forwards 2V4 = high-pressure limiting valve, reverse Fig.
Page 491: Replacing The Purge Valve
1080 - Transmission/drive train G - Repair Replacing the purge valve Preparatory work: Drain off transmission oil (approx. 87 l), unscrew the screw plugs on the underside of the trans- mission. Dismantle the 2V5 = purge valve using a socket wrench (SW 22) Fig.
Page 492: Top Up The Transmission Oil
1080 - Transmission/drive train G - Repair Top up the transmission oil During normal maintenance work, e.g. transmission oil change and/or filter change, top up transmission oil at rear left. Observe instructions for oil type and quantity. First filling approx. 87 l Refilling approx.
Page 493 1200 General Faults Transmission/front PTO Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 495 1200 - Transmission/front PTO Table of contents 1200 Transmission/front PTO Documents and diagrams ..... .5 Measuring and testing ......11...
Page 496 1200 - Transmission/front PTO Table of contents...
Page 497 1200 - Transmission/front PTO Table of contents C Documents and diagrams Technical drawing of front PTO ..........7 Technical drawing: front PTO drive .
Page 498 1200 - Transmission/front PTO Table of contents...
Page 499 1200 - Transmission/front PTO C - Documents and diagrams Technical drawing of front PTO Fig. 1. Front PTO transmission I002975 T001201 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 500 1200 - Transmission/front PTO C - Documents and diagrams Fig. 2. Front PTO clutch I003543 T001201 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 ..
Page 501 1200 - Transmission/front PTO C - Documents and diagrams Technical drawing: front PTO drive Fig. 3. I003561 Greased screw seat Assembly sequence: 1. Tighten axial bolts (tightening torque = 220 Nm) 2. Tighten radial bolts (tightening torque = 220 Nm) For drive belt change: Loosen the radial bolts and slide the bush forwards T001206...
Page 502 1200 - Transmission/front PTO C - Documents and diagrams Fig. 4. I003562 Item Designation Item Designation Adapter Connecting sleeve Socket head cap screw Clutch Bush Socket head cap screw T001206 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 ..
Page 503 1200 - Transmission/front PTO Table of contents E Measuring and testing Checking the front PTO system and clutch pressure......13 919 ..
Page 504 1200 - Transmission/front PTO Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 505 1200 - Transmission/front PTO E - Measuring and testing Checking the front PTO system and clutch pressure Circuit diagram: Front PTO valve block Fig. 1. I003545 T001202 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 ..
Page 506 1200 - Transmission/front PTO E - Measuring and testing Item Designation Item Designation Front PTO - brake Oil filter: Bypass = 7 bar Front PTO - clutch Y011 Front PTO solenoid valve Front PTO OFF= 0 ADC Front PTO ON = approx. 1.7 ADC Hydraulic pump: System pressure Pressure-limiting valve (DBV): 25 bar...
Page 507 1200 - Transmission/front PTO E - Measuring and testing Check the clutch pressure and system pressure Fig. 2. I003548 T001202 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 508 1200 - Transmission/front PTO E - Measuring and testing M1 = system pressure M2 = clutch pressure at the on front PTO transmission Fig. 3. I003549 System pressure (M1) Clutch pressure (M2) Front PTO OFF approx. 4 bar 0 bar Y011 solenoid valve de-energised (clutch open, brake closed) Front PTO ON...
Page 509 1200 - Transmission/front PTO E - Measuring and testing Item Designation Item Designation Spring washer Hex screw Hose bend Spring washer Hose clamp Pressure pipe Prefilter strainer Suction pipe Pressure pipe Gasket Flange socket Washer O-ring Screw plug (only for 1-circuit brake) Socket head cap screw Seal ring Socket head cap screw...
Page 510 1200 - Transmission/front PTO E - Measuring and testing Item Designation Item Designation Shaft seal ring Seal ring Circlip Socket head cap screw Notched ring Washer O-ring Socket head cap screw Description Delivery rate Oil pressure Tractors with 1-circuit brake and front 8 cc/revolution 25 bar Drive ratio = 0.896...
Page 511 1220 General Faults Transmission / Live PTO Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 513 1220 - Transmission / Live PTO Table of contents 1220 Transmission / Live PTO Documents and diagrams ..... .5 Repair........9...
Page 514 1220 - Transmission / Live PTO Table of contents...
Page 515 1220 - Transmission / Live PTO Table of contents C Documents and diagrams Technical drawing of live PTO ..........7...
Page 516 1220 - Transmission / Live PTO Table of contents...
Page 517 1220 - Transmission / Live PTO C - Documents and diagrams Technical drawing of live PTO Fig. 1. I001469 T002636 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 518 1220 - Transmission / Live PTO C - Documents and diagrams T002636 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 .. 1001- 931 ..
Page 519 1220 - Transmission / Live PTO Table of contents G Repair Assembling and removing live PTO clutch........11 Assembling and dismantling live PTO clutch and gears.
Page 520 1220 - Transmission / Live PTO Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 521 1220 - Transmission / Live PTO G - Repair Assembling and removing live PTO clutch Fig. 1. I001469 T001259 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 ..
Page 522 1220 - Transmission / Live PTO G - Repair Fig. 2. I003639 T001259 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 ..
Page 523 1220 - Transmission / Live PTO G - Repair Fig. 3. I003640 Item Designation Item Designation Shim Hex screw Deep-groove ball bearing Spring washer Bell housing Bush Socket head cap screw Spur gear Locating ring Deep-groove ball bearing Internally toothed disc carrier Nozzle Shim Half-ring...
Page 524 1220 - Transmission / Live PTO G - Repair Preliminary work: – Lower the rear power lift – Drain transmission oil (approx. 67 l) – Remove the trailer hitch – Mark and unplug the X169 separation point at the B020 rear PTO stub shaft sensor –...
Page 525 1220 - Transmission / Live PTO G - Repair Remove the nozzle (29) Fig. 8. I003645 Set up the X899.980.145 jig. Tighten the clutch. Remove the half-rings (30) Remove the internal toothed disc carrier (6) and disc pack- age (10). Fig.
Page 526 1220 - Transmission / Live PTO G - Repair Remove one hex screw (21) and dismantle the disc (18). Fig. 12. I003649 Snap out the circlip (31) and remove the brake disc (20). Fig. 13. I003650 Assembling the PTO clutch Place the new O-ring (32) in the groove of the shaft (35) and grease it.
Page 527 1220 - Transmission / Live PTO G - Repair Put the disc (18) in place. Coat the threads of the hex screw (21) with X 903.054.084 synthetic bonding agent. Attach the spring washer (22) and bush (23). Tighten the hex screw Fig.
Page 528 1220 - Transmission / Live PTO G - Repair Determine the preload of the belleville springs (9) If it has been removed: Mount the locating ring (5) on the internal toothed disc carrier (6). Coat the threads of the socket head cap screw (4) with X 903.050.084 synthetic bonding agent.
Page 529 1220 - Transmission / Live PTO G - Repair Thread the disc package (10) on the internally toothed disc carrier (6). Starting with an externally toothed disc (11), continue alternately with an internally toothed disc (12). In the process, the narrow groove (item 2) in each inter- nally toothed disc (12) and the broad groove (item 3) in ev- ery other internally toothed disc (12) must be aligned.
Page 530 1220 - Transmission / Live PTO G - Repair Coat the thread of the nozzle (29) with X 903.050.084 syn- thetic bonding agent. Tighten the nozzle (29) with a torque of 25 Nm . Fig. 28. I003670 If it has been removed: Press the deep-groove ball bearing (28) with the closed side facing the top into the clutch bell housing (3) until it fits in place.
Page 531 1220 - Transmission / Live PTO G - Repair Clean the flange surfaces. Ensure that the two locating pins (arrowed) are fitted. Coat flange surface with X 903.050.074 surface sealant. Fig. 32. I003675 Place the existing shims (1) in the upper bore. Determining the shim (1) see §2 Fit and grease four new O-rings for the pressure connec-...
Page 532 1220 - Transmission / Live PTO G - Repair Assembling and dismantling live PTO clutch and gears PTO transmission Fig. 36. I001469 T001262 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 ..
Page 533 1220 - Transmission / Live PTO G - Repair Fig. 37. I003639 T001262 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 ..
Page 534 1220 - Transmission / Live PTO G - Repair Fig. 38. I003640 Item Designation Item Designation Shim Hex screw Deep-groove ball bearing Spring washer Bell housing Bush Socket head cap screw Spur gear Locating ring Deep-groove ball bearing Internally toothed disc carrier Nozzle Shim Half-ring...
Page 535 1220 - Transmission / Live PTO G - Repair Fig. 39. I003681 Item Designation Item Designation Taper roller bearing Circlip Locating ring Washer Clutch body Taper roller bearing Slider Shim Circlip Setscrew Washer Shaft seal ring Needle bearing O-ring Spacer Bearing cover Circlip Socket head cap screw...
Page 536 1220 - Transmission / Live PTO G - Repair PTO gear shift Fig. 40. I003726 T001262 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 ..
Page 537 1220 - Transmission / Live PTO G - Repair Fig. 41. I003682 Item Designation Item Designation Strap Hex screw Hex nut Cylinder Stud bolt O-ring Hex screw Compact seal ring Hex nut Compact seal ring Spacer sleeve Pressure spring Hex nut Piston Hex nut Piston...
