Agrotron 110 mk3

SAME DEUTZ-FAHR DEUTSCHLAND GmbH
WORKSHOP MANUAL
AGROTRON 106 MK3

AGROTRON 110 MK3
AGROTRON 115 MK3
AGROTRON 120 MK3
AGROTRON 135 MK3
AGROTRON 150 MK3
AGROTRON 165 MK3
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INTRODUCTION
INTRODUCTION
The purpose of this workshop manual is to provide instruction for repair technicians and
a practical guide to improving the quality of repairs.
This manual enables repair technicians to acquire a thorough knowledge of the ma-
chine, indicating the correct methods for fault diagnosis, for working in safety and for
accurate dimensional checks and visual inspections. The instructions also indicate the
products to use, the tightening torques and the adjustment data.
The technical material contained in this manual is reserved to Authorised Dealers and
Service Centres who will be duly informed of any technical changes to the machines in
question through the issue of documents regarding modifications, updates and sup-
plements for optional equipment.
All technicians and their colleagues are expressly forbidden from reproducing any part
of this manual in any form or from communicating the contents to third parties without
the express written permission of the Manufacturer, who remains the sole owner of this
document with all rights reserved in accordance with applicable laws.
00-1
GENERAL SAFETY RULES
SAFETY NOTES
To ensure that machines entrusted to Authorised Service Centres for repair or overhaul continue to function cor-
rectly, it is very important that all repair work is carried out in the prescribed manner.
The procedures for checks and repairs indicated in this manual are safe and effective.
Some of the operations described require the use of special tools and equipment: these tools have been designed for
a specific purpose and may ordered directly from the Manufacturers.
DO NOT USE MAKESHIFT TOOLS; not only is there is risk of personal injury, but such tools are rarely suited to the
purpose for which they are used.
To prevent injury to operators, the symbols and are used in this manual to indicate the safety precautions re-
quired. The warnings accompanying these symbols must always be adhered to carefully.
In potentially hazardous situations, always give priority to personal safety and take the necessary actions to eliminate
the danger.

1- Even if you have a thorough knowledge of the ma- 8 - Ensure that the area is well ventilated before starting
chine as regards its components, operation and the engine in order to avoid the formation of danger-
controls, always take particular care when carrying ous concentrations of toxic gases; always connect
out the following operations. Remember that the ma- suitable fume extraction equipment to the exhaust
chine you are working on is in need of repair or over- pipe.
haul and consequently may not always behave as
expected. 9 - Under no circumstances start the engine with the
safety guards removed; all repair and adjustment
2 - Before starting work, clean the machine thoroughly operations must be carried out with the engine
to remove all mud, dust and road dirt. stopped.
Also clean the cab to remove all traces of oil, snow
and ice from the access steps and grab rails. 10 - Do not top up fuel, oil or coolant levels when the en-
gine is running.
3 - When climbing up to or down from the cab, always
ensure you maintain three points of contact at a time 11 - Never smoke and ensure there are no naked flames
(foot or handholds) in order to keep your balance and nearby when topping up fuel or oil.
prevent accidental falls. Always remove the battery from the machine before
recharging.
4 - Always take special care when carrying out fault di-
agnosis operations; these operations often require 12 - Before checking or removing the battery, stop the
two persons, who must never stand in front of the engine and remove the key from the starter switch.
wheels when the engine is running. 13 - Remove the battery and recharge in a well-ventilated
5 - When carrying out checks and repairs, wear close- area where the temperature exceeds 0°C.
fitting clothing, safety goggles and protective gloves 14 - When checking or recharging the battery, do not
that are suitable for the task (cleaning, draining flu- smoke or allow naked flames in the vicinity as the hy-
ids, repairs). drogen gas given off by the battery is highly explo-
When working near moving parts, long hair should sive.
be gathered up and secured safely under a cap to
prevent the risk of entanglement and sever injury. 15 - The liquid (electrolyte) contained in the battery is very
harmful if it comes into contact with the skin and the
6 - Do not allow anyone who is not directly involved in eyes; for this reason, always wear gloves and safety
the work to come near the machine; ensure that they
goggles with side shields when checking or topping
remain at a safe distance.
up the battery.
7 - Keep well clear of moving parts; when the engine is Should any electrolyte accidentally come into con-
running, some moving parts are not easily visible and tact with your skin, wash the affected parts imme-
therefore present a risk of entanglement, even if pro- diately with copious amounts of water. If electrolyte
tected by safety guards. comes into contact with your clothing, this should be
removed as soon as possible.
00-3
In case of accidental ingestion of electrolyte, drink 25 - Always use lifting equipment of suitable capacity for
copious amounts of water, milk or vegetable oil and the weight of the components to be removed. Ensure
take antacids such as magnesium, bicarbonate, lifting equipment is attached correctly.
etc.. and seek medical attention immediately.
26 - When lifting or supporting an assembly or compo-
16 - Before working on the electrical systems, always nent, manoeuvre the parts slowly and carefully to
disconnect the battery terminals. avoid oscillation or collision with other components.
IMPORTANT!
Always disconnect the negative terminal (--) first and 27 - Never work on components suspended from a hoist
then the positive terminal (+); when re-connecting or crane.
the battery on completion of the work, first connect 28 - When removing the retaining bolts of a component
the positive terminal (+) and then the negative (--). that could fall, always leave two opposing bolts in
17 - Before carrying out any arc welding, on the tractor, place for safety; before removing these last two bol-
always disconnect the battery terminals and unplug ts, attach the component to suitable lifting equip-
all the connectors of the electronic control units and ment or position support blocks.
the alternator. 29 - Any oil or fuel spilled during removal or dismantling
18 - When topping up lubricants, always wear suitable operations should be cleaned up as soon as possible
protective gloves. to prevent the risk of slipping and fire.
19 - Do not wear clothing contaminated by engine or hy- 30 - When refitting electrical cables and wires, ensure
draulic oil; prolonged contact with the skin can be that they are secured with their original retaining
harmful and may cause allergic reactions. straps or brackets to prevent the possibility of dam-
age caused by vibration.
20 - Used engine oil and hydraulic oil must be disposed
of in a proper manner; recover used lubricants and 31 - Never insert your fingers or hands to check the align-
dispose of them in accordance with the applicable ment between fixing holes in components; always
regulations. use a suitable dowel of soft material.
21 - Before carrying out any work on the hydraulic or 32 - When refitting assemblies or components, always
pneumatic systems, discharge all residual pressure use the specified tightening torques; the tightening
from the circuits. torques indicated in the paragraphs regarding as-
sembly/refitting operations have been determined
22 - Before carrying out any work on the hydraulic system through experimentation and must be scrupulously
or engine, allow the oil and engine coolant to cool adhered to.
down.
33 - When refitting parts that are subject to vibration or
23 - When removing and refitting certain assemblies, it that rotate at high speed, take particular care when
will be necessary to support the machine; use carrying final installation checks.
stands, jacks or blocks capable of supporting the
weight and arrange them in a triangular pattern to
prevent the machine from overturning.
24 - To lift heavy components, use a hoist or crane.
Check that wire ropes, chains or fibre slings are not
worn and that hooks are not damaged.
00-4
HOW THE MANUAL IS STRUCTURED
HOW THE MANUAL IS STRUCTURED
Section 00 Contains the general safety rules, information on how to use and update
the manual, the symbols used, the products required, the standard tight-
ening torques and a conversion table for units of measurement.
Section 10 Contains technical descriptions and information regarding the mechan-

ical and hydraulic operation of machine components, the designations of
the various components, hydraulic diagrams and general technical data.
Section 20 Contains a guide to the use of the necessary software for machine and en-
gine configuration and for diagnostic.
Section 30 Contains the methods, checks and adjustments regarding the external
components; the operations dealt with in this section do not require re-
moval of the various assemblies that form the tractor frame and cab.
Section 40 Contains information and diagrams regarding the machine's electrical

and electronic systems.
ATTENTION!
This manual does not contain the engine and transmision sections.
For these sections refer to the follow manuals:
Italian
English
Engine DEUTZ 1012 - 1013 0297 9771
French
German
0298 6837 German
0298 6838 English
Transmission ZF 7100L
0298 6839 French
0298 6840 Spanish
0298 6871 German
0298 6872 English
Transmission ZF 7100S
0298 6873 French
0298 6874 Spanish
0298 6877 German
0298 6878 English
Rear axle 7100
0298 9879 French
0298 9880 Spanish
0298 6831 German
0298 6832 English
Trasmission/rear axle 7200 L-S-H
0298 6833 French
0298 6834 Spanish
0298 6803 German
0298 6856 English
Front axle ZF 2025-2035-2045 AS
0298 6857 French
0298 6858 Spanish
00-5
HOW TO CONSULT THE MANUAL
HOW TO CONSULT THE MANUAL
1. Removal and refitting of assembled units

(1) For the removal or refitting of assembled units, the sequence of operations and the methods to be applied are de-
scribed in the removal procedure; if the refitting sequence of operations is the exact reverse of the removal pro-
cedure, it is not described.
(2) All special techniques that apply only to the refitting procedure are indicated by the symbol 1 ; this same
symbol appears at the end of each major step in the removal procedure to indicate the parts for which special
techniques are to be applied during refitting.
E.g.: REMOVAL OF UNIT : ................................................ Operation heading
: ............................................................................. Safety rules to be observed when carrying out the pro-
cedure described
1 - Remove part (1):...................................................... Step of the procedure
★: ................................................................................. Technique or important information regarding the re-
moval operation.
2 - Disconnect (2) ......... 1 : ...................................Indicates the existence of special information regar-
ding refitting of the component in question.
.......... : .............................................................. Recover oil, liquid or fuel and the quantity to be recov-
ered
E.g.: REFITTING UNIT: ...................................................... Operation heading
• Refitting is the reverse of removal
1 :.......................................................................Technique to be applied during refitting

★: ................................................................................. Technique or important information regarding the refit-
ting operation
• .......... : ........................................................... Filling with oil or liquid with quantity
2. During removal and refitting operations, in addition to the general safety rules, you must also apply the specific
«SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS».
Always adhere to these precautions.
3. List of special tools

(1) For details regarding the type, code numbers and quantity of all the tools (T1, T2, etc.) specified in the operating
procedures, see the heading «SPECIAL TOOLS».
4. Tightening torques
1 - In the operating procedures, the symbol denotes a specific tightening torque that has been determined ex-
perimentally and that must be adhered to.
2 - If the symbol does not appear, the torque values to be used are those indicated in the table in Section 00 of this
manual.
00-6
HOW TO UPDATE THE MANUAL
HOW TO USE AND UPDATE THE MANUAL
1. UPDATING THE MANUAL

All additions, corrections or amendments to the manual will be sent to the Authorised Service Centres.
Before starting any repair or overhaul operations, check that you have the most recent updates as these may contain
supplementary data not present in previous issues.
2. INSERTING UPDATES
1- Check the number of the page and insert it in the appropriate section of the manual following the consecutive or-
der of the page numbers. Example:
20 5
Consecutive page number

Section number
2 - Supplementary pages: indicated with a hyphen (-) and consecutive number after the page number. Example:
20-5
20-5-1
Supplementary page
20-5-2
20-6
NOTE. The contents of supplementary pages are structured so that there is no overlap with existing pages.
3 - Updated pages: indicated by a consecutive number in a circle; this symbol appears below the page number.
Example:
20-5
20-5-1 Existing page
20-5-1 Update page
20-5-2 Existing page
NOTE. All supplementary and updated pages are indicated in the manual page list; a revised page list is
sent with each update and supersedes the previous list.
3. SYMBOLS USED IN THE MANUAL

For greater clarity, important information pertaining to operator safety and to critical stages in the working proce-
dures is highlighted by the symbols shown in the following table.
Symbol Meaning Notes Symbol Meaning Notes

Safety rules to be applied during Parts must be coated with adhesive,
Coating
operation. lubricant, etc.
Safety Points at which oil, water or fuel
Operation requiring special safety
Oil, water must be added and quantity requi-
measures due to internal pressure.
red.
Operations requiring special techni-
★ Warning cal or other precautionsto ensure
compliance with standard values.
Drain
Points from which oil, water or fuel
must be drained with quantity.
Weight of main assemblies.