Page 538 1220 - Transmission / Live PTO G - Repair Unscrew all fixing bolts and nuts. Remove the plugs from the threaded bores and screw in two jack screws M12 (arrows). Secure the housing cover in the hoist and release the housing cover.
Page 539 1220 - Transmission / Live PTO G - Repair If required, note the adjustment value of the hex nut (210 and 211). Unscrew the hex nuts (210 and 211). Remove the stops (116). Dismantle the shift gear. Fig. 47. I003684 Remove the spur gears (118) and (118a).
Page 540 1220 - Transmission / Live PTO G - Repair Snap out the circlip (107). Remove the washer (108) and the spur gears Fig. 51. I003688 Snap out the circlip (112). Press out the spur gear (118). Fig. 52. I003689 Assembling PTO transmission and shift gears Assemble the PTO transmission Press the deep-groove ball bearing (113) until it fits into the spur gear (118a).
Page 541 1220 - Transmission / Live PTO G - Repair Press the inner ring of the tapered roller bearing (123) on to the shaft (120). Fit the washer (120). Put the circlip (121) in place. Grease two setscrews (125) with X 903.050.084 syn- thetic bonding agent and turn them until they reach the in- ner ring of the tapered roller bearing (123).
Page 542 1220 - Transmission / Live PTO G - Repair Fit cylinder (217) and cylinder (226). Coat the threads of the hex screw (216) and (225) with X903.050.084 synthetic bonding agent and tighten them with a torque of 49 Nm . Fit the hydraulic lines that have been dismantled in the housing cover (316).
Page 543 1220 - Transmission / Live PTO G - Repair Insert the pre-assembled pair of wheels and spur gear (25). Fig. 63. I003700 Fit the pre-assembled strap (201) Coat the threads of the hex screw (205) with X903.050.084 synthetic bonding agent. Fit the spacers (207) and bearing jewels (214).
Page 544 1220 - Transmission / Live PTO G - Repair Insert the pre-assembled strap (201). Place the washer (212) with the depression facing down- wards. Fit the hex nuts (211) and (210). Fig. 67. I003704 Coat the threads of the hex screw (115) with X903.050.084 synthetic bonding agent.
Page 545 1220 - Transmission / Live PTO G - Repair In case of deviations: Change the adjusting nuts M12 above and below until the play is 0.1 mm ... 0.2 mm . Fig. 71. I003708 Remove the hoist. Unscrew the ring nut M12 (self-made). Tighten the hex nuts.
Page 546 1220 - Transmission / Live PTO G - Repair Remove the vice. The shift gear latches in the "Neutral" position The spur gears of the gear position 750 or 540 and 1000 must be free to turn. The free travel of the shift gear must be the same in both the up and down directions.
Page 547 1220 - Transmission / Live PTO G - Repair Adjust the play on the bearing of the bell housing (3) Fit the existing shim (1) or the shim (1) on the deep- groove ball bearing (2). Measure and record the distance to the flange surface. E.g.
Page 548 1220 - Transmission / Live PTO G - Repair Secure the housing cover in the hoist and fit the rear axle housing. Do not walk or stand under sus- ARNING pended loads! Fig. 83. I003643 Tighten the fixing bolts and nuts M18 with 400 Nm . Fig.
Page 549 1220 - Transmission / Live PTO G - Repair Turn the shaft (120) approx. 10 times. Attach gauge. Press in the shaft (120) once and observe the play. Fig. 87. I003721 Turn the shaft (120) approx. 10 times. Attach gauge. Pull back the shaft (120) once and observe the play.
Page 550 1220 - Transmission / Live PTO G - Repair Clamp the flange pin (137) tight with screw M16 (arrow). (Assembly kit) Tighten the hex nuts (134) (M10 - 10) with 69 Nm . Replenish transmission oil. Fig. 91. I003725 T001262 919 ..
Page 551 1320 General Faults Transmission/front wheel drive Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 553 1320 - Transmission/front wheel drive Table of contents 1320 Transmission/front wheel drive Repair........5...
Page 554 1320 - Transmission/front wheel drive Table of contents...
Page 555 1320 - Transmission/front wheel drive Table of contents G Repair Removing and dismantling the front wheel drive clutch ......7 Fitting the front wheel drive clutch .
Page 556 1320 - Transmission/front wheel drive Table of contents...
Page 557 1320 - Transmission/front wheel drive G - Repair Removing and dismantling the front wheel drive clutch Preliminary work: – see §1 – Separate the transmission housing from the clutch housing – Chapter ... The work was carried out on a model for greater clarity. Remove the screw M8 and the fixing washer Fig.
Page 558 1320 - Transmission/front wheel drive G - Repair Remove the suction filter Fig. 4. I002759 Remove the suction filter housing Fig. 5. I002760 Remove the hex bolts of the shielding panels Fig. 6. I002764 Remove the hex bolts and press off the cover with two screws Fig.
Page 559 1320 - Transmission/front wheel drive G - Repair Pull out the shaft with a slide hammer puller Fig. 8. I002762 Pull out the shaft After dismantling the shaft the front AUTION wheel drive clutch has no guide Risk of injury! Fig.
Page 560 1320 - Transmission/front wheel drive G - Repair Remove the spur gear Fig. 12. I002767 Remove the belleville package Fig. 13. I002768 Remove the piston and the disc package from the disc carrier Fig. 14. I002769 T000840 919 .. 0101-1000 925 ..
Page 561 1320 - Transmission/front wheel drive G - Repair Fitting the front wheel drive clutch The work was carried out on a model for greater clarity. Fig. 15. I002780 Item Designation Item Designation Cover Supporting plate Circlip Bell housing Cylinder roller bearing Dowel pin Shaft Washer...
Page 562 1320 - Transmission/front wheel drive G - Repair Fig. 16. I002781 Item Designation Item Designation Cover Supporting plate Circlip Bell housing Cylinder roller bearing Dowel pin Shaft Washer Screw plug Circlip Rectangular-section ring External disc Rectangular-section ring Internally toothed disc Disc carrier Supporting plate Snap ring...
Page 563 1320 - Transmission/front wheel drive G - Repair Fit new lip seal (22) into the piston disc (20) Fig. 17. I002770 Fit the piston disc (20) into the piston (18) Fig. 18. I002771 Fit new lip seal (19) and O-ring (21) into the disc carrier Fig.
Page 564 1320 - Transmission/front wheel drive G - Repair Fit the disc carrier (9) into the clutch bell housing (25) Fig. 21. I002791 Fit the supporting plate (32) and the disc package (30, 31) to the disc carrier Fit the supporting plate (32) with the groove to the bell housing (25) Begin with an internal disc (31) Fig.
Page 565 1320 - Transmission/front wheel drive G - Repair Fit the bellville spring pack (17) Both bellville springs with the curve upwards Fig. 25. I002795 Fit the spur gear (15) Fig. 26. I002767 Fit the assembly bracket Press the bellville spring pack (17) together with a clamp Snap on the circlip (14) Fig.
Page 566 1320 - Transmission/front wheel drive G - Repair Emplace and lock the rectangular-section rings (7, 8) into the grooves of the shaft (5) Turn each of the rectangular-section rings through 180° and grease Fig. 29. I002785 Fit the shaft (5) When fitting the shaft (5) ensure that the rectan- gular section rings (7, 8) are not damaged Fig.
Page 567 1320 - Transmission/front wheel drive G - Repair Fit the suction filter housing Fig. 33. I002760 Fit new O-rings to the suction pipe Fig. 34. I002776 Insert the suction pipe into the suction filter housing Fig. 35. I002799 Fit the screw M8 and fixing washer Fig.
Page 568 1320 - Transmission/front wheel drive G - Repair Fit the suction filter Fig. 37. I002759 Fit the suction filter cover with a new O-ring Fig. 38. I002758 Final procedures: – see §2 – see §6 T000844 919 .. 0101-1000 925 .. 1001- 934 ..
Page 569 2000 General Faults Overall system/engine Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 571 2000 - Overall system/engine Table of contents 2000 Overall system/engine General........5 Faults .
Page 572 2000 - Overall system/engine Table of contents...
Page 573 2000 - Overall system/engine Table of contents A General General description of the common rail system ....... . . 7 Emergency mode (emergency running) .
Page 574 2000 - Overall system/engine Table of contents...
Page 575: General Description Of The Common Rail System
2000 - Overall system/engine A - General General description of the common rail system All previous systems operated by generating the fuel injection pressure separately for each injection event. The injection pressure increases in principle with increasing fuel quantity and increasing engine speed. Between injection events, the pressure in the system is low.
Page 576 2000 - Overall system/engine A - General Fig. 1. I006081 Item Designation Item Designation Power supply Output signals (actuators) Output stage A051 ECU, engine control unit Micro-controller CAN connection to tractor EEPROM and diagnostics interface Monitoring module Input signals (sensors) Signal pre-processing Power supply High-pressure sensor...
Page 577 2000 - Overall system/engine A - General – programming Comparison between EMR 2 (COM II) and EMR 3 (COM III). Sensors and switches for EMR 2 (COM II) Component Duty B041 EMR (camshaft) sensor Reports the engine speed (actual value) B042 EMR (crankshaft) sensor Reports the engine speed (actual value);...
Page 578 2000 - Overall system/engine A - General Actuators of the EMR 3 (COM III) Component Duties B077 - Engine fan (speed sen- The fan speed is controlled via the engine control unit so that the coolant water sor/magnetic clutch) temperature is maintained at approx. 95°C. However, the fan can also be con- trolled by the hydraulic oil temperature and the transmission oil temperature.
Page 579: Emergency Mode (Emergency Running)
2000 - Overall system/engine A - General Emergency mode (emergency running) After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! If the A051 ECU, engine control unit (EDC 7) detects a fault in the fuel system, it initiates emergency mode. Warning message High-pressure limiting valve opened A fault code FC 1E.1.51 is logged Running in emergency mode means:...
Page 581 2000 - Overall system/engine A - General Item Designation Item Designation Right/left fuel tank B034 - Immersed tube sensor (fuel) Water sedimentor (pre-filter) B055 - Sensor, foot throttle Hand pump B085 - Camshaft speed sensor supply pump B086 - Rail pressure sensor Fuel filter (main filter) B087 - Fuel low pressure sensor High-pressure pump...
Page 582: A051 Ecu, Engine Control Unit (Edc 7)
2000 - Overall system/engine A - General A051 ECU, engine control unit (EDC 7) Fig. 3. I007324 T002538 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 2 922 .. 0101-1000 928 ..
Page 583 The A051 - ECU, engine control unit (EDC 7). forwards the EMR fault data to the A007 - Instrument panel, where the error messages are output on a display. (FENDT fault code) Fault diagnosis using the SERDIA service diagnostics program Reads all the sensors and the A051 - ECU, engine control unit (EDC 7).
Page 584 2000 - Overall system/engine A - General Displays measured values graphically ("program: Measured values graphics") Reads the fault log (SERDIA fault log) Tests the functioning of all actuators ("program: Function test") Loads engine data record using the Service - Diagnostics program (SERDIA) For optimum management of the diesel engine by the A051 - ECU, engine control unit (EDC 7)., the reference data (max- imum power, engine cut-off speed, the engine mapping field (injection quantity at a specific operating point), maximum permissible operating temperature etc.) must be loaded into the A051 - ECU, engine control unit (EDC 7)..
Page 585: B055 Sensor, Foot Throttle
2000 - Overall system/engine A - General B055 sensor, foot throttle Function Earth + supply (8.5 VDC) Signal Earth + supply (5.0 VDC) Signal Fig. 4. I001074 Duty: The B055 - Sensor, foot throttle conveys the driver's desired torque/power to the A051 - ECU, engine control unit (EDC 7)..
Page 586: B085 Camshaft Speed
2000 - Overall system/engine A - General B085 camshaft speed Function Signal Earth Shielding against interfer- ence Fig. 5. I001060 Functions of the B085 - Camshaft speed sensor Sensing the current engine position (cylinder 1 igni- tion) Sensing the engine speed (camshaft speed) for emer- gency running characteristics Self diagnosis Fig.
Page 587 2000 - Overall system/engine A - General Induction voltage and frequency Inductive sensor Induced voltage Fig. 7. I001547 Measurement of inductive sensors The inductive sensor receives pulses directly from a pulse generator (gearwheel or disc). Where the magnetic field of the inductive sensor is intersected by measuring points, an AC induction voltage (VAC) is generated.
Page 588: B086 Rail Pressure Sensor
2000 - Overall system/engine A - General B086 rail pressure sensor After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Function Earth Signal Supply Fig. 10. I001086 Item Designation Separation point Evaluation circuit Steel membrane with...
Page 589 2000 - Overall system/engine A - General Fig. 12. Voltage pressure diagram I001559 The B086 - Rail pressure sensor measures the current pressure in the high-pressure circuit and supplies a voltage signal to the A051 - ECU, engine control unit (EDC 7). for further processing. The exact reading of the high pressure in the rail is essential for the functioning of the common rail system.
Page 590 2000 - Overall system/engine A - General When the high-pressure limiting valve opens, the warning message "High-pressure limiting valve opened " is displayed on the A007 instrument panel. A fault code FC 1E.1.51 is logged Since high pressure (approx. 400 bar) is relieved via the pressure-limiting valve, the fuel is heated. Therefore, the diesel engine is switched off automatically by the A051 - ECU, engine control unit (EDC 7).
Page 591: B087 Fuel Low Pressure And B090 Oil Pressure Sensor
2000 - Overall system/engine A - General B087 fuel low pressure and B090 oil pressure sensor Function B087 Function B090 + supply + supply Signal Signal Not assigned Earth Earth Fig. 15. I001087 Duty: Component B087 - Fuel low pressure sensor reports the fuel low pressure (primary pressure) to the A051 - ECU, engine control unit (EDC 7).
Page 592: B088 Crankshaft Speed
2000 - Overall system/engine A - General B088 crankshaft speed Function Signal Earth Shielding against interfer- ence Fig. 16. I001060 Detection of current engine position (TDC cylinder 1 and cylinder 6) Detection of engine speed Self diagnosis Fig. 17. I005049 As the crankshaft rotates, the teeth of the gear plate on the flywheel induce an AC voltage (VAC) in the B088 - Crankshaft speed sensor.
Page 593: B089 Deutz Temperature Sensor
2000 - Overall system/engine A - General B089 Deutz temperature sensor Function Earth Signal Fig. 19. I001088 Duty: Component B089 - Engine temperature sensor (Deutz) reports the engine temperature to the A051 - ECU, engine control unit (EDC 7).. This temperature signal is used for many purposes: –...
Page 594 2000 - Overall system/engine A - General B091 water in fuel sensor Function Earth Signal Fig. 20. Version A I007328 Function Earth Signal Fig. 21. Version B I007329 Version A is fitted up to chassis numbers: 919/../1011; 922/../1006; 925/../1010; 928/../1013; 931/../1009; 934/../1083 Version B is fitted from the following chassis numbers onwards: 919/../1012;...
Page 595: B091 Water In Fuel Sensor
2000 - Overall system/engine A - General Fig. 22. Function I002155 Item Designation Item Designation Drain cock Vent Bleed screw B091 Water in fuel sensor Water sedimentor Electrode Water level The B091 - Sensor, water in fuel measures the water level in the water sedimentor. If the water level reaches the maxi- mum, the water forms a contact across the two electrodes.
Page 596: B092 Boost Pressure/Temperature Sensor
2000 - Overall system/engine A - General B092 boost pressure/temperature sensor Function Earth Temperature signal Supply Pressure signal Fig. 23. I005051 Duty: Component B092 - Sensor, charge air pressure/temperature reports the boost pressure and charge air temperature to the A051 - ECU, engine control unit (EDC 7). The B092 - Sensor, charge air pressure/temperature is a combination sensor.
Page 597: Starter Control
2000 - Overall system/engine A - General Starter control On the FENDT 900 COM III series, as on all other COM III tractors, the starter is controlled by means of the A051 - ECU, engine control unit (EDC 7).. Fig. 25.
Page 598: Starter
2000 - Overall system/engine A - General starter. Diagram: starter. Fig. 26. I000762 Item Designation Item Designation Pinion Exciter winding Gear rim Anchor Roller-type freewheel Commutator with carbon brushes Engagement lever Engagement relay with pull-in and hold-in wind- Planetary gear (reduction gear) K065 starter relay Pole shoe G001 battery...
Page 599 2000 - Overall system/engine A - General Diagram: Reduction gear starter with free running pinion Fig. 27. I002396 T002844 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 ..
Page 600: Calculating The Fuel Consumption Of A Diesel Engine
Tractor type Chassis no. Engine horsepower Fuel consumption (max. power ECE R24 under full load KW/HP) FENDT 922 Vario 919 / .. / ... 162 / 220 approx. 44 l/Rhr FENDT 924 Vario 922 / .. / ... 176 / 240 approx.
Page 601 2000 - Overall system/engine A - General Using the foot throttle (B055 foot throttle sensor), set the engine speed to approx. 2000 rpm, accelerate the tractor using the joystick (A039 multifunction armrest), engine speed reaches approx. 1800..1900 rpm. (The diesel engine is running in the partial-load operating range) Measuring fuel consumption with the Vario terminal (approx.
Page 602: Belt Drive: Deutz Tcd 2013
2000 - Overall system/engine A - General Belt drive: Deutz TCD 2013 Fig. 33. I001732 T000813 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 23-11-2007 922 ..
Page 603 2000 - Overall system/engine A - General Fig. 34. I002538 Fig. 35. I002550 T000813 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 23-11-2007 922 ..
Page 604: Air Intake And Exhaust Routing: Deutz Tcd 2013
2000 - Overall system/engine A - General Air intake and exhaust routing: Deutz TCD 2013 Diagram: Air intake and exhaust routing Fig. 36. I003270 Item Designation Item Designation Zyklon pre-cleaner Exhaust gas cooler Air filter Non-return valve Turbocharger (pump wheel P) Turbocharger (exhaust gas turbine T) Intercooler Wastegate (bypass valve)
Page 605 2000 - Overall system/engine A - General Item Designation Item Designation R002 Heater flange Silencer Note: Chapter 9000 Reg. E – Measuring and testing R002 heater flange B092 Boost pressure/charge air temperature sensor Engine brake Note: Chapter 9000 Reg. E – Measuring and testing B092 sensor Drulu Air compressor...