Tightening Parts requiring special tightening
Weight Choose lifting ropes/slings careful-
torques torque during refitting or assembly.
ly; supports required, etc.
00-7
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS
SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS
★ When removing or refitting parts, always take the following safety precautions.
1. Precautions for removal operations

• Unless otherwise indicated, lower the working equipment until it rests on the ground.
• After disconnecting hydraulic and fuel system pipes, always fit plugs to the open ends of the pipes to prevent in-
gress of impurities.
• Before removing a cylinder, fully retract the piston and secure it in this position using a retaining strap.
• Use containers of sufficient capacity when draining oil, coolant or fuel.
• Before removing a part from the machine, check for alignment markings indicating the correct assembly po-
sition. If necessary, make new markings to ensure correct assembly.
• When unplugging electrical connectors, always grip the connectors firmly to avoid pulling on the wires.
• Where necessary, label wires and pipes before removal to avoid confusion when reconnecting.
• Check the number and thickness of any shims removed and keep them together in a safe place.
• To lift the machine or any of its main components, use lifting equipment of suitable capacity.
• When using bolts or eye bolts to remove parts, ensure they are screwed home fully.
• Before removing a part, clean the surrounding area and, after removing the part, cover it to prevent the ingress of
dirt and dust.
2. Precautions for refitting operations

• Tighten nuts and bolts to the specified tightening torques.
• When refitting flexible pipes and wires, take care not to twist or tangle them.
• Always fit new seals, O-rings, cotter pins and safety stop rings; ensure that cotter pins are bent over so that they
cannot work loose.
• Ensure that circlips are correctly installed in their seatings.
• When applying threadlocking compound, first clean the part removing all oil and grease, then cover the thread
evenly applying a few drops of the compound.
• When applying sealant, first clean the surface removing all traces of oil and grease and check for dirt or inden-
tations, then apply the sealant evenly making sure that it forms a continuous film around any fixing holes.
• Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and indentations.
• Coat all moving parts with a thin film of engine oil.
• When reconnecting electrical connectors, first remove all traces of oil, dust and water from the inside of the con-
nector and then connect the two halves together firmly.
• When using eyebolts for lifting, check that they are not deformed, screw them fully home and align the eye with
the lifting hook.
• Bolt down flanged fittings evenly, tightening the bolts gradually in a crosswise pattern.
3. Precautions to be taken on completion of removal/refitting operations

• If coolant has been drained from the engine, refit the drain plug and add new coolant to the correct level. Start the
engine to circulate the coolant and then check the level again and top up.
• After removing hydraulic components, top up the hydraulic oil to the specified level. Start the engine to circulate
the oil in the hydraulic circuits and then recheck the level and top up as necessary.
• After having removed the variable displacement pump, before connecting the discharge pipe, fill the pump cas-
ing with oil.
• Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.
00-8
LIFTING INSTRUCTIONS
LIFTING INSTRUCTIONS
Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equip-
ment with wire rope or polyester slings.
In the paragraphs regarding removal and refitting operations, the weight of the component or assembly to be lifted is
indicated with the symbol
WIRE ROPES - SLINGS

• Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:
WIRE ROPES POLYESTER SLINGS

(standard twisted «S» or «Z» type) (eye-and-eye - simple loop)
Capacity (kg) Capacity (kg)
Ø rope Width
mm 60° 90° (mm) 60° 90°
8 650 620 500 25 500 400 860 700

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

• The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the
rope/sling, this could cause the load to slip during lifting.
• Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope
strands to untwist or the load to slip; this could lead to serious injury.
• Never lift a heavy load when the two branches of the ropes form a wide angle.
The permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the
permitted load varies according to the angle of suspension for two Ø 10 mm ropes each with a load capacity of 1000 kg.
2000
1900
1700
2000
Load capacity: kg
1400
1000
1000
500
30° 60° 90° 120° 150°

Angle of suspension: ␣
00-9
STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS
STANDARD TIGHTENING TORQUES FOR NUTS AND

BOLTS
The tightening torques for certain specific components and special tightening methods are indicated in the
relative assembly paragraphs.
★ The tightening torques indicated below refer to bolts and nuts assembled without lubrication and, where ap-
plicable, with anaerobic threadlocking compound.
The values apply to tightening on steel or cast iron components; for soft materials such as aluminium, copper,
plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.
BOLT CLASS
BOLT SIZE 8.8 10.9 12.9

Nm lb.ft. Nm lb.ft. Nm lb.ft.
M6x1 8.0 – 8.8 5.9 – 6.5 11.8 – 13.0 8.7 – 9.6 13.8 – 15.2 10.2 – 11.2
M8x1.25 19.4 – 21.4 14.3 – 15.8 28.5 – 31.5 21.0 – 23.2 33.3 – 36.9 24.5 – 27.2
M10x1.5 38.4 – 42.4 28.3 – 31.2 56.4 – 62.4 41.6 – 46.0 67.4 – 74.4 49.7 – 54.8
M12x1.75 66.5 – 73.5 49.0 – 54.2 96.9 – 107 71.4 – 78.9 115 – 128 84.8 – 94.3
COARSE THREAD
M14x2 106 – 117 78.1 – 86.2 156 – 172 115.0 – 126.8 184 – 204 135.6 – 150.3
M16x2 164 – 182 120.9 – 134.1 241 – 267 117.6 – 196.8 282 – 312 207.8 – 229.9
M18x2.5 228 – 252 168.0 – 185.7 334 – 370 246.2 – 272.7 391 – 432 288.2 – 318.4
M20x2.5 321 – 355 236.6 – 261.6 472 – 522 347.9 – 384.7 553 – 611 407.6 – 450.3
M22x2.5 441 – 487 325.0 – 358.9 647 – 715 476.8 – 527.0 751 – 830 553.5 – 611.7
M24x3 553 – 611 407.6 – 450.3 812 – 898 598.4 – 661.8 950 – 1050 700.2 – 773.9
M27x3 816 – 902 601.4 – 664.8 1198 – 1324 882.9 – 975.8 1419 – 1569 1045.8 – 1156.4
M8x1 20.8 – 23.0 15.3 – 17.0 30.6 – 33.8 22.6 – 24.9 35.8 – 39.6 26.4 – 29.2
M10x1.25 40.6 – 44.8 29.9 – 33.0 59.7 – 65.9 44.0 – 48.6 71.2 – 78.6 52.5 – 57.9
M12x1.25 72.2 – 79.8 53.2 – 58.8 106 – 118 78.1 – 87.0 126 – 140 92.9 – 103.2
M12x1.5 69.4 – 76.7 51.1 – 56.5 102 – 112 75.2 – 82.5 121 – 134 89.2 – 98.8
FINE THREAD
M14x1.5 114 – 126 84.0 – 92.9 168 – 186 123.8 – 137.1 199 – 220 146.7 – 162.1
M16x1.5 175 – 194 129 – 143 257 – 285 189.4 – 210.0 301 – 333 221.8 – 245.4
M18x1.5 256 – 282 188.7 – 207.8 375 – 415 276.4 – 305.9 439 – 485 323.5 – 357.4
M20x1.5 355 – 393 261.6 – 289.6 523 – 578 385.5 – 426.0 611 – 676 450.3 – 498.2
M22x1.5 482 – 532 355.2 – 392.1 708 – 782 521.8 – 576.3 821 – 908 605.1 – 669.2
M24x2 602 – 666 443.7 – 490.8 884 – 978 651.5 – 720.8 1035 – 1143 762.8 – 842.4
00-10
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS
THREADLOCKERS, ADHESIVES, SEALANTS AND

LUBRICANTS
FUNCTION DESIGNATION DESCRIPTION
Loctite 222
Anaerobic product suitable or low-strength locking of retaining, adjustment and precision
Colour:
fasteners.
opaque fluorescent All traces of lubricant must first be removed using the specific activator.
purple
Anaerobic product that prevents loosening of all types of nut and bolt; used in place of con-
THREADLOCKER
Loctite 242
ventional mechanical locking systems.
Colour:
Used for medium-strength locking.
fluorescent blue All traces of lubricant must first be removed using the specific activator.
Loctite 243
Alternative product to 242; oil tolerant and so can used on lightly lubricated surfaces without
Colour: opaque
prior use of activator.
fluorescent blue
Loctite 270 Anaerobic product for high-strength locking of bolts and studs that do not normally require
disassembly.
Colour:
Parts must be heated to approximately 80°C for removal.
fluorescent green All traces of lubricant must first be removed using the specific activator.
DEGREASERS AND
Product used for degreasing and cleaning parts prior to application of Loctite anaerobic prod-
Loctite 703
ACTIVATORS
ucts; after drying, promotes uniform curing of threadlockers.
Product used for specifically for treatment of passive metals prior to use of slow-cure anaer-
obic threadlockers(series 5 and 6).
Loctite 747
Can also be used to increase cure speed at low temperatures or in applications where there is
large gaps between the parts.
Super-rapid anaerobic sealant for sealing between rigid metal faces; can eliminate the need
Loctite 510 for conventional gaskets as it can fill gaps up to 0.4 mm.
Colour: red Does not shrink and therefore fasteners do not need re-tightening to specified torque values
after curing.
Loctite 542 Anaerobic product used a liquid sealant for threaded fittings up to 3/4” gas; rapid curing and
Colour: brown parts may be disassembled with ordinary tools.
(for faces and flanges)
Loctite 554 Anaerobic sealant and locking compound used for sealing cooling and industrial fluid circuits.
SEALANTS
Colour: red Slow curing, also suitable for use on non-ferrous alloys.
Anaerobic sealant and locking compound used for sealing pipes and threaded fittings up to 2"
Loctite 572
in diameter.
Colour: white Very slow curing on most metal surfaces.
Loctite 576 Anaerobic product used a liquid thread sealant for large diameter threaded fittings (up to 2").
Colour: brown Very slow curing; also suitable for non-ferrous alloys and parts requiring subsequent removal.
Thixotropic anaerobic product used for sealing joints between metal faces.
Loctite 576 Ensures total contact between surfaces with maximum tolerance of 0.10 mm, filling micro-
Colour: green voids caused by flatness errors.
Very slow curing on most metal surfaces and requires prior application of an activator.
00-11
THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS
FUNCTION DESIGNATION DESCRIPTION
Cyanoacrylate instant adhesive suitable for bonding a wide range of acidic and porous ma-
Loctite 401 terials including, ceramics, wood, rubber and plastic (excluding polyolefin).
ADHESIVES
INSTANT
Colour: colourless Curing takes place in a few seconds as an effect of the condensed humidity present on the
surfaces to be bonded, and is independent of environmental conditions.
Loctite 495 Cyanoacrylate instant adhesive suitable for bonding a rubber, plastics and metal in any com-
Colour: colourless bination.
Silastic 738 One-part silicone adhesive/sealant, ready for use.

(Dow Corning) Cures on exposure to air to form a rubbery solid and obviates the need for conventional seals
SEALANTS
SILICONE
Colour: milky white on flexible joints, filling gaps greater than 1 mm.
One-part silicone adhesive/sealant, shrinking, ready for use.

Dirko Transparent
Cures rapidly when exposed to humidity in the air to form a rubbery solid; resistant to high
Colour: transparent temperatures.
POLYURETHANE
SEALANTS
Betaseal HV3 Polyurethane prepolymer based adhesive/sealant, high viscosity, suitable for permanent,
high-strength flexible bonding.
(Gurit Essex)
Slow curing, used for bonding glass to frames, wire mesh, metal plates, etc. surfaces must be
Colour: black degreased with primer.
Loctite 601 Anaerobic, fast-curing, high-strength adhesive.

Colour: Suitable for sealing and retaining cylindrical assemblies with gap clearances of up to 0.10 mm;
fluorescent green used for retaining rotors, gears, bearings, pulleys, bushes etc. on shafts.
RETAINING COMPOUNDS
Loctite 638
Anaerobic structural adhesive, quick-curing, very high strength; suitable for bonding cylin-
Colour:
drical parts in non-ferrous alloys.
fluorescent green
Loctite 648 Anaerobic structural adhesive, quick-curing, high-strength; suitable for bonding cylindrical
parts, permanent retention of threaded parts, sealing of refrigeration systems, retention of
Colour:
bearings, etc.
fluorescent green Alternative to Loctite 601 in high-temperature applications.
Loctite 986/AVX Anaerobic sealant/retaining compound for metal cylindrical parts.