Page 606 2000 - Overall system/engine A - General R002 heater flange The heater flange is activated at temperatures below 5°C . It is preheated for approx. 1 minute. Ignition on, preheat indicator lit When the preheat indicator is extinguished, start the trac- tor ("Start readiness") At the front of the engine Fig.
Page 607 2000 - Overall system/engine A - General Non-return valve "chatter valve" (R) Fig. 44. I002586 Turbocharger (TL) T = turbine wheel (exhaust side) P = pump wheel (intake side) Wastegate = bypass valve At top in engine compartment Fig. 45. I002582 Y006 solenoid valve, engine brake At top in engine compartment, left side of...
Page 608 2000 - Overall system/engine A - General Air compressor (Drulu) On right of engine Fig. 48. I002607 Intake for the air compressor (Drulu) At top in engine compartment Fig. 49. I002608 T000815 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 609: Cleaning The Air Filter (With Zyklon Pre-Cleaner)
2000 - Overall system/engine A - General Cleaning the air filter (with Zyklon pre-cleaner) Function: Zyklon pre-cleaner Fig. 50. I002567 Dust is extracted via the fan (arrow) Fig. 51. I002568 T000816 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 610 2000 - Overall system/engine A - General Air filter Replacing air filter Open fasteners (A) and remove the cover Fig. 52. I002563 Pull out main cartridge (A) Clean filter housing and ensure sealing surfaces are free of defects Fig. 53. I002564 Clean main cartridge (A) Tap out the cartridge with the palm of the hand only...
Page 611 2000 - Overall system/engine A - General Fit cover (A) Fig. 56. I002563 T000816 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 ..
Page 612: Function: Turbocharger With Wastegate (Bypass Valve)
Fig. 57. I002590 The diesel engine in the FENDT 900 Vario is fitted with a wastegate turbocharger. Unlike a normal turbocharger, wastegate turbochargers are controlled by the engine speed. This means that full boost pressure is reached as early as approx. 1100 rpm.
Page 613: A051 Ecu, Engine Control Unit (Installing Engine Software)
Read off the serial number of the Serdia adapter Example: SN:131467 Report the Serdia adapter serial number to FENDT Cus- tomer Service: Telephone: +49 8342 / 77 - 123 Fax: +49 8342 / 77 - 222...
Page 614 A - General Determine the SERDIA password Read off the serial number (arrow) on the Serdia adapter. Example: SN:131467 Request the SERDIA password from FENDT Customer Service Telephone: +49 8342 / 77 - 123 Fax: +49 8342 / 77 - 222 Fig.
Page 615 2000 - Overall system/engine A - General Fig. 61. I003156 Open the Deutz diagnostics program (Serdia) Fig. 62. I003157 Green bar = connection established between A051 ECU, engine control unit and laptop Red bar = a connection has not been established between the A051 ECU, engine control unit and the laptop T000949 919 ..
Page 616 2000 - Overall system/engine A - General Fig. 63. I006506 Press the ECU selection button Fig. 64. I006507 Press the Program ECU button T000949 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 2 922 ..
Page 617 2000 - Overall system/engine A - General Fig. 65. I006508 Enter the Serdia password and confirm with OK Example: 12345 Fig. 66. I006509 Press the show button T000949 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 ..
Page 618 2000 - Overall system/engine A - General Fig. 67. I006510 The baud rate is displayed. The baud rate must be set to 67200. The A051 ECU, engine control unit memory is displayed. "Flash area selection" This section must be set to "All areas". Select with the "select file"...
Page 619 2000 - Overall system/engine A - General Fig. 68. I006511 Select the operating software file and open it. Example: C:\Program files\Deutz\Data\chassis number.hex Operating software: Type: Hex file Size: Approx. 800 KB Call up the operating software file with the open button. T000949 919 ..
Page 620 2000 - Overall system/engine A - General Fig. 69. I006512 Start the programming procedure with the programming button. A few prompts may appear after this. Confirm these prompts with "OK". After that, the programming routine will execute automatically. Fig. 70. I003157 T000949 919 ..
Page 621 2000 - Overall system/engine A - General When the operating software has been programmed successfully, the A051 ECU, engine control unit is read out again automatically. This display (arrow) first turns red (the A051 ECU, engine control unit is powered down) The display (arrow) then turns green again (the A051 ECU, engine control unit is powered up) Wait until the display (arrow) is steady green again.
Page 622 2000 - Overall system/engine A - General T000949 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 2 922 .. 0101-1000 928 .. 1001- 31-10-2008 922 .. 1001- 931 .. 0101-1000 925 ..
Page 623 2000 - Overall system/engine Table of contents B Faults Faults on the Common Rail diesel engine (without fault code) ..... 57 919 ..
Page 624 2000 - Overall system/engine Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 625 2000 - Overall system/engine B - Faults Faults on the Common Rail diesel engine (without fault code) Faults Cause Note The engine does Incorrect ignition key Chapter 9000 Reg. E – B083 immobiliser con- not start or starts The tractor has an immobiliser. When using an trol unit poorly unauthorised ignition key, the A051 ECU,...
Page 626 2000 - Overall system/engine B - Faults Faults Cause Note air in the fuel system Chapter 2060 Reg. A – Fuel system, Engine air bleed clogged Chapter 2210 Reg. A – Crankcase air bleed (overpressure in the crankcase) Fuel pump (gear driven) worn Chapter 2060 Reg.
Page 627 2000 - Overall system/engine B - Faults Faults Cause Note Engine has no or Wrong engine oil See the fuels and lubricants list too low oil pres- sure (warning message on A007 instru- ment panel) Engine oil level too low See the operating manual Engine incline too large See the operating manual...
Page 628 2000 - Overall system/engine B - Faults Faults Cause Note Engine emits Air filter clogged See the operating manual black smoke (burning of diesel) Y095/Y096/Y097/Y098/Y100/Y101 injector Chapter 9000 Reg. E – defective Y095/Y096/Y097/Y098/Y100/Y101 injector Incorrect fuel See the fuels and lubricants list T000963 919 ..
Page 629 2010 General Faults Engine/cylinder head Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 631 2010 - Engine/cylinder head Table of contents 2010 Engine/cylinder head Repair........5...
Page 632 2010 - Engine/cylinder head Table of contents...
Page 633 2010 - Engine/cylinder head Table of contents G Repair Adjusting valves (Deutz engine) ..........7...
Page 634 2010 - Engine/cylinder head Table of contents...
Page 635 80 °C) Inlet valve Exhaust valve Tractors with Deutz engine ("Common Rail " high-pressure accumulator) Note: 1. Cylinder on flywheel FENDT 900 Vario TCD 2013 L6 V4 75° 105° 20 Nm X899.980.236.03 COM3 X899.980.236.030 adjustment tool Fig.
Page 636 2010 - Engine/cylinder head G - Repair Adjusting valve clearance (FENDT 900 Vario COM3 / Deutz TCD 2013) See engine sign plate for engine type. See also: - Technical datasheets - Maintenance schedule Fig. 3. I002481 Remove fixing bolts from K063 heater flange relay Put K063 heater flange relay to one side Fig.
Page 637 2010 - Engine/cylinder head G - Repair EX = exhaust valve IN = inlet valve Fig. 7. I002485 1 = rocker arm 2 = valve spring 3 = push rod 4 = adjustment screw with locknut Fig. 8. I002489 Rotate the engine on the G002 or G004 alternator The engine can only be turned against its rota- tional direction Adjust valves according to valve adjustment diagram...
Page 638 2010 - Engine/cylinder head G - Repair Position X899.980.236.030 adjustment tool Loosen locknut Screw in the adjustment screw until the rocker arm lies directly on the valve with no clearance Set the indicator to 0 Turn back the adjustment screw until the required clear- ance is achieved.
Page 639 2010 - Engine/cylinder head G - Repair Refit the K063 heater flange relay Fig. 14. I002484 T002569 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 ..
Page 640 2010 - Engine/cylinder head G - Repair T002569 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 641 2050 General Faults Engine/cooling Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 643 2050 - Engine/cooling Table of contents 2050 Engine/cooling General........5 Repair.
Page 644 2050 - Engine/cooling Table of contents...
Page 645 2050 - Engine/cooling Table of contents A General Coolant circuit: Deutz TCD 2013 ..........7 B077 electrical viscous fan.
Page 646 2050 - Engine/cooling Table of contents...
Page 648 2050 - Engine/cooling A - General Item Designation Item Designation Wapu Water pump B089 Water temperature sensor Note: See also: Chapter 9000 Reg. E - Measuring and testing the B089 water temperature sensor Engine oil cooler (heat exchanger) Cooler cover: Important: Do not open the cooler cover unless the engine is cold! Coolant pre-heater (optional)
Page 649 2050 - Engine/cooling A - General WT = engine oil cooler (heat exchanger) On right side of engine Remove the filter mount The heat from the engine oil is transferred to the coolant in the engine oil cooler. The engine oil is cooled to approx. 120...130°C. When the engine is cold, the cold engine oil is heated by the warm coolant.
Page 650 2050 - Engine/cooling A - General The bush is caulked (rolled) against the cylinder (combus- tion chamber) (arrow) Remove the cylinder head Fig. 7. I002729 The cylinder liner is sealed off from the crankcase by two O-rings Fig. 8. I002730 Upper guidance and sealing of the cylinder liner with a conical guide Fig.
Page 651 2050 - Engine/cooling A - General Therm. = thermostat At the front of the engine Remove the thermostat housing Fig. 11. I002723 Water cooler with drain plug On left side of engine. Fig. 12. I002726 B089 water temperature sensor At front of the engine, on the thermostat housing Fig.
Page 652 2050 - Engine/cooling A - General A053 air conditioning unit (heater stepper motor and heat exchanger) Installed under the cab Open the service hatch in the cab floor Fig. 15. I001501 Exhaust gas recirculation (AGR) The recirculated gas is water-cooled On left side of engine.
Page 653 2050 - Engine/cooling A - General B077 electrical viscous fan Instead of a bi-metal viscous coupling, the FENDTD 900 COM III series has an electrical viscous fan installed. The B077 - Engine fan (speed sensor/magnetic clutch) is controlled via the A051 - ECU, engine control unit (EDC 7). and should maintain the coolant temperature at approx.
Page 654 2050 - Engine/cooling A - General Connecting the B077 electr. viscous fan Unplugging the X1532 separation point causes the viscous fan clutch to become fully engaged. The fan belt drive ratio is i = 1.2 to high speed. The clutch is hydraulically calibrated so that a residual slip of about 5% remains even when the clutch is fully en- gaged.
Page 655 2050 - Engine/cooling A - General Designation Sensor Condition for engage- Note ment Diesel engine B089 coolant temperature approx. 95 °C (approx. 200 If the temperature limit is sensor ohms) reached, the A051 ECU, engine control unit engages the B077 electr. viscous fan.
Page 656 2050 - Engine/cooling A - General T002571 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 04-09-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 657 2050 - Engine/cooling Table of contents G Repair Removing radiators individually ..........19 Fitting radiators individually .
Page 658 2050 - Engine/cooling Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 .. 1001-...
Page 659: Removing Radiators Individually
2050 - Engine/cooling G - Repair Removing radiators individually This section explains how to remove all radiators. It may not be necessary to carry out all the steps, depending on which radiator is causing the problem. Drain the coolant. Only if the water cooler is being removed! Fig.
Page 660 2050 - Engine/cooling G - Repair Remove the condenser bracket. Fig. 4. I001418 Remove the protective cover from the radiator. Fig. 5. I001419 Remove clamps and retaining brackets from the coolant hoses. Fig. 6. I001420 Attach condenser to the engine Fig.
Page 661 2050 - Engine/cooling G - Repair Loosen clamp and pull out air hose Fig. 8. I003266 Loosen clamp and pull out coolant hose Fig. 9. I003267 Disconnect hydraulic line from the transmission oil cooler Fig. 10. I003268 Loosen clamp and remove charge air hose Fig.
Page 662 2050 - Engine/cooling G - Repair Loosen clamp and remove coolant hose Fig. 12. I003322 Remove screws on the hydraulic oil cooler Fig. 13. I003212 Remove the hydraulic oil cooler Fig. 14. I003213 Remove the water cooler bracket on the intercooler Fig.
Page 663 2050 - Engine/cooling G - Repair Remove the cover panel from the charge air transmission oil cooler Fig. 16. I003259 Remove the retaining bolts on the charge air transmission oil cooler Fig. 17. I003260 Remove the charge air transmission oil cooler Fig.
Page 664 2050 - Engine/cooling G - Repair Remove the ventilator cowl bolts and slide the cowl back Fig. 20. I003219 Remove the bolts on the water cooler retaining bracket Fig. 21. I003323 Remove the retaining bolts on the water cooler Fig. 22. I003262 Remove the water cooler Fig.
Page 665: Fitting Radiators Individually
2050 - Engine/cooling G - Repair Fitting radiators individually Use a small amount of grease to seat the O-rings Fig. 24. I003320 Fit the water cooler Fig. 25. I003263 Fit the water cooler retaining bolts and bearing Fig. 26. I003262 Slide the ventilator cowl forwards and fit the cowl bolts Fig.
Page 666 2050 - Engine/cooling G - Repair Fit the water cooler on the retaining bracket Fig. 28. I003323 Fit the intake air duct Fig. 29. I003217 Fit the charge air transmission oil cooler Take care not to damage the O-rings! Fig. 30. I003261 Fit the retaining bolts on the charge air transmission oil cooler...
Page 667 2050 - Engine/cooling G - Repair Fit the cover panel bolts on the charge air transmission oil cooler Fig. 32. I003259 Fit the water cooler bracket on the intercooler Fig. 33. I003258 Fit the hydraulic oil cooler Take care not to damage the O-rings! Fig.
Page 668 2050 - Engine/cooling G - Repair Fit the charge air hose and tighten the clamp Fig. 36. I003211 Fit the coolant hose and tighten the clamp Fig. 37. I003322 Fit the hydraulic line on the transmission oil cooler Fig. 38. I003268 Fit the coolant hose and tighten the clamp Fig.
Page 669 2050 - Engine/cooling G - Repair Fit the air hose and tighten the clamp Fig. 40. I003266 Place condenser in position and fit the bracket Fig. 41. I001418 Fit the protective cover on the radiator. Fig. 42. I001419 Fit clamps and retaining brackets on the coolant hoses. Fig.
Page 670 2050 - Engine/cooling G - Repair Fit all screw plugs that were removed on the left and right sides Fig. 44. I003256 Fit screw plug and fill with coolant Fig. 45. I001470 T001174 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 ..
Page 671: Removing The Cooler Assembly
2050 - Engine/cooling G - Repair Removing the cooler assembly Drain the coolant. Fig. 46. I001470 Loosen plugs (arrows) on the left side and drain the oil Fig. 47. I003256 Loosen plugs (arrows) on the right side and drain the oil Fig.
Page 672 2050 - Engine/cooling G - Repair Remove the protective cover from the radiator. Fig. 50. I001419 Remove clamps and retaining brackets from the coolant hoses. Fig. 51. I001420 Attach condenser to the engine Fig. 52. I003298 Loosen clamp and pull out air hose Fig.
Page 673 2050 - Engine/cooling G - Repair Loosen clamp and pull out coolant hose Fig. 54. I003267 Disconnect hydraulic line from the transmission oil cooler Fig. 55. I003268 Disconnect both hydraulic lines from the cooler pan Fig. 56. I003417 Loosen clamp and remove charge air hose Fig.
Page 674 2050 - Engine/cooling G - Repair Loosen clamp and remove coolant hose Fig. 58. I003322 Disconnect the hydraulic line from the front return flow Fig. 59. I003202 Loosen clamps and remove bottom charge air line Fig. 60. I003209 Remove the intake air duct Fig.
Page 675 2050 - Engine/cooling G - Repair Remove the ventilator cowl bolts and slide the cowl back Fig. 62. I003219 Remove the bolts on the water cooler retaining bracket Fig. 63. I003323 Remove nuts and bearings from the pan Fig. 64. I003220 Carefully lift and remove the cooler assembly Ensure there is sufficient clearance between all...
Page 676: Fitting Cooler Assembly
2050 - Engine/cooling G - Repair Fitting cooler assembly Carefully lift the cooler assembly and raise it into position Ensure there is sufficient clearance between all components. Do not walk or stand under sus- ANGER pended loads! Fig. 66. I003418 Fit nuts and bearings on the cooler pan Fig.
Page 677 2050 - Engine/cooling G - Repair Fit the intake air duct Fig. 70. I003217 Fit the charge air hose and tighten the clamp Fig. 71. I003211 Fit the coolant hose and tighten the clamp Fig. 72. I003322 Fit the hydraulic line on the front return flow Fig.
Page 678 2050 - Engine/cooling G - Repair Fit the hydraulic line on the transmission oil cooler Fig. 74. I003268 Fit the coolant hose and tighten the clamp Fig. 75. I003267 Fit the air hose and tighten the clamp Fig. 76. I003266 Place condenser in position and fit the bracket Fig.
Page 679 2050 - Engine/cooling G - Repair Fit the protective cover on the radiator. Fig. 78. I001419 Fit clamps and retaining brackets on the coolant hoses. Fig. 79. I001420 Fit all screw plugs that were removed on the left and right sides Fig.
Page 680 2050 - Engine/cooling G - Repair T001192 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 .. 1001- 931 .. 0101-1000 925 ..
Page 681 2060 General Faults Engine/fuel system Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 683 2060 - Engine/fuel system Table of contents 2060 Engine/fuel system General........5 Measuring and testing .
Page 684 2060 - Engine/fuel system Table of contents...
Page 685 2060 - Engine/fuel system Table of contents A General Fuel system ............. 7 Water sedimentor (pre-filter) .
Page 686 2060 - Engine/fuel system Table of contents...