Colour: Slow-curing, high-strength, heat-resistant and resistant to chemical pressure.
fluorescent red Parts must be first treated with an activator.
Grease
Multi-purpose Lithium grease used for lubrication of seals, to prevent oxidization and to fa-
(NLGI 2 EP
cilitate assembly operations.
ASTM D217: 265/295)
LUBRICANTS
Molikote Anti-wear compound, contains Molybdenum bisulphate, use neat or diluted with engine oil
(Dow Corning) for assembly of main engine bearings.
Vaseline Neutral pH compound used to protect battery terminals against oxidization and corrosion.
Engine oil
Used to dilute Molikote anti-wear lubricant during assembly of main engine bearings.
10W - 30
00-12
SPECIAL TOOLS
SPECIAL TOOLS
SYMBOL CODE DESCRIPTION NOTES
T1 00239496 Tool for removal of steering unit inner gasket
T2 00239497 Tool for removal of steering unit dust seal
T3 00239498 Tool for mounting of steering unit inner gasket
T4 00239499 Tool for mounting of steering unit dust seal
T5 5.9030.743.1 Test lead for checking sensors with multimeter
T6 5.9030.743.0 Test lead for checking sensors with multimeter
T7 5.9030.740.0 SERDIA installation disc
T8 5.9030.741.0 Adapter cable
T9 5.9030.740.2 Interface level III
T10 5.9030.742.0 EDS software pack
00-13
CONVERSION FACTORS
CONVERSION FACTORS
CONVERSION FROM BRITISH TO METRIC UNITS CONVERSION FROM METRIC TO BRITISH UNITS
mm = inch x 25.40 inch = mm x 0.0394
foot x 0.305 foot = m x 3.281
m =
yard x 0.914 yard = m x 1.094
km = Eng.miles x 1.609 Eng.miles = km x 0.622
cm² = Sq.in. x 6.452 Sq.in. = cm² x 0.155
Sq.ft. x 0.093 Sq.ft. = m² x 10.77
m² =
Sq.yard x 0.835 Sq.yard = m² x 1.197
cm³ = Cu.in. x 16.39 Cu.in. = cm³ x 0.061
Cu.ft. x 28.36 Cu.ft = m³ x 0.035
m³ =
Cu.yard x 0.763 Cu.yard = m³ x 1.311
Imp.gall. x 4.547 Imp.gall. = litres x 0.220
US gall. x 3.785 US gall. = litres x 0.264
litres=
pint x 0.568 pint = litres x 1.762
quart x 1.137 quart = litres x 0.880
/min = US.gpm x 3.785 US.gpm = /min x 0.2642
oz. x 0.028 oz. = kg x 35.25
kg =
lb. x 0.454 lb. = kg x 2.203
kgm = lb.ft. x 0.139 lb.ft. = kgm x 7.233
kg/m = lb.in. x 17.87 lb.in. = kg/m x 0.056
kg/cm² = psi x 0.070 psi = kg/cm² x 14.22
lb./Imp.gall x 0.100 lb./Imp.gal. = kg/ x 10.00
kg/=
lb./US.gall x 0.120 lb./US.gal. = kg/ x 8.333
kg/m³ = lb./cu.ft. x 16.21 lb./cu.ft. = kg/m³ x 0.062
Nm = lb.ft. x 1.356 lb.ft. = Nm x 0.737
bar = psi x 0.07 psi = bar x 14.503
Example:
42 mm →???? inch
42x0.0394= 1.6548 inch
42 inch →???? mm
42x25.4=1066.8 mm
00-14
CONTENTS
SECTION 10
CONTENTS
1. TRANSMISSION................................................................. 1 3. HYDRAULIC FRONT AXLE SUSPENSION..................... 48

• INTRODUCTION.................................................................. 1 • 3.1 FRONT SUSPENSION CONTROL VALVE ................. 49
• 1.1 TRANSMISSION (Power Shift version) ........................ 2
4. FRONT AXLE.................................................................... 53
• • 1.1.1 MAIN COMPONENTS.......................................2
• • 1.1.2 TRANSMISSION HYDRAULIC SYSTEM...........5 • 4.1 HUB CARRIER AND FINAL REDUCTION UNIT......... 54
• • 1.1.3 GEARBOX .........................................................6 • 4.2 DIFFERENTIAL ........................................................... 56
• • GEARBOX COMPONENTS ........................................7
• • 1.1.4 MAIN CLUTCH..................................................8 5. HYDRAULIC SYSTEM ..................................................... 58
• • 1.1.5 HYDRAULIC GEARBOX AND SHUTTLE • HYDRAULIC SYSTEM
DISTRIBUTION VALVE......................................9
(106-115 CV models) (CCLS version)................................ 59
• • 1.1.6 CLUTCH ENGAGEMENT AND SOLENOID
VALVE OPERATION SCHEMATIC ..................13 • HYDRAULIC SYSTEM
• • 1.1.7 TRANSMISSION ELECTRONIC (120-165 CV models) (CCLS version)................................ 60
SYSTEM SCHEMATIC ....................................14 • HYDRAULIC SYSTEM
• 1.2 TRANSMISSION (Power Shuttle version) .................. 15 (106-115 CV models) (LS version) ..................................... 61
• • 1.1.1 MAIN COMPONENTS.....................................15 • HYDRAULIC SYSTEM
• • 1.1.2 TRANSMISSION HYDRAULIC SYSTEM.........18
(120-165 CV models) (LS version) ..................................... 62
• • 1.2.3 GEARBOX .......................................................19
• • GEARBOX COMPONENTS ......................................20 • 5.1 VARIABLE DISPLACEMENT PUMP ............................ 63
• • 1.2.4 MAIN CLUTCH................................................21 • • 5.1.1 BOOST PUMP ................................................ 66
• • 1.2.5 HYDRAULIC GEARBOX AND • • 5.1.2 HYDRAULIC PUMP ........................................ 67
SHUTTLE DISTRIBUTION VALVE...................22 • • 5.1.3 LOAD SENSING VALVE, PRESSURE
• • 1.2.6 CLUTCH ENGAGEMENT AND SOLENOID CUT-OFF VALVE ............................................ 69
VALVE OPERATION SCHEMATIC ..................26 • 5.2 HYDRAULIC SERVICES GEAR PUMP
• • 1.2.7 TRANSMISSION ELECTRONIC SYSTEM (106-115 CV models) ................................................. 77
SCHEMATIC ...................................................27
• 5.3 STEERING GEAR PUMP
• 1.3 REAR AXLE ................................................................ 29 (106-115 CV models) ................................................. 78
• 1.4 REAR PTO.................................................................. 31 • 5.4 GEAR PUMP FOR HYDRAULIC SERVICES
AND STEERING (120-165 CV models) ...................... 79
2. BRAKING SYSTEM.......................................................... 33
• 5.5 PRIORITY VALVE ....................................................... 81
• 2.1 BRAKE MASTER CYLINDER ..................................... 34
• 5.6 AUXILIARY SERVICES CONTROL VALVE................. 82
• 2.2 BRAKE ....................................................................... 35
• • 5.6.1 TYPES OF CONTROL VALVE WITH FIXED
• 2.3 TRAILER BRAKING SYSTEM .................................... 36 DISPLACEMENT PUMP (CCLS) .................... 85
• • 2.3.1 HYDRAULIC TRAILER BRAKING • • 5.6.2 TYPES OF CONTROL VALVE WITH
(ITALY VERSION) ............................................36 VARIABLE DISPLACEMENT PUMP (LS) ....... 87
• • 2.3.2 HYDRAULIC TRAILER BRAKING • • 5.6.3 SERVICES CONTROL SECTION .................... 88
(EXPORT VERSION)........................................38 • • 5.6.4 DESCRIPTIONS OF COMPONENTS.............. 89
• • 2.3.3 AIR TRAILER BRAKING • • 5.6.5 INLET MANIFOLD (CC version) ...................... 91
(ITALY VERSION) ............................................41 • • 5.6.6 LIFT CONTROL VALVE SECTION .................. 94
• • 2.3.4 AIR TRAILER BRAKING
(EXPORT VERSION)........................................42
• • COMPRESSOR ........................................................43
• • PRESSURE LIMITING VALVE...................................44
• • CAB SUSPENSION FEED VALVE ............................45
• • TRAILER BRAKING VALVE (2-WAY) ........................46
• • TRAILER BRAKING VALVE (1-WAY) ........................47
10-i
TRANSMISSION INTRODUCTION
1. TRANSMISSION
INTRODUCTION
• The AGROTON MARK III series is supplied to the customer with two transmission configurations:
a. POWER SHIFT transmission
b. POWER SHUTTLE transmission
The main difference between these two configurations lies in the behaviour of the electronic control unit when
reversing the direction of travel.
In the POWER SHIFT version, when the operator operates the shuttle control to change the direction of travel, the
command is actually only implemented when the speed of the tractor falls below 10 km/h and when the operator
depresses the clutch pedal.
In the POWER SHUTTLE version, the reversal of the direction of travel is managed entirely by the electronic control
unit without the operator having to depress the clutch pedal.
This type of control is achieved by way of a proportional solenoid valve that directly controls the main clutch.
• The transmission can be divided into the following three sections:

A. Gearbox
B. Rear axle
C. Rear PTO
A B
D0004360
10-1

TRANSMISSION MAIN COMPONENTS (Power Shift version)
1.1 TRANSMISSION (Power Shift version)
1.1.1 MAIN COMPONENTS
1 2
3 4 5 6
17
16
15
14 13 12 11 10 9 8 7 D0004370
1. Rear PTO control solenoid valve 6. Pilot line fitting for main clutch 11. Transmission oil temperature sensor 16. Rear PTO speed selector lever
2. Rear PTO control valve 7. Main clutch control pump (Booster) 12. Four-wheel drive control solenoid valve 17. Rear PTO speed selector lever (Optional)
3. Engine speed sensor (nLse - nMot) 8. Transmission oil low pressure sensor 13. Transmission oil suction line filter
4. Hydraulic pump for transmission 9. Gearbox output shaft speed sensor (nLsa) 14. Speed sensor for odometer (nAb)
5. Hydraulic gearbox control distribution valve 10. Creeper engagement shaft 15. Rear power take-off
10-2

18
19
23
22 21 20
18. Left brake cylinder

19. 30 km/h speed limiting pin
20. Mechanical gearbox shift lever
21. Right brake cylinder
D0004380 22. Differential lock control valve
23. Differential lock control solenoid valve
10-3

25
24
26
29 28 27 D0004390
24. Left axle casing

25. Lift shaft
26. Right axle casing
27. Rear PTO speed sensor
28. Gearbox oil level indicator
29. Rear reduction unit oil level indicator
10-4

TRANSMISSION TRANSMISSION HYDRAULIC SYSTEM (Power Shift version)
1.1.2 TRANSMISSION HYDRAULIC SYSTEM
The transmission hydraulic system is supplied by a gear pump driven from a lateral power-take-off.
The gear pump supplies pressurised fluid for the following uses:
• hydraulic gearbox control valve
• forward/reverse shuttle control valve
• main clutch pump (Booster)
• 4WD control solenoid valve
• rear PTO control solenoid valve
• differential lock control solenoid valve
• lubrication of the gearbox, rear differential and rear PTO clutch control shaft.
Lubrication circuit
pressure relief valve
Lubrication of
rear differential
PTO control
solenoid valve
Lubrication
Gearbox of rear PTO
lubrication drive shaft
Cooler
(not part of the
transmission)
Four-wheel
drive control
solenoid valve Gearbox control
distribution valve
To main clutch
Pressure Temperature
sensor sensor
Booster Gear pump
Cold starting Suction filter

safety valve
D0004411
10-5
GEARBOX DESCRIPTION (Power Shift version)
1.1.3 GEARBOX
DESCRIPTION
• The POWER SHIFT transmission receives drive from the engine (1) and transmits drive through the hydraulically-con-
trolled gearbox (2), the creeper unit (3), the main clutch (4) and the 6-speed mechanical gearbox (5) to the pinion (6)
and the power take-off (7) that provides the drive to the front axle .
The POWER SHIFT transmission is equipped with a double-output power take-off (9) to drive the hydraulic system
pumps.
9 4
2
1
3 5
NO LL 4ª 3ª 6ª 5ª 2ª 1ª
8 7 D0004400
COMPONENTS
1. Engine
2. Hydraulically-controlled 8-speed gearbox (4 forward and 4 reverse)
3. Creeper unit
4. Main clutch
5. 6-speed mechanical gearbox
6. Pinion
7. 4WD engagement clutch
8. Power take-off for front axle drive
9. Power take-off for hydraulic pumps
10-6
GEARBOX COMPONENTS (Power Shift version)
GEARBOX COMPONENTS
1 2 3 4 7 10 15
5 6 8 9 11 12 13 14
NO LL 4ª 3ª 6ª 5ª
2ª 1ª
D0004480
23 21 22 20 19 18 17 16
1. Flywheel and damper 6. Clutch “A” 11. Hydraulic pumps PTO drive gear 16. 1st and 2nd speed synchronizer 21. Clutch “G”
2. Clutch housing 7. Creeper unit 12. 3rd and 4th speed synchronizer 17. Pinion 22. Clutch “B”
3. Input shaft 8. Creeper unit synchronizer 13. 5th and 6th speed synchronizer 18. 4WD control clutch 23. Clutch “D”
4. Hydraulically-controlled gearbox 9. Main clutch 14. 1st and 2nd speed drive shaft 19. Creeper unit driven shaft
5. Clutch “C” 10. Mechanical gearbox 15. Rear PTO drive shaft 20. Clutch “F”
10-7

GEARBOX MAIN CLUTCH (Power Shift version)
1.1.4 MAIN CLUTCH
The main clutch of the POWER SHIFT transmission is an oil-bath multiplate unit with servo-assisted engagement and
hydraulic pilot system.
Clutch operation is entirely manual by way of the clutch pedal.
The system is equipped with a clutch cylinder (Booster) that directs fluid under pressure to the main clutch in accordance
with the travel of the clutch pedal.
ECU
D0004420
1. Clutch pedal
2. Clutch pilot cylinder
3. Transmission gear pump
4. Clutch control cylinder (Booster)
5. Main clutch
10-8