Page 688: Fuel System
2060 - Engine/fuel system A - General Item Designation Item Designation Right fuel tank B034 Immersed tube sensor Water sedimentor B086 Rail pressure sensor Hand pump B087 Low pressure "primary pressure" approx. 5 … 10 bar Fuel delivery pump B091 Water in fuel sensor Fuel filter (main filter) M010...
Page 689 2060 - Engine/fuel system A - General Fuel system Component Function Reference Y098 injector 4 Y100 injector 5 Y101 injector 6 Fig. 2. I001583 T000708 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 ..
Page 690: Water Sedimentor (Pre-Filter)
2060 - Engine/fuel system A - General Water sedimentor (pre-filter) Fig. 3. I006254 Water sedimentor with pre-filter Fuel inlet from the tank Fuel outlet to the system Filter unit 30 μm – – Water sedimentation greater than 98% – Sight glass with B091 - Sensor, water in fuel –...
Page 691: Fuel System: Water Sedimentor
2060 - Engine/fuel system A - General Fuel system: water sedimentor Fig. 4. I006584 T002194 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 ..
Page 692 2060 - Engine/fuel system A - General Fig. 5. I006585 T002194 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 .. 1001- 931 ..
Page 693 2060 - Engine/fuel system A - General B091 water in fuel sensor Fig. 6. I001617 The B091 sensor measures the water level in the water sedimentor. Item Designation Item Designation Drain cock Vent Vent plug B091 Water in fuel sensor Water sedimentor Electrode Water level...
Page 694 2060 - Engine/fuel system A - General B091 water in fuel sensor Resistance Container filled with diesel approx. 1 mega-ohm Container filled with water (water level too high) approx. 500 Kohms For further tests, see chapter 9000 Reg. E – Measuring and testing T002194 919 ..
Page 695: Fuel Pump
2060 - Engine/fuel system A - General Fuel pump Fig. 8. I006256 Fuel pump The fuel pump draws fuel from the fuel tank through the pre-filter and delivers it to the dispensing unit. The suction pres- sure is 0.5 to 0.8 bar and the delivery pressure is maintained at approx. 7 bar by means of the overflow valve. The delivery quantity is very nearly proportional to the engine speed.
Page 696: Y091 Dispensing Unit (Fuel)
2060 - Engine/fuel system A - General Y091 dispensing unit (fuel) After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Ensure the utmost cleanliness! AUTION See Service Information 14/2007. Fig.
Page 697 2060 - Engine/fuel system A - General Fuel flow: Dispensing unit Fig. 10. I006258 Item Designation Item Designation Y091 Dispensing unit Return flow Feed Overflow valve To the high-pressure pumps Zero-delivery choke The Y091 - Dispensing unit (fuel), which is governed by the engine control unit according to the engine load and speed, supplies the amount of fuel that is fed to the high pressure pumps.
Page 698 2060 - Engine/fuel system A - General Fig. 11. I002243 Item Designation Item Designation X1662 separation point Residual air disc Housing Solenoid core Bearing O-ring Anchor with plunger Piston with control slits Winding with coil bobbin Spring Housing Locking element Piston (10) is actuated by magnetism and opens a flow cross-section depending on its position.
Page 699: High-Pressure Pump (Pf 45)
2060 - Engine/fuel system A - General High-pressure pump (PF 45) After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Ensure the utmost cleanliness! ARNING See Service Information 14/2007. Fig.
Page 700: High-Pressure Accumulator (Rail)
2060 - Engine/fuel system A - General High-pressure accumulator (rail) After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Ensure the utmost cleanliness! ARNING See Service Information 14/2007. Fig. 13. I006261 High-pressure limiting valve Rail pressure sensor...
Page 701: Design And Function Of The High-Pressure Limiting Valve
2060 - Engine/fuel system A - General Design and function of the high-pressure limiting valve After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Duty: – The high-pressure limiting valve limits the maximum permitted fuel high pressure in the rail (pressure ac- cumulator) to approx.
Page 702 2060 - Engine/fuel system A - General Y095 to Y101 injector valves 1 to 6 After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Ensure the utmost cleanliness! ARNING See Service Information 14/2007.
Page 703 2060 - Engine/fuel system A - General Cutaway views: Injector valve (injector) Fig. 17. I002264 Item Designation Item Designation Idle state Injection nozzle spring Injector valve (injector) opens Exposed annular surface of the injection noz- zle needle "Start of injection" Injector valve (injector) closes Chamber volume "End of injection"...
Page 704 2060 - Engine/fuel system A - General Injector closes - "end of injection" The A051 ECU, engine control unit (EDC 7) switches off the holding current. When the current is less than the switch- off value (approx. 8 A), the solenoid valve closes and injection nozzle needle (16) closes. The fuel volume in the solenoid valve chamber damps the vibration of the ignition armature.
Page 705 2060 - Engine/fuel system A - General Installation of injector valve (injector) Fig. 19. I002145 Item Designation Item Designation Cover Pressure pipe Clamping shoe O-ring seal Torx screw O-ring seal Injector valve (injector) Edge-type filter Y095 injector valve (1 cylinder) (on flywheel) O-ring seal O-ring seal Sealing washer...
Page 706 2060 - Engine/fuel system A - General T002573 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 31-10-2008 922 .. 1001- 931 .. 0101-1000 925 ..
Page 707 2060 - Engine/fuel system Table of contents E Measuring and testing Measuring fuel return pressure ..........29 Measuring fuel low pressure .
Page 708 2060 - Engine/fuel system Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 710 2060 - Engine/fuel system E - Measuring and testing If the pressure in the return line is too high, the pressure in the dispensing unit also rises. This causes too much fuel to be delivered to the high pressure pumps, which means that the pressure in the rail is above the value set by the engine control unit (A051).
Page 711 2060 - Engine/fuel system E - Measuring and testing Connect SERDIA adapter (level 3) to X810 diagnostics socket and launch the program Cab, on the right mudguard Remove cover. Fig. 4. I003168 Fig. 5. I003557 In the list, find the two values for rail pressure target value and max. rail pressure (see arrows), and compare these two values If the return pressure is greater than 0.5 bar and the max.
Page 712 2060 - Engine/fuel system E - Measuring and testing Measuring fuel low pressure Measuring fuel low pressure "primary pressure" (B087 sensor) Fig. 6. I001583 Connect pressure gauge (measuring range: 15 bar) to the feed of the Y091 - Dispensing unit (fuel) Fig.
Page 713 2060 - Engine/fuel system E - Measuring and testing If the target fuel low pressure value (approx. 6 bar) is not reached: – Fuel starvation – Fuel filter (main filter) clogged – Water sedimentor (pre-filter) contaminated – Hand pump leaking –...
Page 714 2060 - Engine/fuel system E - Measuring and testing Measuring fuel pressure at Y091 dispensing unit Checking fuel pressure (low pressure) at the Y091 dispensing unit Fig. 9. I001583 Checking fuel pressure (low pressure) upstream of Y091 dispensing unit (ZME) Screw measuring connection into the fuel filter housing.
Page 715 2060 - Engine/fuel system E - Measuring and testing Note: Testing is carried out with diesel engine not under load. Fuel pressure upstream of Y091 Fuel pressure downstream of dispensing unit Y091 dispensing unit Energise Y091 dispensing unit with Approx.6 bar approx.
Page 716 2060 - Engine/fuel system E - Measuring and testing When the high-pressure limiting valve opens, the return line (arrowed) heats up. The diesel engine is switched off by the A051 ECU, en- gine control unit after approx. 3 minutes. Fig. 14. I001560 T002866 919 ..
Page 717 2060 - Engine/fuel system Table of contents G Repair Water sedimentor: drain water ..........39 Bleeding air from the fuel system .
Page 718 2060 - Engine/fuel system Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 719 2060 - Engine/fuel system G - Repair Water sedimentor: drain water Drain water and dirt Version I Drain water and dirt Turn off the engine. Open vent plug (A). To open drain plug (B), press in and turn. Drain water and dirt. Catch it with a drain pan and dispose of in an environmentally compatible manner.
Page 720 2060 - Engine/fuel system G - Repair Change filter (as required, if engine performance starts to fall) Turn off the engine. Disconnect the fuel supply line. Disconnect connector, unscrew filter cap (A). Unscrew and remove filter cartridge (B). Lightly oil the seals or spray with diesel. Tighten filter cartridge (B) by hand until the seal makes contact.
Page 721 2060 - Engine/fuel system G - Repair Bleeding air from the fuel system Bleeding air from the fuel system High-pressure lines must not be opened, as the common rail system is permanently pressurised ANGER and serious injuries may result. Fig. 5. I001583 Version I Prime with the hand pump (A).
Page 722 2060 - Engine/fuel system G - Repair If necessary, bleed the low pressure circuit: vent plug (A)Unscrew Prime with the hand pump until fuel is discharged without any air bubbles. Close vent plug (A). Vent plug Water drain plug Filter cap Fig.
Page 723 2060 - Engine/fuel system G - Repair Removing and installing the high-pressure limiting valve and rail pressure sensor After switching off the diesel engine, wait at least 30 seconds before starting any work on the ANGER fuel system! Ensure the utmost cleanliness! ARNING See Service Information 14/2007.
Page 724 2060 - Engine/fuel system G - Repair Carefully remove O-ring seal. Fig. 13. I001569 Fit a new O-ring seal (arrowed). Fig. 14. I001570 Apply a thin coat of X 902.002.472 high-pressure grease for long-term lubrication to the thread and sealing lip of the pressure-limiting valve Fig.
Page 725 2060 - Engine/fuel system G - Repair Removing and fitting the B086 - Rail pressure sensor Unplug the X1655 separation point. Remove the B086 sensor. Collect any escaping fuel. Fig. 17. I001566 To avoid electrostatic discharge, do not touch the contact pins on the B086 - Rail pressure sensor with bare hands Check the thread and sealing lip for damage (arrows).
Page 726 2060 - Engine/fuel system G - Repair T002829 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 04-09-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 727 2210 General Faults Engine/crankcase Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 729 2210 - Engine/crankcase Table of contents 2210 Engine/crankcase Repair........5...
Page 730 2210 - Engine/crankcase Table of contents...
Page 731 2210 - Engine/crankcase Table of contents G Repair Crankcase air bleed: Deutz TCD 2013 ......... 7...
Page 732 2210 - Engine/crankcase Table of contents...
Page 733 2210 - Engine/crankcase G - Repair Crankcase air bleed: Deutz TCD 2013 Fig. 1. I003137 Item Designation Item Designation Return line Gasket Pipe clamp Banjo bolt Seal ring Lock valve Crankcase air bleed Seal ring Hex screw Adapter Hose clamp Hex screw Rubber hose Loosen hoses and remove crankcase air bleed...
Page 734 2210 - Engine/crankcase G - Repair Carefully unlock and open cover Fig. 3. I003133 Fig. 4. I003134 Item Designation Item Designation Feed Air bleed (to the atmosphere) Engine oil drain to the crankcase T000930 919 .. 0101-1000 925 .. 1001- 934 ..
Page 735 2210 - Engine/crankcase G - Repair Lightly oil the O-ring and insert it in the groove Fig. 5. I003135 Lock the cover Fig. 6. I003133 Lightly oil the seal and insert it in the groove Fig. 7. I003136 Install crankcase air bleed, attach hoses Fig.
Page 736 2210 - Engine/crankcase G - Repair T000930 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 07-11-2007 922 .. 1001- 931 .. 0101-1000 925 ..
Page 737 2312 General Faults Engine/lubrication Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 739 2312 - Engine/lubrication Table of contents 2312 Engine/lubrication General........5...
Page 740 2312 - Engine/lubrication Table of contents...
Page 741 2312 - Engine/lubrication Table of contents A General Diagram: engine lubrication ..........7...
Page 742 2312 - Engine/lubrication Table of contents...
Page 743 2312 - Engine/lubrication A - General Diagram: engine lubrication Engine lubrication diagram Fig. 1. I001608 Item Designation Item Designation Oil sump Plunger Intake duct Push rod (oil feed for the rocker arm) Lubrication pump Rocker arm 3.1 DBV lubricating oil Return line to the oil sump Lubrication oil cooler Oil line to the exhaust turbocharger...
Page 744 2312 - Engine/lubrication A - General Item Designation Item Designation Camshaft bearing Oil duct for cooling the piston head Injection nozzle for cooling the piston head Oil filter console Fig. 2. I002047 Item Designation Item Designation Oil filter console Cone (lubrication oil cooler bypass) Engine oil cooler Valve seat Gasket...
Page 745 2312 - Engine/lubrication A - General Oil intake and lubrication pump TCD 2013 series engines have forced feed lubrication. The lubrication oil flows from the lubrication pump to the oil filter through the oil cooler. Both components are attached to the oil filter console. The oil filter console is flange-mounted on the crankcase.
Page 746 2312 - Engine/lubrication A - General Crankcase end cover with the lubrication pump Fig. 6. I003274 Crankcase end cover with the lubrication pump Fig. 7. I003275 Lubrication pump (rotor pump) Fig. 8. I003276 Function diagram of the lubrication pump (rotor pump) Internal pipe Pressure chamber for crankcase...
Page 747 2312 - Engine/lubrication A - General DBV lubricating oil See also: Chapter 9000 Reg.E - Measuring and testing the B090 en- gine oil pressure sensor Fig. 10. I003277 B090 engine oil pressure sensor X1659 separation point on B090 sensor B087 fuel low pressure sensor On oil filter housing.
Page 748 2312 - Engine/lubrication A - General T000794 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 4 922 .. 0101-1000 928 .. 1001- 04-02-2010 922 .. 1001- 931 .. 0101-1000 925 ..
Page 749 2400 General Faults Engine/exhaust system Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 751 2400 - Engine/exhaust system Table of contents 2400 Engine/exhaust system General........5...
Page 752 2400 - Engine/exhaust system Table of contents...
Page 753 2400 - Engine/exhaust system Table of contents A General Y094 actuator unit, AGR (exhaust gas recirculation) ......7...
Page 754 2400 - Engine/exhaust system Table of contents...
Page 755 2400 - Engine/exhaust system A - General Y094 actuator unit, AGR (exhaust gas recirculation) Diagram: exhaust gas recirculation (AGR) Fig. 1. I006293 Item Designation Item Designation Inlet air Exhaust gases Exhaust turbocharger Intercooler A051 - ECU, engine control unit (EDC 7). Non-return valve (flutter valve) B092 - Sensor, charge air pressure/temperature Exhaust gas cooler...
Page 756 2400 - Engine/exhaust system A - General Fig. 2. I001841 Item Designation Item Designation X1674 separation point Exhaust gas cooler Y094 exhaust gas recirculation actuator motor Non-return valve (flutter valve) Exhaust-gas flap Exhaust gas recirculation Water cooler feed Intake manifold Reason for exhaust gas recirculation Due to exhaust gas recirculation into the combustion chamber (cylinder), the burning speed of the diesel-air mixture de- creases, thus lowering the maximum combustion temperature.
Page 757 2400 - Engine/exhaust system A - General Due to the drop in combustion temperature, the nitrogen oxide ratio in the exhaust decreases. The A051 - ECU, engine control unit (EDC 7). controls the exhaust gas recirculation into the combustion chamber depend- ing on the engine load and speed.
Page 758 2400 - Engine/exhaust system A - General T002580 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 2 922 .. 0101-1000 928 .. 1001- 05-10-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 759 2712 General Faults Engine/injectors Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 761 2712 - Engine/injectors Table of contents 2712 Engine/injectors Measuring and testing ......5...
Page 762 2712 - Engine/injectors Table of contents...
Page 763 2712 - Engine/injectors Table of contents E Measuring and testing Switching off the injector valve (injector) ........7...
Page 764 2712 - Engine/injectors Table of contents...
Page 765 2712 - Engine/injectors E - Measuring and testing Switching off the injector valve (injector) It is possible to switch the cylinders off individually with the aid of adapter cable X899.980.259.101 (short-circuit- ing) Engine without load Y095 injector 1 (on flywheel side) Fig.
Page 766 2712 - Engine/injectors E - Measuring and testing T002574 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 31-10-2008 922 .. 1001- 931 .. 0101-1000 925 ..
Page 767 3000 General Faults Overall system/front axle Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 769 3000 - Overall system/front axle Table of contents 3000 Overall system/front axle General........5 Repair.
Page 770 3000 - Overall system/front axle Table of contents...
Page 771 3000 - Overall system/front axle Table of contents A General Front axle overview ............7 Functional description: front axle suspension .
Page 772 3000 - Overall system/front axle Table of contents...
Page 773: Front Axle Overview
3000 - Overall system/front axle A - General Front axle overview Front axle overview Vehicle type Chassis number FENDT spare part num- Front axle type 309 Vario COM III 336 / .. / 0101 onwards E 339.300.020.021 Company: CARRARO Type: 20.19 310 Vario COM III 337 / ..
Page 774 3000 - Overall system/front axle A - General Front axle overview Vehicle type Chassis number FENDT spare part num- Front axle type 922 Vario COM III "Profi" (1- 919/23/from 0101 E 931.303.000.030 Company: DANA circuit brake) Type: 970/140 (40/50/60) km/h 924 Vario COM III "Profi"...
Page 775: Functional Description: Front Axle Suspension
3000 - Overall system/front axle A - General Functional description: front axle suspension Fig. 1. I001321 Raise suspension If the raise suspension button in the multifunction armrest is depressed for approx. 5 seconds, the solenoid valve (MVFH) is energised and the oil flows to the piston side of the suspension cylinders via the raise suspension non-return valve (RVFH).
Page 776 3000 - Overall system/front axle A - General Fig. 2. I001322 Lower suspension If the lower suspension button in the multifunction armrest is depressed for approx. 5 seconds, the pressure cut-off valve (DRVF) is energised and the oil flows through the lower suspension non-return valve (RVFS) at a pressure of 100 bar to the piston rod side of the suspension cylinder.
Page 777: Front Axle Suspension Operation And Function
With the 2-circuit brake system, the wobble stabiliser (FSC) automatically engages over 40 km/h and automatically disengages at below 15 km/h. FSC = Fendt Stability Control Lower front axle suspension Press "Lock suspension" button (A) for more than 3 seconds.