GEARBOX HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE (Power Shift version)
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE
The function of the hydraulic gearbox distribution valve is to pilot and control the engagement of the gears in the
hydraulically-controlled gearbox .
The distribution valve controls the operation of:
A. the hydraulic gearbox control valve (1) to select S, H, M and L ratios
B. the shuttle control valve (2) to select FORWARD and REVERSE gears.
This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox, the rear differential and
the rear PTO control shaft.
1 2
Y7
B
F
Y6
Y5
VR1 VR2
VR
Y1
G1
Y4
H1
B1 S2
W
S1
R1 U
P2
P1
H2
PILOT P4
PRESSURE
VALVE 10 bar
Y2 G2
PILOT PRESSURE
VALVE 18 bar
P4
Y3
1
D
D0004430
CONTROL AND
LUBRICATING PUMP
10-9
GEARBOX GEARBOX CONTROL VALVE (Power Shift version)
A. GEARBOX CONTROL VALVE
PRESSURE TEST POINTS
a b c d e f
g
h
n m D0004440
Pos. Function Thread size
a. A or F clutch pressure M10x1
b. B or G clutch pressure M10x1
c. Y3 or Y4 solenoid valve pressure M10x1
d. Pressure Pg to relief valve M10x1
e. Pressure Pr from relief valve (18 bar) M10x1
f. Engagement pressure of clutch C or D M10x1
g. General pressure (18 bar) M10x1
h. Engagement pressure of clutch A/B or F/G M10x1
l. Pilot pressure (10 bar) M10x1
m. D clutch pressure M10x1
n. C clutch pressure M10x1
p. Modulated pressure M10x1
10-10
GEARBOX GEARBOX CONTROL VALVE (Power Shift version)
MAIN COMPONENTS
G1 S1 H2 H1
B1 Y3
R1 Y4
P1 Y1
P2 Y5
U Y2
P4 G2 P3
D0005320
B1 Breather valve
G1 Clutch selection valve for A/B or F/G clutches
S1 Relief valve
H2 Clutch engagement valve for C/D clutches
H1 Clutch engagement valve for A/B or F/G clutches
Y3 Pilot solenoid valve for engagement valve H2
Y1 Pilot solenoid valve for clutch selection valve G1
Y5 Pilot solenoid valve for road/field selection valve
Y2 Pilot solenoid valve for C or D clutch selection valve G2
P3 Pilot pressure regulating valve
G2 Clutch selection valve for C or D clutches
P4 General pressure regulating valve
U Road/field operating mode selection valve
P1 Pressure modulating valve
P2 2-stage valve
R1 Null shift valve
10-11
GEARBOX SHUTTLE CONTROL VALVE (Power Shift version)
B. SHUTTLE CONTROL VALVE
MAIN COMPONENTS
VR Y6 Y7 S2
1 1
D0005330
Y6 Pilot solenoid valve for FORWARD gear

Y7 Pilot solenoid valve for REVERSE gear
VR FORWARD/REVERSE control spool valve
S2 Relief valve
1 Neutral return device
10-12
GEARBOX CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC (Power Shift version)
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC

Forward
C A C A C A C A
Input
shaft D B D B D B D B
C A
Output
shaft GF GF GF GF
L gear M gear H gear S gear

D B
Reverse
GF
C A C A C A C A
Neutral
D B D B D B D B
GF GF GF GF

D0004501
Solenoid valve operation when shifting from L to S gear (L→M→H→S)

Forward Reverse
Solenoid valve
L M H S L M H S
Y6 ● ● ● ●
Y7 ● ● ● ● ● = Solenoid valve energised
Y1 ● ● ● ● ❍ = Solenoid valve briefly
Y2 ● ● ● ● energised
Y3 ❍ ❍ ❍ ❍ ❍ ❍ during gear change
Y4 ❍ ❍
Solenoid valve operation when shifting from S to L gear (S→H→M→L)

Forward Reverse
Solenoid valve
S H M L S H M L
Y6 ● ● ● ●
Y2 ● ● ● energised
Y4 ❍ ❍
10-13

GEARBOX TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC (Power Shift version)
1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC
COMPONENTS
A1 Electronic transmission control unit
A1- E8G
A2 Shuttle control lever (FORWARD/REVERSE)
EDM1 18
ED1+ 10 67 SD2 A6
ED2-
ED3(V)
45
37
17
25, 27
AD1
AD2 A3 Gearbox control valve
ED4(R) 9 32, 49 AD3
ED6 6 2, 24 AD4
EAM3 7
30
33
AD5
AD6 A4 Shuttle control valve
EDM2 13 5 AD7 H4
EAM1 35 26 AD8
EAM2
EF1
22
42
29 AD9 A14 A5 Range selector lever (L M H S)
EF2 16, 19 51 SD1
EF3
PWM1
71, 47
39
50 SDD1
1V A7 A6 Provision for tachymeter connection
A8
A7 Display
A2
A8 Diagnostics connection
A10 Engine load sensor
A5 +
A11 -
A11 Clutch pedal position sensor
A13 Transmission oil temperature sensor
Starting
A13 S3 inhibitor
S4 switch A14 Transmission oil low pressure indicator
A10
S6
B2 Pinion speed sensor (nAb) (theoretical groundspeed)
B3 Hydraulic gearbox output speed sensor (nLsa)
B2
B3 B4 Transmission input speed sensor (nLse - nMot)
ENGINE
B4 A3 A4 F1 Fuse (1A)
F2 Fuse (8A)
H4 FORWARD/REVERSE indicator lamp
H5 Audible alarm
S3 Clutch pedal depressed sensor
S4 Mechanical gearbox neutral sensor
1 F1 2 KL.30 PERMANENT PLUS
(+)
(+)
1 F2 2 KL.15 IGNITION S6 Transmission oil low pressure sensor (18 bar)
A14 A5
H
A13 T
07 29 08 10 45 55 31 54 (+)
(+) 37 EAM3 AD9 ED6 ED1 ED2 VP2 VP1 VP1
AD1 ED3(V) (T+) (T-) 50
09 SDD1 ED1 A8
AD2 ED4(R)
11 17
A2 UREF(5V) AD1 Y1 (GV1) (-)
25/27
AD2 Y2 (GV2)
H
22 32/49
X EAM2 AD3 Y3 (HV1) A3
A11 02/24
21 VMA AD4 Y4 (HV2)
47 26
DIAG. AD8 Y5 (MVKL)
71 30
EF3 AD5
19
DIAG. 33
16 AD6 (+)
EF2
42 51
EF1 SD1 SD1
A10 VMG1 EAM1 PWM1 EDM2 EDM1 AD7 VPS VM1 VM2 SD2 (-) A7
28 35 39 13 18 05 03 52 06 34 67
H5
Y7 Y6
(MVR) (MVV)
B2 B3 B4
S4
S3 S6 A6
P H4 A4
(-)
D0004491
10-14

TRANSMISSION MAIN COMPONENTS (Power Shuttle version)
1.2 TRANSMISSION (Power Shuttle version)
1.1.1 MAIN COMPONENTS
1 2 3 4 5 6
17
16
15
14 13 12 11 10 9 8 7 D0005170
1. Rear PTO control solenoid valve 6. Hydraulic gearbox distribution valve 11. Four-wheel drive control solenoid valve 16. Rear PTO speed selector lever
2. Rear PTO control valve 7. Transmission oil low pressure sensor 12. Transmission oil suction line filter 17. Rear PTO speed selector lever (Optional)
3. Engine speed sensor (nLse - nMot) 8. Gearbox output shaft speed sensor (nLsa) 13. Speed sensor for odometer (nAb)
4. Clutch control solenoid valve 9. Creeper engagement shaft 14. Clutch speed sensor (nHk)
5. Hydraulic pump for transmission 10. Transmission oil temperature sensor 15. Rear power take-off
10-15

18
19
23
22 21 20
18. Left brake cylinder

19. 30 km/h speed limiting pin
20. Mechanical gearbox shift lever
21. Right brake cylinder
22. Differential lock control valve
23. Differential lock control solenoid valve
D0005230
10-16

25
24
26
29 28 27 D0004390
24. Left axle casing

25. Lift shaft
26. Right axle casing
27. Rear PTO speed sensor
28. Gearbox oil level indicator
29. Rear reduction unit oil level indicator
10-17

TRANSMISSION TRANSMISSION HYDRAULIC SYSTEM (Power Shuttle version)
1.1.2 TRANSMISSION HYDRAULIC SYSTEM
The transmission hydraulic system is supplied by a gear pump driven from a lateral power take-off.
The gear pump supplies pressurised fluid for the following uses:
• hydraulic gearbox control valve
• forward/reverse shuttle control valve
• proportional solenoid control valve for main clutch
• 4WD control solenoid valve
• rear PTO control solenoid valve
• differential lock control solenoid valve
• lubrication of the gearbox, rear differential and rear PTO clutch control shaft.
Lubrication circuit
pressure relief valve
Lubrication of
rear differential
PTO control
solenoid valve
Lubrication
Gearbox of rear PTO
lubrication drive shaft
Gearbox control
distribution valve
Cooler
(not part of the
Main clutch transmission)
Four-wheel
drive control
solenoid valve
Proportional
solenoid valve
Pressure Temperature
sensor sensor
Gear pump
Cold starting Suction filter

safety valve
D0005181
10-18

GEARBOX DESCRIPTION (Power Shuttle version)
1.2.3 GEARBOX
DESCRIPTION
• The POWER SHUTTLE transmission receives drive from the engine (1) and transmits drive through the hydraulically-
controlled gearbox (2), the creeper unit (3), the main clutch (4) and the 6-speed mechanical gearbox (5) to the pinion
(6) and the power take-off (7) that provides the drive to the front axle .
The POWER SHUTTLE transmission is also equipped with a double-output power take-off (9) to drive the hydraulic
system pumps.
9 4
2
1
3 5
NO LL 4ª 3ª 6ª 5ª 2ª 1ª
8 7 D0004400
COMPONENTS
1. Engine
2. Hydraulically-controlled 8-speed gearbox (4 forward and 4 reverse)
3. Creeper unit
4. Main clutch
5. 6-speed mechanical gearbox
6. Pinion
7. 4WD engagement clutch
8. Power take-off for front axle drive
9. Power take-off for hydraulic pumps
10-19

GEARBOX COMPONENTS (Power Shuttle version)
GEARBOX COMPONENTS
1 2 3 4 7 10 15
5 6 8 9 11 12 13 14
NO LL 4ª 3ª 6ª 5ª
2ª 1ª
D0005190
23 21 22 20 19 18 17 16
1. Flywheel and damper 6. Clutch “A” 11. Hydraulic pumps PTO drive gear 16. 1st and 2nd speed synchronizer 21. Clutch “G”
2. Clutch housing 7. Creeper unit 12. 3rd and 4th speed synchronizer 17. Pinion 22. Clutch “B”
3. Input shaft 8. Creeper unit synchronizer 13. 5th and 6th speed synchronizer 18. 4WD control clutch 23. Clutch “D”
4. Hydraulically-controlled gearbox 9. Main clutch 14. 1st and 2nd speed drive shaft 19. Creeper unit driven shaft
5. Clutch “C” 10. Mechanical gearbox 15. Rear PTO drive shaft 20. Clutch “F”
10-20

GEARBOX MAIN CLUTCH (Power Shuttle version)
1.2.4 MAIN CLUTCH
The main clutch of the POWER SHUTTLE transmission is an oil-bath multiplate unit with hydraulic control.
Clutch operation is entirely automatic and is controlled by an electronic control unit which receives signals from the clutch
pedal position sensor.
The system has a clutch control solenoid valve that directs pressurised fluid to the clutch in accordance with the pedal
position.
4
2
3
1
ECU
D0005200
1. Clutch pedal
2. Clutch pedal position sensor
3. Electronic transmission control unit
4. Transmission gear pump
5. Clutch control proportional solenoid valve
6. Main clutch
10-21
GEARBOX HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE (Power Shuttle version)
1.2.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE
The function of the hydraulic gearbox distribution valve is to pilot and control the engagement of the gears in the
hydraulically-controlled gearbox .
The distribution valve controls the operation of:
A. the hydraulic gearbox control valve (1) to select S, H, M and L ratios
B. the shuttle control valve (2) to select FORWARD and REVERSE gears.
This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox, the rear differential and
the rear PTO control shaft.
1
A
Y7
B
F
Y6
Y5
VR1 VR2
VR
Y1
G1
Y4
H1
B1 S2
W
S1
R1 U
P2
P1
H2
PILOT P4
PRESSURE
VALVE 10 bar
Y2 G2
PILOT PRESSURE P4
VALVE 18 bar
1
Y3
D
Y8
CONTROL AND
LUBRICATING PUMP D0005210
10-22
GEARBOX GEARBOX CONTROL VALVE (Power Shuttle version)
A. GEARBOX CONTROL VALVE
PRESSURE TEST POINTS
a b c d e f
g
h
n m D0004440
Pos. Function Thread size
a. A or F clutch pressure M10x1
b. B or G clutch pressure M10x1
c. Y3 or Y4 solenoid valve pressure M10x1
d. Pressure Pg to relief valve M10x1
e. Pressure Pr from relief valve (18 bar) M10x1
f. Engagement pressure of clutch C or D M10x1
g. General pressure (18 bar) M10x1
h. Engagement pressure of clutch A/B or F/G M10x1
l. Pilot pressure (10 bar) M10x1
m. D clutch pressure M10x1
n. C clutch pressure M10x1
p. Modulated pressure M10x1
10-23
GEARBOX GEARBOX CONTROL VALVE (Power Shuttle version)
MAIN COMPONENTS
G1 S1 H2 H1
B1 Y3
R1 Y4
P1 Y1
P2 Y5
U Y2
P4 G2 P3
D0005320
B1 Breather valve
G1 Clutch selection valve for A/B or F/G clutches
S1 Relief valve
H2 Clutch engagement valve for C/D clutches
H1 Clutch engagement valve for A/B or F/G clutches
Y1 Pilot solenoid valve for clutch selection valve G1
Y5 Pilot solenoid valve for road/field selection valve
Y2 Pilot solenoid valve for C or D clutch selection valve G2
P3 Pilot pressure regulating valve
G2 Clutch selection valve forC or D clutches
P4 General pressure regulating valve
U Road/field operating mode selection valve
P1 Pressure modulating valve
P2 2-stage valve
R1 Null shift valve
10-24
GEARBOX SHUTTLE CONTROL VALVE (Power Shuttle version)
B. SHUTTLE CONTROL VALVE
MAIN COMPONENTS
VR Y6 Y7 S2
1 1
D0005330
Y6 Pilot solenoid valve for FORWARD gear