Page 778: Functional Plans
3000 - Overall system/front axle A - General Functional plans Operating status: tractor suspended Function: – Suspension = oil exchange between cylinder and nitrogen diaphragm accumulator – Peak pressures are limited to 250 bar with the stock valve DBVF1 – A050 - ECU, basic control unit continuously determines the mean value of all movements (B066 left wheel position sensor and B068 right wheel position sensor) –...
Page 779 3000 - Overall system/front axle A - General Operating status: "raise" Function: – MVL charge solenoid valve activates the LS pump (PR) – MVFH solenoid valve, raise suspension, is energised, causing the RVFS lower suspension non-return valve to be opened and oil to be fed to the piston crown side (compression stage) –...
Page 780 3000 - Overall system/front axle A - General Operating status: "lower" Function: – MVL charge solenoid valve activates the LS pump (PR) – The suspension pressure cut-off valve is energised with approx. half voltage, causing the suspension non-return valve to be opened hydraulically and oil to be fed to the piston rod side (retraction stage) up to approx. 100 bar –...
Page 781 3000 - Overall system/front axle A - General Operating status: "locking the suspension" Function: – Lock suspension solenoid valve (MVFF) is energised; oil flow to the hydraulic accumulators is stopped – The suspension can only be locked below 20 km/h. If the vehicle exceeds this speed, the MVFF lock suspension solenoid valve is no longer energised by the A050 ECU, basic control unit.
Page 782 3000 - Overall system/front axle A - General "Tractors without wobble stabiliser" – The suspension wobble stabiliser solenoid valve MVFW is not installed as standard in tractors with a 1-circuit brake system. Fig. 8. I007362 Vehicles with chassis numbers 9XX/21/1701 and higher can be retrofitted with this equipment upon request. Operating status: "wobble stabiliser"...
Page 783 3000 - Overall system/front axle A - General – MVFW suspension wobble stabiliser solenoid valve is energised when certain conditions are met: – The tractor is driving faster than 20 km/h. – Rotary position sensors B066, left wheel position sensor and B068 right wheel position sensor are in the same po- sition.
Page 784 3000 - Overall system/front axle A - General Wobble stabiliser diagnostics Fig. 10. I010491 The activation conditions depend on the EOL software version. The best way to control the activation condition is via the Vario diagnostics (arrow). T002576 919 .. 0101-1000 925 ..
Page 785 3000 - Overall system/front axle A - General Operating status: "suspension blocked" = "suspension OFF" Function: – There is always some hydraulic pressure in the suspension cylinders at the pressure stage (load) and retraction stage – This pressure cannot be released either by pressing a button or switching off the engine –...
Page 786 3000 - Overall system/front axle A - General T002576 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 3 922 .. 0101-1000 928 .. 1001- 05-10-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 787 3000 - Overall system/front axle Table of contents G Repair Removing front axle ............23 Fitting front axle .
Page 788 3000 - Overall system/front axle Table of contents 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- 922 .. 0101-1000 928 .. 1001- 922 .. 1001- 931 .. 0101-1000 925 .. 0101-1000 931 ..
Page 789 3000 - Overall system/front axle G - Repair Removing front axle Preliminary work: – Remove cooler assemblysee §3 Disconnect all cable connectors in the area of the front axle and attach them to the engine Fig. 1. I003201 Relieve pressure on the front axle suspension accumula- tor (open both suspension lock valves) Fig.
Page 790 3000 - Overall system/front axle G - Repair Remove front axle suspension diaphragm accumulator Fig. 4. I003207 Remove hydraulic lines (arrows) on the right side (may vary according to equipment) Fig. 5. I003204 Remove hydraulic lines of the auxiliary control valves in the middle (arrows) (may vary according to equipment) Fig.
Page 791 3000 - Overall system/front axle G - Repair Remove filter for front axle (if present) together with hy- draulic line Fig. 8. I003208 Remove front axle suction line (if present) Fig. 9. I003210 Place assembly trestle under engine, carefully lift the front axle and remove the connecting bolts between the engine and the front axle Fig.
Page 792 3000 - Overall system/front axle G - Repair Fitting front axle Carefully lift and fit the front axle Ensure there is sufficient clearance between all components. Do not walk or stand under sus- ANGER pended loads! Fig. 12. I004194 Tighten flange screws Tightening torque: 580 Nm Fig.
Page 793 3000 - Overall system/front axle G - Repair When replacing the front axle: Fit screw sockets for brake line Fig. 16. I003224 When replacing the front axle: Install brake line from the front Fig. 17. I003225 Connect brake line on the left and right Fig.
Page 794 3000 - Overall system/front axle G - Repair When replacing the front axle: Fit screw sockets for steer- ing hydraulic system Fig. 20. I003251 Install line for the steering hydraulic system Fig. 21. I003248 When replacing the front axle: Install diaphragm accumu- lator for the front hydraulic system Fig.
Page 795 3000 - Overall system/front axle G - Repair When replacing the front axle: Fit screw sockets Fig. 24. I003253 When replacing the front axle: Fit screw sockets for the lubrication line Fig. 25. I003254 Fit suction line Fig. 26. I003210 Fit pressure line with filter Fig.
Page 796 3000 - Overall system/front axle G - Repair Tighten all hydraulic lines that were loosened on the left side Fig. 28. I003203 Tighten all hydraulic lines that were loosened on the right side Fig. 29. I003204 Tighten all hydraulic lines that were loosened on the cen- tral control block Fig.
Page 797 3000 - Overall system/front axle G - Repair Screw in and lock the suspension stop valves Fig. 32. I003206 Final procedures: – Fitting cooler assemblysee §4 T000999 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 ..
Page 798 3000 - Overall system/front axle G - Repair T000999 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 2 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 .. 1001- 931 .. 0101-1000 925 ..
Page 799 3120 General Faults Front axle/steering cylinder Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 801 3120 - Front axle/steering cylinder Table of contents 3120 Front axle/steering cylinder Documents and diagrams ..... .5...
Page 802 3120 - Front axle/steering cylinder Table of contents...
Page 803 3120 - Front axle/steering cylinder Table of contents C Documents and diagrams Technical drawing: Steering cylinder and track rod ....... 7...
Page 804 3120 - Front axle/steering cylinder Table of contents...
Page 805 3120 - Front axle/steering cylinder C - Documents and diagrams Technical drawing: Steering cylinder and track rod Workshop manual (DANA—front axle) X 990.005.058.000 valid for: Type 970/130 without front-wheel brake Type 970/140 with front-wheel brake – Remove steering cylinder – Calculate if shims required –...
Page 806 3120 - Front axle/steering cylinder C - Documents and diagrams Fig. 2. I004874 Steering cylinder Item Designation Item Designation Steering cylinder, Snap ring Seal set Piston rod Shim Guide bush Snap ring Cylinder barrel Hex screw Stop Hose clamp O-ring Gaiter Snap ring Gripper clamp...
Page 807 3120 - Front axle/steering cylinder C - Documents and diagrams Fig. 3. I004873 Track rod Item Designation Item Designation Track rod Hex nut Application Application Gaiter Jack screw (not available individually) Castellated nut Socket head cap screw Split pin Synthetic bonding agent (X 903.050.041.000) T001521 919 ..
Page 811 3180 General Faults Front axle/cardan shaft Documents and Diagrams Component location Testing Setting and Calibration Repair Service – Info...
Page 813 3180 - Front axle/cardan shaft Table of contents 3180 Front axle/cardan shaft Documents and diagrams ..... .5...
Page 814 3180 - Front axle/cardan shaft Table of contents...
Page 815 3180 - Front axle/cardan shaft Table of contents C Documents and diagrams Technical drawing: Front-wheel drive shaft ........7...
Page 816 3180 - Front axle/cardan shaft Table of contents...
Page 818 3180 - Front axle/cardan shaft C - Documents and diagrams Fig. 2. I004879 T001522 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 ..
Page 819 3180 - Front axle/cardan shaft C - Documents and diagrams Fig. 3. I004880 Front-wheel drive shaft Item Designation Item Designation Shaft Snap ring Profile connector Washer O-ring Circlip T001522 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 ..
Page 820 3180 - Front axle/cardan shaft C - Documents and diagrams Fig. 4. I004881 Front-wheel drive shaft Item Designation Item Designation Spur gear Hex screw Spur gear O-ring wheel-driven emergency steering pump (PNL) Profile connector Deep-groove ball bearing Shaft Circlip Deep-groove ball bearing Shim pack Circlip Shaft seal ring...
Page 821 3180 - Front axle/cardan shaft C - Documents and diagrams Fig. 5. I004882 Clutch housing Item Designation Item Designation Clutch housing Hex screw Sleeve Parallel pin O-ring Hex screw Circlip Stud bolt Cover Hex nut Hex screw Stud bolt Screw plug Stud bolt Seal ring Screw plug...
Page 822 3180 - Front axle/cardan shaft C - Documents and diagrams T001522 919 .. 0101-1000 925 .. 1001- 934 .. 0101-1000 919 .. 1001- 928 .. 0101-1000 934 .. 1001- Version 1 922 .. 0101-1000 928 .. 1001- 21-04-2009 922 .. 1001- 931 ..

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