Y7 Pilot solenoid valve for REVERSE gear
VR FORWARD/REVERSE control spool valve
S2 Relief valve
1 Neutral return device
10-25
GEARBOX CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC (Power Shuttle)
1.2.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC

Forward
C A C A C A C A
Input
shaft D B D B D B D B
C A
Output
shaft GF GF GF GF

D B
Reverse
GF
C A C A C A C A
Neutral
D B D B D B D B
GF GF GF GF

D0004501
Solenoid valve operation when shifting from L to S gear (L→M→H→S)

Forward Reverse
Solenoid valve
L M H S L M H S
Y6 ● ● ● ●
Y2 ● ● ● ● energised
Y4 ❍ ❍
Solenoid valve operation when shifting from S to L gear (S→H→M→L)

Forward Reverse
Solenoid valve
S H M L S H M L
Y6 ● ● ● ●
Y2 ● ● ● energised
Y4 ❍ ❍
10-26
GEARBOX TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC (Power Shuttle version)
1.2.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC
COMPONENTS
A1 Electronic transmission control unit(EST45)
EST-45
SD 2 59 36 SD 4 A9
A2.1 Range selector lever (L M H S)
ED 11 29
ED 8 44 57 ADM 5
EU 1
ED 6
38
67
11
34
ADM 6
ADM 7
A2.2 Shuttle control lever (FORWARD/REVERSE)
ED 7 22 33 ADM 8
ED 1 63 50 AIP 7
ED 2
ED 3
65
20 A1
32
55
AIP 3
AIP 4
A3 Gearbox control valve
ED 12 30
EDM 1
ER 1
31
39
56 AIP 1 H3 A5 Diagnostics
EF 7 17 5 ADM 4 A12
EF 6 40
EF 5 16 A6 Display
EF 4 62 14 SD 1 A6
15 SDDK
H5
A9 Tachymeter
S7 A5 A10 Engine load sensor

A11 Proportional solenoid valve for main clutch control
B10 +
-
A2.1 A12 INFOCENTER
A2.2
B1 Engine speed sensor (nLse - nMot)
B11 B13
B3 Hydraulic gearbox output speed sensor (nAb)
A11 S4
A10 S6 PEDAL
CLUTCH
K1 B4 Transmission input speed sensor (nLsa)
B9 Clutch speed sensor (nHk)
B3 B9 6-SPEED
TRANSMISSION B4
B10 Clutch pedal position sensor
ENGINE CLUTCH
B11 Temperature sensor
A3 A4
B1 B13 Clutch proximity sensor
F1 Fuse (8A)
F2 Fuse (8A)
H3 Low oil pressure indicator lamp
H5 Audible alarm
1 F1 2 KL.30
(+)
(+)
1 F2 2 KL.15
K1 Interlock starter relay 70A
1
S7
1
P
1
S6
S4 Mechanical gearbox neutral sensor
B13 H3
B9 3 B4 3 B3 3 B1 3 2 2 2
A5 1
2 2 2 2 44 45 23 68 5 21 30 29 S6 Transmission oil low pressure sensor (18 bar)
ED8 VP1 VPE1 VPE2 ADM4 ED10 ED12 ED11
4 15 2
1 1 1 1 VMG2 SDDK
17
3
EF7
36 A6 X2:D H5 S7 Interlock button
40
VMG1 SD4 A9
EF6
62 3 X2:A
EF4 14 X1:B
16 SD1
EF5 57 B
38 ADM5 Y1(GV1)
EU1 11 C
37 ADM6 Y2(GV2)
2 AU 34 D
ADM7 Y3(HV1) X2:C
A1 33 E A3
B10 H
3
ADM8
50 A
Y4(HV2) A12
T AIP7
24 Y5(MVR)
1 VMGA1 8 F
VPS2 (+) OPTION
H
T
B11 32 1
39 AIP3 Y6(MVV)
ER1 55 2
VP 67
ED6
AIP4 Y7(MVR) A4
A2.1 TIPP + 22 VPS1
12 3
(+)
TIPP - ED7
56 1
63 AIP1 FK
V - AUTOM. ED1 13 2 A11
65 VPS1 (+)
VP N - AUTOM. ED2
20
R - AUTOM. ED3
EDM1 VM1 VM2 SD2
A2.2
KL.30 31 01 02 59
87 85
1
K1 S4 OPTION
30 86 A10
2
KL.50a KL.50
Mot. avv. Blocco. avv.
D0005221
10-27

PAGE INTENTIONALLY
LEFT BLANK

REAR AXLE DESCRIPTION
1.3 REAR AXLE
DESCRIPTION
The rear axle receives drive from the pinion (4) and transmits drive through the differential (5) and epicyclic reduction units
(2) to the rear wheels (1).
The rear axle is equipped with an electro-hydraulically controlled differential lock (6) and two hydraulically operated brakes
(3).
4
2 2
3 3
1 1
6 5
D0004450
COMPONENTS
1. Wheels
2. Epicyclic reduction unit
3. Brake
4. Pinion
5. Differential
6. Differential lock
10-29

REAR AXLE COMPONENTS
COMPONENTS
1 2 3 4 5 6 7 8
D0004470
12 11 10 9
1. Differential lock 7. Hub

2. Central axle housing 8. Axle casing
3. Differential 9. Planet carrier
4. Brake control device 10. Ring gear
5. Brake 11. Planet pinion
6. Half-shaft 12. Crown wheel
10-30

REAR AXLE DESCRIPTION
1.4 REAR PTO
DESCRIPTION
The rear PTO provides drive for external implements at a preselected rotation speed.
The rotary drive is taken directly from the engine and then reduced through a 2 -or 4-speed gearbox with manual speed
selection.
The PTO is engaged by way of an electro-hydraulically controlled clutch .
a b
3 3
1 1
4 4
6 5 6 5
562 1046 c d
D0004460
1. Clutch Speed of PTO output shaft - 4-speed version

2. Synchronizer 1 Synchronizer 2
3. Intermediate shaft Synchronizer 1
c d
4. Intermediate shaft
5. PTO shaft a 562 1046
6. Synchronizer 2 b 772 1437
10-31

REAR PTO COMPONENTS
COMPONENTS
2 SPEED VERSION 4 SPEED VERSION

a b
1 2 1 2
3 3
4 4
8
5 5
6 6
7 7
D0005340
c d c d
1. PTO engagement clutch 5. Synchronizer (speeds a/b)

2. PTO input shaft 6. PTO end shaft
3. Intermediate shaft 7 PTO output shaft
4. Intermediate shaft 8. Synchronizer (speeds c/d)
10-32

BRAKING SYSTEM DESCRIPTION
2. BRAKING SYSTEM
DESCRIPTION
The braking system is comprised of 2 braking devices (one for each rear wheel) operated by two hydraulic pumps by way
of mechanical controls.
Each pump supplies fluid to the brake on one side (left or right) thereby allowing the operator to brake on one side only and
thus reduce the steering radius.
3
2
5
4
6
8
7
D0004510
1. Brake fluid reservoir 5. Rear axle

2. Right master cylinder 6 Right brake
3. Brake microswitches (n° 2) 7. Left brake
4. Brake pedal 8 Left master cylinder
10-33
BRAKING SYSTEM MASTER CYLINDER
2.1 BRAKE MASTER CYLINDER
1
2
3
D0004520
1. Bleed screw TECHNICAL DATA

2. Barrel Piston diameter: 23.81 mm (0.938 in.)
3. Push-rod Piston stroke: 30 mm (1.182 in.)
Maximum operating pressure: 120 bar (1740 psi)
10-34
BRAKING SYSTEM BRAKE
2.2 BRAKE
5
1
A-A
A A
7
D0004530
1. Piston 5. Support
2. Plunger 6. Rod
3. Adjustment nuts 7. Parking brake control lever
4. Lever
10-35
BRAKING SYSTEM TRAILER BRAKING SYSTEM
2.3 TRAILER BRAKING SYSTEM
The tractor may be equipped with one of the four following trailer braking systems:
1. hydraulic trailer braking (Italy version)
2. hydraulic trailer braking (Export version)
3. air trailer braking (Italy version)
4. air trailer braking (Export version)
2.3.1 HYDRAULIC TRAILER BRAKING (ITALY VERSION)
Freno a mano
Hand brake
P
Y
B N LS 2
D0004540
1. Valve activation lever in position “1”

• When the lever (1) is in position “1” (valve activated) and the brake pedals are not pressed, a pressure of 12.5 bar
(181.3 psi) is available at port B.
• This pressure is supplied constantly to the trailer to release the parking brake.
• When the operator engages the parking brake, the solenoid valve (2) is energised; this nullifies the pressure at
port B.
• The pressure at port B is directly proportional to the pressure present in the tractor braking circuits Y.
2. Valve activation lever in position “O”

• When the lever (1) is in position “O” (valve deactivated), there is no pressure at port B.
In this condition, the pressure at port B is always null independently of the pressure in the tractor braking circuits.
10-36
1
N
LS
B
HYDRAULIC DIAGRAM
P
N LS
E
B T
D0004550
FUNCTION TECHNICAL DATA

Port P - Valve feed • Maximum pressure at port N:
Port N - To lubrication line 210 bar (3046 psi)
Port B - To trailer brake • Minimum constant pressure at port B:
Port T - Drain 12.5±2 bar (181.3±29 psi)
Port Y - Connection to tractor braking system • Maximum pressure at port B:
135 --0 5 bar (1957.5 --0 72.5 psi)
Port LS - Load Sensing signal
• Feed flow rate:
20–80 /min (5.3 -- 21.14 US.gpm)
10-37
2.3.2 HYDRAULIC TRAILER BRAKING (EXPORT VERSION)
N
LS
B
D0004560
• When the brakes are not operated the pressure at port B is null.
• When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at
port B increases proportionally to the pressure in the tractor braking circuit.
10-38
MODELS 106 - 110 - 115 CV
HYDRAULIC DIAGRAM
P T
D0004570
N B
Port P - Valve feed TECHNICAL DATA

Port N - To lubrication line • Maximum pressure at port N:
Port B - To trailer brake 210 bar (3046 psi)
Port Y - Connection to tractor braking system • Minimum constant pressure at port B:
Port T - Drain 0 bar (0 psi)
• Maximum pressure at port B:
142 +0 8 bar (2059 +0 116 psi)
• Feed flow rate:
20–80 /min (5.3 -- 21.14 US.gpm)
10-39
MODELS 120 - 135 - 150 - 165 CV
LS B LS
HYDRAULIC DIAGRAM
P T
N B LS D0004580
Port P - Valve feed TECHNICAL DATA

Port N - To lubrication line • Maximum pressure at port N:
Port B - To trailer brake 210 bar (3046 psi)
Port T - Drain • Minimum constant pressure at port B:
Port Y - Connection to tractor braking system 0 bar (0 psi)
Port LS - Load Sensing signal • Maximum pressure at port B:
142 +0 8 bar (2059 +0 116 psi)
• Feed flow rate:
20–80 /min (5.3 -- 21.14 US.gpm)
10-40
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)
3
E
2 4 5
1
Capacity 20
G
10
11
9 8
STANDARD SYSTEM BRAKING

D0004600
COMPONENTS
1. Compressed air reservoir 7. Trailer braking valve
2. Air compressor 8. Circuit pressure sensor
3. Engine 9. Circuit pressure indicator
4. Pressure limiting valve (7.8 bar (113 psi)) 10. Brake master cylinder
5. Quick-action coupler for trailer 11. Brake
6. Feed valve for cab air suspension
10-41
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION)
3
E
2 4
1 5
Red
Capacity 20
5
6
Yellow 5
7 Black
8
G
10 9
11 12
STANDARD SYSTEM BRAKING

D0004591
1. Compressed air reservoir 7. Trailer braking valve (2-way)

2. Air compressor 8. Trailer braking valve (1-way)
3. Engine 9. Circuit pressure sensor.
4. Pressure limiting valve (7.8 bar (113 psi)) 10. Circuit pressure indicator
5. Quick-action coupler for trailer 11. Brake master cylinder
6. Feed valve for cab air suspension 12. Brake
10-42
BRAKING SYSTEM COMPRESSOR
COMPRESSOR
4
a
D0004620
a. Port 0.1 - Compressor lubrication TECHNICAL DATA

b. Port 0 Bore: 90 mm (3.546 in.)
c. Port 2 - Compressed air delivery Stroke: 36 mm (1.418 in.)
Displacement: 229 cm³
1. Cylinder head
2. Cylinder Max. pressure.: 10 bar (145 psi)
3. Flange Crankshaft end float: 0.08–0.38 mm (0.003 – 0.015 in.)
4. Crankshaft
10-43
BRAKING SYSTEM PRESSURE LIMITING VALVE
PRESSURE LIMITING VALVE
1 21
1-2
DIAGRAM
7,8±0,2 bar
1 21
0
12 + 2 bar
22 3 1-2
D0004690
Port 1 - From compressor TECHNICAL DATA

Port 3 - Excess pressure vent Cut-out pressure: 7.8±0.2 bar (113±2.9 psi)
Port 21 - To compressed air reservoir Cut-in pressure: 0.6–1 bar (8.7 – 14.5 psi)
Relief valve setting: 12 +0 2 bar (174 +0 29 psi)
10-44
BRAKING SYSTEM CAB SUSPENSION FEED VALVE
CAB SUSPENSION FEED VALVE
FUNCTION
Supplies compressed air to the pneumatic cab suspension system only when the pressure in the trailer braking circuit
exceeds 6 --0 0.3 bar (87 --0 4.35 psi)
D0004700
TECHNICAL DATA
Opening pressure: 6 --0 0.3 bar (87 --0 4.35 psi)
Maximum operating pressure: 13 bar (188 psi)
10-45
BRAKING SYSTEM TRAILER BRAKING VALVE (2-WAY)
TRAILER BRAKING VALVE (2-WAY)
41 42 1
DIAGRAM 3
1
41
42
P2 (bar)
9
8
Delivery pressure
7
2
)
.42
6
41
(P
)
5 42
f( 1
f
2=
2 =
P4
4 P4
1)
3 P4
f(
2=
2 P4
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
P41/P42 (bar) D0004761
Hydraulic control pressure
1. Parking brake actuating lever Port 1 - From compressed air reservoir

2. Bleed screw Port 2 - To trailer brake
Port 41 - From left brake
Port 42 - From right brake
10-46
BRAKING SYSTEM TRAILER BRAKING SYSTEM (1-WAY)
TRAILER BRAKING VALVE (1-WAY)
4
2
1
D0004710
Port 1 - From compressed air reservoir

Port 2 - To trailer brake
Port 4 - Pilot from delivery line to trailer
(2-way braking)
10-47
HYDRAULIC FRONT AXLE SUSPENSION DESCRIPTION
3. HYDRAULIC FRONT AXLE SUSPENSION
DESCRIPTION
The function of the hydraulic front suspension system is to absorb impacts when travelling over rough terrain and to keep
the tractor body on an even keel on the road.
The system comprises:
• swinging axle support arm (1)
• position sensor (2)
• 2 suspension cylinders (3)
• front suspension control valve (4)
• electronic control unit (5)
4
5
2
1 D0004720
10-48
HYDRAULIC FRONT AXLE SUSPENSION FRONT SUSPENSION CONTROL VALVE
3.1 FRONT SUSPENSION CONTROL VALVE
FUNCTION
In addition to the primary function of enabling front axle suspension by charging the hydraulic-pneumatic accumulators
that constitute the elastic elements of the system, the front suspension control valve also serves to control the raising and
lowering of the front axle.
1 ASP
A
SV1
BL2 RV3
DBV2 LS-V
LS 6
5 BL3 AV2
SV2
2
B
ZSP1
ASP
3
RV1
BL1
DIAGRAM
LS
5
A
LS DBV1
LS-V P T
BL3
BL2
ASP1 ASP2 T AV1
S
RV2
AV DBV1 DBV2
SV1
250 +10 bar 250 +10 bar RV3

A
AV2
RV2
H
ZSP1 SV2
BL1
RV1
B P
D0004750
1. Cylinder retraction control solenoid valve 5. Pressure discharge valve

2. LS signal control solenoid valve 6. Accumulator (setting: 140 bar)
3. Cylinder extension control solenoid valve 7. Use A relief valve (setting: 250 bar)
4. Accumulator (setting: 65 bar) 8. Use B relief valve (setting: 250 bar)
10-49
OPERATION
1. When the suspension is deactivated
LS
LS
A
1
LS-V
BL3
P T 7
6 ASP1 ASP2 T
BL2
4 S
DBV1 DBV2
SV1
AV
RV3
A AV2
3 ZSP1
RV2
5 2
H
b
SV2
BL1
B RV1 P
a D0004640
• When the suspension is deactivated, the electronic control unit energises the solenoid (1) by sending an LS signal to
the priority valve (in the case of the gear pump version) or to the variable displacement pump.
• This allows the pressurised oil from the pump (2) to flow to line a and compress the membrane of the accumulator (3)
up to the maximum circuit pressure.
• The oil is discharged from the piston side through passage B and through the solenoid valve (7) which is energised.
• The piston (4) is consequently pushed upwards to its stroke-end position, thereby returning the system to fixed axle
condition.
• The suspension is deactivated by the operator pressing a switch.
10-50
2. When the operator activates the system
A
LS
LS
LS-V
P T
BL3
6 ASP1 ASP2 T
BL2 S
4
DBV1 DBV2
SV1
AV
RV3
5
A AV2
RV2
ZSP1
2
b H
SV2
BL1
B RV1 P
a D0004650
• When the operator presses the switch to activate the suspension, the electronic control unit energises the solenoids
(1) and (5).
• This allows the pressurised oil from the pump (2) to flow to line b and thus start to push the piston (4) downwards.
• At the same time, the oil compresses the membranes of the accumulators and the oil in lines a and b increases.
• When the pressure in line a reaches the opening pressure of the relief valve (8), the valve opens and discharges some
of the oil to the drain circuit.
• When the position sensor detects that the suspension has attained the levelling position, the electronic control unit
de-activates the solenoids (1) and (5) and the part of the system containing the precharged accumulators is isolated
from the rest of the system.
10-51
3. When the system is active

• When the tractor is in motion and the wheels encounter an obstacle, the front axle is pushed upwards.
• This causes the pressure P2 to increase (the accumulators 6 are compressed) while the pressure P1 decreases
(accumulator 3 is decompressed).
• The pressure balance is thus altered and the system (which is closed) acts to restore the original condition.
1
A
LS
LS
LS-V
P T
BL3
6 ASP1 ASP2 T
BL2 S
DBV1 DBV2
SV1
P2 AV
RV3
5
A AV2
3 ZSP1 RV2
2
P1 H
SV2
BL1
B RV1 P
4 D0004660
S
S max
P2 max
S,P2
S min
t
P1
P1 min
t shock t damping t
D0002411
10-52
FRONT AXLE
4. FRONT AXLE
B B
1710
=
A A
=
52º –0 2
1710
D0004780
10-53
FRONT AXLE HUB CARRIER AND FINAL REDUCTION UNIT
4.1 HUB CARRIER AND FINAL REDUCTION UNIT
VERSION WITHOUT SBA
4 5 6 7
8
1 2 3
9
10 11
12
18 17
16 15 14 13 D0004790
A-A
1. Planet carrier 10. Oil seal

2. Planet pinion 11. Plain bearing
3. Ring gear 12. Half-shaft
4. Bearing 13. Lower kingpin
5. Flange 14. Oil seal
6. Oil seal 15. Bearing
7. Upper kingpin 16. Oil seal
8. Hub carrier 17. Bearing
9. Front axle 18. Sun wheel
10-54
FRONT AXLE HUB CARRIER AND FINAL REDUCTION UNIT
VERSION WITH SBA
4 5 6 7
8
1 2 3 C
9
10 11
12
18 17
16 15 14 13
B-B
19
19 20
C-C 21 22
D0004800
1. Planet carrier 12. Half-shaft

2. Planet pinion 13. Lower kingpin
3. Ring gear 14. Oil seal
4. Bearing 15. Bearing
5. Flange 16. Oil seal
6. Oil seal 17. Bearing
7. Upper kingpin 18. Sun wheel
8. Hub carrier 19. Steering sensor (n° 2)
9. Front axle 20. Shim
10. Oil seal 21. Disc
11. Plain bearing 22. Lock ring
10-55
FRONT AXLE DIFFERENTIAL
4.2 DIFFERENTIAL
VERSION WITH 100% HYDRAULIC LOCKING
3 4 5 6 7 8
2 9
1 10
11
21 12
20
19
18
17
13
16
14
15
D0004810
1. Roller cage 12. Spacer

2. Belleville springs 13. Bearing
3. Bearing 14. Oil seal
4. Cover 15. Hub
5. Clutch plates 16. Pinion shaft
6. Differential cage 17. Bearing
7. Planet pinion 18. Crown wheel
8. Differential cage 19. Thrust plate
9. Sun gear 20. Thrust levers
10. Bearing 21. Piston
11. Half-shaft
10-56
FRONT AXLE DIFFERENTIAL
45% SELF-LOCKING VERSION
2 3 4 5 6
1 7
8
14
13
9
12
10
11
D0005350
1. Bearing 8. Half-shaft
2. Clutch plates 9. Bearing
3. Differential cage 10. Oil seal
4. Planet pinion 11. Hub
5. Differential cage 12. Pinion shaft
6. Sun gear 13. Bearing
7. Bearing 14. Crown wheel
10-57
HYDRAULIC SYSTEM DESCRIPTION
5. HYDRAULIC SYSTEM
DESCRIPTION
The AGROTON MK3 series may be equipped with two different types of hydraulic system:
1- CCLS hydraulic system, with fixed displacement pump.
2- LS hydraulic system, with variable displacement pump.
The CCLS system has fixed displacement gear pump that supplies oil to the various hydraulic functions at a flow rate that
is proportional to the engine speed.
When the engine is running at maximum speed and none of the hydraulic actuators are in operation (e.g. during road use),
oil is pumped through the system at around 80 litres per minute (with a consequent increase in temperature and fuel
consumption).
Furthermore, if two or more actuators are operated when the engine is running at low speed, the pump will be unable to
meet the demand and consequently the actuators will operate at a lower speed in accordance with the available oil flow.
The LS system has a variable displacement piston pump which sends oil to the hydraulic functions only according to need.
In this system, when the engine is running at maximum speed and no hydraulic actuators are in operation, the pump
effectively only circulates the oil that is dispersed through internal leakage in the devices connected to the system (just a
few litres per minute), thus saving energy and fuel.
Furthermore, the variable displacement pump has a higher capacity than the gear pump (120 litres/min.) and can thus
provide a sufficient flow rate to operate all the hydraulic functions simultaneously.
10-58
HYDRAULIC SYSTEM 106-115 CV models (CCLS version)
HYDRAULIC SYSTEM (106-115 CV models) (CCLS version)
Druckloser
Ruecklauf
LS M7
A AP WV3 WV4
LS
R1
LS-V P T X
BL3
Y
ASP1 ASP2 P
BL2 T X
p =65bar p =65bar
0 0
S
AV1 DBV1 DBV2
SV1
ø3 ø3 RV3
A 250 +10 bar 250 +10 bar
ZSP1 1 1
RV2 AV2
p =140bar
0
H 0 0
SV2
2 2
RV1 BL1
B P
F F
Schmierkreis Einfuellstutzen
-DBV 4 bar A B A B
Wärmetauscher
N B
Schmierung
Zapfwellenkupplung
Systemdruck- Y
Schmierung Halteventil 20 - 2 bar
Schaltgetriebe Bypass- Ventil 3 bar DS
P T
Hydrostatische Lenkung
P L
LS-Block
Lastschalt- M4
18 bar kupplungen
T R Hubwerk
Schmierung
Mech. betätigtes Magnetventil Hinterachse
Ventil für Hinterachs-
Zapfwellenkupplung differential Lenkzylinder
Sperre
LS LS
Zusätzliche P CF
P
Anschlüsse EF
AP WV1 EHR WV2 EP Y
Magnetventil PP
Temperatur- Vorderachskupplung R
X
Druckschalter schalter
Durchm.0,5mm
X
S
P
Pumpe am Getriebe
Kaltstart-DBV 25 bar G Fördermenge 25 cm3/U
∆p=8,4 bar in Schaltstellg.1 od.2
61 l/min bei Nenndrehzahl

∆p=3 bar in Schaltstellg.0
Feinfilter mit β10=1,5 1 1

Bypass-Ventil β30=20 Grobfilter
200 ␮m M6 0 0
2 2
M3 H
F F
Hydraulikpumpe
Pumpe 16 ccm 32 cm3 Motor
A B R1 A A B
Ansaugfeinfilter Bypassventil
25 ␮m
D0004740
Getriebegehäuse
10-59

HYDRAULIC SYSTEM 120-165 CV models (CCLS version)
HYDRAULIC SYSTEM (120-165 CV models) (CCLS version)
LS
A AP WV3 WV4
LS
R1
LS-V P T X
BL3 Y
P
ASP1 ASP2 BL2 T X
p =65bar p =65bar
0 0
S
AV1 DBV1 DBV2
SV1
ø3 ø3 RV3
A 250 +10 bar 250 +10 bar
ZSP1
1 1
RV2 AV2
p 0=140bar
0 0
H
SV2
2 2
BL1
B RV1 P
F F
Einfuellstutzen
A B A B
Nx B LS
P T Hydrostatische Lenkung
P L
Hubwerk
T R
Schmierung
Hinterachse
Lenkzylinder
Resonator
LS
AP WV1 EHR WV2 EP Y

R
X
X
S
P
∆p=8,4 bar in Schaltstellg.1 od.2
∆p=3 bar in Schaltstellg.0
1 1 1
CF EF LS
0 0 0
2 2 2
M3 H
F F F
Motor
Hydraulikpumpe
A B R1 A A B
Ansaugfeinfilter Bypassventil
25 ␮m
D0005250
Getriebegehäuse
10-60

HYDRAULIC SYSTEM 106-115 CV models (LS version)
HYDRAULIC SYSTEM (106-115 CV models) (LS version)
Druckloser
Ruecklauf
LS M7
A AP WV3 WV4
LS
R1
LS-V P T X
BL3 Y
P
ASP1 ASP2 BL2 T X
p =65bar p =65bar
0 0
S
AV1 DBV1 DBV2
SV1
ø3 ø3 RV3
A 250 +10 bar 250 +10 bar
ZSP1 1 1
AV2
p =140bar RV2
0
0 0
H
SV2
2 2
BL1
B RV1 P
F F
Einfuellstutzen
Schmierkreis
-DBV 4 bar A B A B
Wärmetauscher
Power Beyond
Schmierung
Differential
Schmierung N B
Zapfwellenkupplung
Systemdruck-
Schmierung Halteventil 20 - 2 bar Y
Schaltgetriebe Bypass- Ventil 3 bar
DS
P T P L
LS-Block Lastschalt- M4
18 bar kupplungen
T R Hubwerk
Mech. betätigtes Schmierung
Magnetventil Hinterachse
Ventil für Hinterachs-
Zapfwellenkupplung differential Lenkzylinder
Sperre
LS LS
CF
Zusätzliche P
P
Anschlüsse EF
AP WV1 EHR WV2 EP Y
Magnetventil PP
Vorderachskupplung M3 R
Temperatur- 0,3 X
Druckschalter schalter Y
P
X
S
Pumpe am Getriebe
Kaltstart-DBV 25 bar G Fördermenge 25 cm3/U
61 l/min bei Nenndrehzahl B M5 X
Ls
Feinfilter mit β10=1,5 1 1
Bypass-Ventil β30=20 G
Grobfilter
200 ␮m filter FO
0 0
M6
2 2
FI 235 bar
H
F F
M2
5 bar 57
Pumpe 16 ccm
A B R1 A A B
S L1,L M1
100-(280)␮m DS
P = max 0,2bar at 130 l/min
D0005260
Getriebegehäuse
10-61

HYDRAULIC SYSTEM 120-165 CV models (LS version)
HYDRAULIC SYSTEM (120-165 CV models) (LS version)
Druckloser
Ruecklauf
M7
LS
A AP WV3 WV4
LS R1
LS-V P T X
BL3 Y
P
ASP1 ASP2 BL2 T X
p =65bar p =65bar
0 0
S
AV1 DBV1 DBV2
SV1
ø3 ø3 RV3
A 250 +10 bar 250 +10 bar
ZSP1 1 1
AV2
p 0=140bar RV2
0 0
H
SV2
2 2
BL1
RV1 P
B
F F
Einfuellstutzen
X
A B A B
Power Beyond
Schmierung N B
Zapfwellenkupplung x
P T P L
M4
T R Hubwerk
Schmierung
Hinterachse
Lenkzylinder
LS LS
P EF
P
CF
AP WV1 EHR WV2 EP Y

M3 R
X
Y
P
X
S
B M5 X
LS
0,5 bar
G 1 1
filter FO
0 0
2 2
FI 235 bar
H
F F
M2
5 bar
A B R1 A A B
S L1,L M1
100-(280)␮m
DS
P = max 0,2bar at 130 l/min
D0005270
Getriebegehäuse
10-62

HYDRAULIC SYSTEM VARIABLE DISPLACEMENT PUMP
5.1 VARIABLE DISPLACEMENT PUMP
L1 A
M1
M2
C C
B A
X
HYDRAULIC DIAGRAM
2 3
S
X
FO
M1
B
235 bar L
L1
G 1
S
5 bar
FI
FO FI M2 4
D0004900
FUNCTION COMPONENTS
Port L: drain 1. Antishock valve
Port X: LS signal 2. Load Sensing valve
Port S: suction 3. Pressure cut-off valve
Port B: delivery 4. By-pass valve
Port G: transmission lubrication
Port FI: filter inlet
Port FO: filter outlet
10-63
6
5
4 7 8
3
10
2
1
19
18
17
16 15 14 13 12 11
A-A
D0004960
COMPONENTS
1. Input shaft 11. Boost pump
2. Oil seal 12. Boost pump housing
3. Swash plate return spring 13. Bearing
4. Swash plate 14. Valve plate
5. Control rod 15. Pistons (n° 9)
6. Control piston 16. Piston retainer ring
7. Cylinder barrel 17. Piston shoe
8. Spacer 18. Taper roller bearing
9. End cover 19. Pump housing
10. Roller bearings
10-64
COMPONENTS
1. Pressure limiting valve
2. Filter by-pass valve
3. Filter by-pass valve spring D0005110 B-B 3 2
1 2 3 4 5 6
12 11 10 9 8 7
D0004910
C-C
COMPONENTS
1. Load Sensing spool valve 7. Adjustment nuts
2. Restrictor 8. Spring cover
3. Collar 9. Pressure cut-off valve spring
4. Load Sensing valve spring 10. Collar
5. Spring cover 11. Restrictor (Ø 0.6 mm) (0.024 in.)
6. Adjustment nuts 12. Pressure cut-off valve spool
10-65
HYDRAULIC SYSTEM BOOST PUMP
5.1.1 BOOST PUMP
FUNCTION
• Rotary drive and torque is transmitted to the pump from the shaft and converted into hydraulic energy. The
pressurised oil flow from the boost pump is directed to the variable displacement pump and the transmission
lubrication circuit.
3
2
45cc
1 57cc 5 6
4
D0004820
OPERATION
• The boost pump (1) draws oil from the rear gearbox and directs it under pressure to the filter (2) and the variable
displacement pump (3).
• The pressurised oil from the boost pump is also used for lubrication of the transmission (4).
• The pressure generated by the boost pump is regulated by the pressure limiting valve (5) (setting: 5 bar (72.3 psi)) that
prevents excessive pressure from building in the lubrication circuit on cold-starting and during cold weather
conditions.
• The pressure-boosting circuit also includes a low boost pressure sensor (6) (set to 5 bar) that detects clogging of the
filter (2) and alerts the operator by illuminating a warning light.
10-66
HYDRAULIC SYSTEM HYDRAULIC PUMP
5.1.2 HYDRAULIC PUMP
FUNCTION
• The rotary drive and torque transmitted from the
shaft to the pump is converted into hydraulic energy;
the pressurised flow from the pump varies according
to the demand from the hydraulic loads.
• The flow rate can be varied by altering the angle of
the swash plate.
5
3 A 4
2
6 B 7
D0005010
STRUCTURE
• The cylinder block (4) is fixed to the shaft (1) by a • The pistons (5) stroke axially within their bores in the
broached fitting B and the shaft (1) is supported by cylinder block (4).
the front and rear bearings.
• The rotation of the cylinder block (4) causes the oil in
• The pistons (5) have ball ends; the piston shoes (6) fit the bores to be pressurised; the positions of the inlet
around the ball ends of the pistons to form a single and outlet ports are determined by slots in the valve
assembly. The pistons (5) and the shoes (6) together plate (7).
form a ball joint. The oil is drawn into the bores and forced out
through the slots in the valve plate (7).
• The swash plate (3) has a flat surface A against which
the piston shoes slide (6) with a circular motion.
10-67
HYDRAULIC SYSTEM HYDRAULIC PUMP
OPERATION
1. Pump operation
1 - The cylinder block (4) rotates with the shaft (1)
and the piston shoes (6) slide on the flat surface
«A».
3 A 6 S 4 C
The swash plate (3) can swing within the arc «B»;
the stroke of the pistons varies according to the 1
angle «α» between the shaft axis (1) and the X x
axis of the swash plate (3). ␣
Angle «α» is known as the «swash plate angle».
2 - When the axis X of the swash plate (3) is at an
angle «α» to the shaft (1) and consequently to the
cylinder block (4), the surface «A» acts as a cam
for the piston shoes (6). Consequently, as the
shaft rotates, the pistons (5) stroke within their
bores in the cylinder block (4), thereby a creating
a difference between the volumes C and D which B Fig. 1
D
causes oil to be drawn in and forced out in
quantities equal to this difference (D –
C=delivery).
In other terms, as the cylinder block (4) rotates,
the volume of chamber D is reduced while the
volume of chamber C is increased, thereby
causing oil to be drawn in.
(Fig. 1 shows the condition of the pump on
completion of the suction stage in chamber D 3 4 C
and the delivery stage in chamber C ).
3 - When the axis X of the swash plate (3) is parallel
to the axis of the cylinder block (4) (swash plate
angle «α»=0), the difference between the
volumes C and D inside the cylinder block (6) is
zero and no oil is pumped (Fig. 2). x
(In reality, the swash plate angle «α» is never truly
equal to 0).
4 - The pump delivery is therefore directly
proportional to the swash plate angle «α».
2. Controlling the requirement of oil

Fig. 2 D
D0000530
• At a given rotation speed input, the required oil
flow is controlled by the angle «α» between the 8
swash plate (3) and the shaft (1).
2 3 C
The swash plate (3) is inclined by the springs (10).
Against the spring works the control piston (8). 10
The position of the control piston (8) defines the
angle «α».
• Below the max. pressure «α» is adjusted in this
way, that between the pressure of the pump and ␣
the pressure of LS-signal is a certain difference
(control pressure difference).
• Work the pump at the max. pressure, «α» is
adjusted to that position which guaranteed not
to exceed this pressure.
That means «α» is set to a smaller value than
from LS-signal whished. (Fig. 3). Fig. 3 D D0005020
10-68
HYDRAULIC SYSTEM LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE
5.1.3 LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE
1 2
PLS=PA
⌬PR 7 8 PA
4 6 PP
3
D0004830
COMPONENTS
1. Load Sensing valve spool
2. Load sensing valve spring
3. Pressure cut-off valve spool
4. Pressure cut-off valve spring
5. Swash plate return spring
6. Control piston
7. Directional control valve
8. Load
10-69
OPERATING PRINCIPLE
Swash-plate angle control
• The swash-plate angle of the pump (and consequently the pump displacement), is controlled in such a way that the
pressure difference ∆PR between the pump delivery pressure PP and the delivery pressure PLS to the load at the
work port of the control valve is maintained at a constant value. (∆PR = Pump delivery pressure PP -- PLS delivery
pressure to load).
• If the pressure difference ∆PR falls relative to the pressure setting of the LS valve, the swash plate angle will increase.
If the pressure difference ∆PR rises, the swash plate angle will decrease.
★ For details of this mechanism, see the description of the «HYDRAULIC PUMP».
Directional
control valve
T PLS
Delivery pump
PP
Control piston
TP Valve
LS Valve
D0004841
10-70
LOAD SENSING (LS) VALVE
FUNCTION
• The LS valve regulates the pump delivery in accordance with the position of the control lever of the directional control
valve i.e. in accordance with the demand from the loads.
• The LS valve senses the demand from the loads by way of the pressure difference ∆PR between the pump delivery
pressure PP and the pressure at the outlet port of the directional control valve PLS ; this enables the valve to regulate
the delivery Q of the main pump.
(PP, PLS and ∆PR, are respectively: the pump delivery pressure, the pressure of the Load Sensing signal and
difference between these two pressures).
• In other terms, the LS valve detects the pressure difference ∆PR, generated by the the flow of oil passing through the
passages uncovered by the spool and regulates the pump delivery Q so as to maintain a constant pressure drop.
This means that the pump delivery is proportional to the demand from the directional control valve.
OPERATION
Pump operation can be divided into four stages:
a. When the directional control valve is in neutral position
b. When a control lever is operated
c. When the flow rate stabilises
d. When the system enters “saturation” condition
10-71
a. When the directional control valve is in «NEUTRAL» position
b 1 d e a 2
PP T PLS
PEN
PP Min Max
7
X
M 5 6
D0004850
• The pressure PLS of the LS signal from the control valve outlet port, enters the chamber a of the LS valve; the pump
delivery pressure PP enters the chamber b on the opposite side.
• The shift in the position of the spool (1) is determined by the combination of the force exerted by the pressure PLS plus
the force of the spring (2) and the force exerted on the opposite side of the spool by the pressure PP.
• Before the engine is started, the control piston (6) is pushed to the right by the spring (5) (position corresponding to
the maximum swash plate angle).
• When the engine is started, if all the control valve spools are in «NEUTRAL» position, the pressure PLS of the LS
signal remains at 0 bar (0 psi) because there is no flow through the control valves and the signal is connected to drain.
At the same time, the pump delivery pressure PP increases because the hydraulic actuators are stationary.
When the force exerted by the pressure PP in chamber b overcomes the force of the spring (2), the spool (1) shifts to
the right thereby allowing the pressure PP to flow to the chamber X of the piston (6) as the connection is made
between the passages c and d.
• The force exerted by the oil pressure on the piston (6) overcomes the force exerted by the spring (5). This causes the
piston to shift to the left i.e. in the direction of the minimum swash plate angle.
• The pump delivery pressure PP stabilises around 22 bar (319 psi), which corresponds to the standby pressure.
10-72
b. When a control lever is operated
b 1 d e a 2
PP T PLS
7 8
PEN
PP Min Max
f
X
M 5 6
D0004860
• When a control lever is moved from the NEUTRAL position, this generates an LS signal corresponding to the load
delivery pressure PLS.
• The LS signal pressure in chamber a causes the spool to shift to the left, thereby connecting the passages d and e.
The chamber X is depressurised and the spring (5) causes the swash plate to move to the maximum displacement
angle.
• System balance is restored when the pressure ∆PR exerts on the spool (1) a force equal to the difference in force due
to the spring (2) thus restoring the connection between the passages c and d.
10-73
c. When the flow rate stabilises
d 1 2
c
d
PP T PLS
g
PEN
PP
X
M 5 6
D0004870
• When the pump delivery reaches the demand from the auxiliary control valve, the pump delivery pressure PP present
in the chamber b of the LS valve balances the combined force of the pressure PLS of the LS in chamber a and the
force exerted by the spring (6).
On reaching this state of equilibrium, the piston (1) comes to a stop in an intermediate position.
• In this condition, the passage connecting chamber c to chamber d remains partially open, thereby maintaining the
pressure in chamber d.
An oil flow enters the control piston (6) at a sufficient pressure to balance the force exerted by the spring (5).
• The stability of this equilibrium is ensured by a stabilised flow from the restrictor g.
• The force of the spring (2) is regulated so that the piston (1) is balanced when
PP -- PLS = ∆PR = 22 bar (319 psi).
• In practical terms, pump delivery is made proportional to the aperture of the auxiliary control valve, maintaining the pressure
difference ∆PR = 22 bar (319 psi).
• This condition remains unaltered until there is a change in the operating conditions (e.g. a change in engine speed, reduction
or increase in the demand for flow or pressure, etc.).
10-74
d. When the system enters “saturation” condition
b 1 d e a 2
PP T PLS
7 8
PEN
PP Min Max
f
X
M 5 6
D0004880
• If the engine speed is reduced during the operation of one or more loads, there will be a corresponding reduction in
the flow from the pump. It follows that the pump will compensate for this by altering the swash plate angle.
• When the pump reaches its maximum displacement, and thus can no longer increase its delivery, the difference
between the pump delivery pressure PP and the pressure PLS of the LS (pressure difference ∆PR) will become
smaller (“saturation” condition).
• The pressure PLS present in chamber a of the LS valve will be nearly equal to the pressure PP and the piston (1) will
be moved left by the combined force of the pressure PLS and the spring (2).
The piston thus closes the passage c and connects the passages d and e.
• The pressurised oil in chamber X of the control piston (6) flows through the passages d and e to reach the pump drain
chamber; in this way the pressure in chamber X of the control piston (6) becomes equal to the drain pressure.
• As a result, the control piston (6) is shifted to the right by the movement of the swash plate determined by the spring
(5) up to the maximum swash plate angle.
10-75
PRESSURE CUT-OFF VALVE (TP)
FUNCTION
• The pressure cut-off valve regulates the pump delivery on reaching maximum pressure.
PP T PLS
PEN
PP
Min Max
D0004890
OPERATION
• The pressure cut-off valve senses the pump delivery pressure and, on reaching the maximum pressure setting,
reduces the pump delivery to zero, by-passing the action of the LS valve.
• The pump delivery is thus returned to a minimum value sufficient for the internal lubrication of the pump of the main
auxiliary services and to maintain the hydraulic system at maximum pressure.
10-76
HYDRAULIC SYSTEM HYDRAULIC SERVICES GEAR PUMP (106-115 CV models)
5.2 HYDRAULIC SERVICES GEAR PUMP (106-115 CV models)
D0005280

Port L: suction Displacement: 32 cc/rev
Port P: delivery Maximum pressure: 200 bar (2900 psi)
10-77
HYDRAULIC SYSTEM STEERING GEAR PUMP (106-115 CV models)
5.3 STEERING GEAR PUMP (106-115 CV models)
D0005290

Port L: suction Displacement: 16 cc/rev.
Port P: delivery Maximum pressure: 180 bar (2610 psi)
10-78
HYDRAULIC SYSTEM GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING (120-165 CV models)
5.4 GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING (120-165 CV

models)
S
EF
CF
LS
A A
View A
HYDRAULIC DIAGRAM
CF EF LS
S D0004970

Port S: suction Displacement: 32 cc/rev.
Port CF: priority delivery Maximum pressure: 200 bar (2900 psi)
Port EF: secondary delivery
Port LS: LS signal
10-79
HYDRAULIC SYSTEM GEAR PUMP FOR HYDRAULIC SERVICES AND STEERING (120-165 CV models)
3
1 2 b
5
B d
4
EF
CF
e
LS
a
c
f
B 7 6
A-A B -B
D0004980
COMPONENTS 5 . Spool
1. Priority valve body 6. Spring
2. Pump housing 7. Driven shaft
3. End cover
4. Input shaft
DESCRIPTION
The gear pump sends oil under pressure to the chamber a from where it is sent through the port CF to the power steering.
At the same time, the pressurised oil reaches chamber b of the spring (6) and the chamber c opposite the spring (6) through
the passage d.
As the LS line is sent to drain by the power steering, a small amount of oil (about 1 litre/min.) flows through the port LS.
This creates a pressure difference between the two sides of the spool (5) that is consequently pushed downwards, thereby
allowing the oil to flow to chamber e and from there to the auxiliary services .
When the steering wheel is turned, the connection between the drain and the LS line is broken and the LS line is connected
to the delivery line to the steering cylinder. This nullifies the pressure difference between the two sides of the spool and
causes the spring to push the spool upwards, thereby allowing oil to flow from chamber a to chamber f.
10-80
HYDRAULIC SYSTEM PRIORITY VALVE
5.5 PRIORITY VALVE
106-115 CV VERSION
HYDRAULIC DIAGRAM
P CF EF
PP
LS
LS PP
P
EF CF
D0005300
FUNCTION
Port P - Valve feed Port EF - Delivery to services
Port LS - Load Sensing signal Port PP - Valve pilot flow
Port CF - Delivery to power steering
120-165 CV VERSION
CF
LS
EF P
HYDRAULIC DIAGRAM
CF EF
LS
P
D0005310
FUNCTION
Port CF - Delivery to the power steering Port EF - Delivery to services
Port P - Valve feed Port LS - Load Sensing signal
10-81
HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE (Version with fixed displacement pump)
5.6 AUXILIARY SERVICES CONTROL VALVE
VERSION WITH FIXED DISPLACEMENT PUMP

FUNCTION
• The function of the auxiliary services control valve is to control the flow of pressurised oil to the auxiliary services and
the rear lift.
• This control valve is a parallel circuit valve, which means that all the services receive oil flow simultaneously .
1 2 3 4 6 4 7 4 6
Y
R
X
X
S
P
9 1 1
0 0
2 2
8
H
F F
A B R1 A A B
5
REAR GEARBOX
D0004990
DESCRIPTION
• The pressurised oil from the pump (1) enters the inlet section (2); from here it is distributed to the spool sections
through internal passages.
• In the inlet section (2) we find an input gauge (8) and a relief valve (3) for LS-signal.
• The input gauge adjusts the pressure to supply the auxiliary valves (6) in this way, that it is always corresponding to
the spring force (9) higher than the pressure of the LS-signal.
• The pressure limitation is provided by limitation of the LS-signal pressure, done by valve (3).
• All the spools, when operated, generate a pressure signal (Load Sensing signal) that is equal to the pressure demand
from each load.
The highest of these pressure signals, selected by the bistable valves (4), is directed to the pressure relief valve (3).
• On the lift spool section there is an antishock valve (5) (on the UP control side) that serves to prevent excessive
pressure caused by jolting of the implement.
10-82
HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE (Version with variable displacement pump)
VERSION WITH VARIABLE DISPLACEMENT PUMP
FUNCTION
The function of the auxiliary services control valve is to control the flow of pressurised oil to the auxiliary services and the
rear lift.
This control valve is of the parallel circuit Load Sensing type.
1 2 3 5 3 6 3 5
Y
R
X
Y
P
X
S
1 1
0 0
2 2
H
F F
A B R1 A A B
REAR GEARBOX 4
D0005000
DESCRIPTION
• The pressurised oil from the pump (1) enters the inlet section (2); from here it is distributed to the spool sections
through internal passages.
• All the spools, when operated, generate a pressure signal (Load Sensing signal) that is equal to the pressure demand
from each load.
The highest of these pressure signals, selected by the bistable valves (3), is sent to the variable displacement pump
through port Y of the control valve.
• On the lift spool section (6) there is an antishock valve (4) (on the UP control side) that serves to prevent excessive
pressure caused by jolting of the implement.
10-83
PAGE INTENTIONALLY
LEFT BLANK

HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE
5.6.1 TYPES OF CONTROL VALVE WITH FIXED DISPLACEMENT PUMP (CCLS)
4-WAY VERSION WITHOUT FURTHER EQUIPMENT (I.E. FRONT AXLE SUSPENSION)
3
2 4 HYDRAULIC DIAGRAM
6 4 3 2 1
5
1
R
X
R1 X
S
P
A A
1
0 1
B A B
0
2
2
H
6
F
R
R
B
B
A
A
7 7 5 7 7
D0005150
1. Cover plate 5. Inlet manifold

2. Control valve section n° 1 6. Relief valve
3. Lift control valve section 7. Check valve
4. Control valve section n° 2
4-WAY VERSION WITH FURTHER EQUIPMENT (I.E. FRONT AXLE SUSPENSION)
3
2 4 HYDRAULIC DIAGRAM
6 4 3 2 1
5 Y
1
R
R1 X
P
S
P
A A
1
0 1
B A B
0
2
2
H
F
Y R 6
R
B
B
A
7 7 5 7 7
D0005160
1. Cover plate 5. Inlet manifold

2. Control valve section n° 1 6. Relief valve
4. Control valve section n° 2
10-85
8-WAY VERSION
3
2 4 7 8
5 9
1 1
R1
P P
A A A A
B A B B B
Y R 6 Y R
10 10 10 10
HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM
6 4 3 2 1 9 7 8 1
Y
R X
R X
Y
X
P X
S
P
1 1 1 1
0 0 0 0
2 2 2 2
H
F F F F
A B R1 A A B A B A B
5 10 10 10 10
D0005140
1. Cover plate 6. Relief valve

2. Control valve section n° 1 7. Control valve section n° 3
3. Lift control valve section 8. Control valve section n° 4
4. Control valve section n° 2 9. Inlet manifold
5. Inlet manifold 10. Check valve
10-86
5.6.2 TYPES OF CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP (LS)

4-WAY VERSION
3
2 4
HYDRAULIC DIAGRAM
5 4 3 2 1
1 5
R
X
X X
R1 X
P
P
S
A A
1
0 1
B A B
0
2
2
H
F
F
R
R
B
B
A
A
6 6 6 6
D0005120
1. Cover plate 4. Control valve section n° 2

2. Control valve section n° 1 5. Inlet manifold
8-WAY VERSION
3
2 4 6 7
8
1 5 1
R1
P
A A A A
P
B B R B B
A
Y R
9 9 9 9
HYDRAULIC DIAGRAM HYDRAULIC DIAGRAM

Y
R X
R X
Y Y
P X
P X
S
1 1 1 1
0 0 0 0
2 2 2 2
H
F F F F
A B R1 A A B A B A B
5 4 9 3 2 9 1 8 7 9 6 9 1 D0005130
1. Cover plate 6. Control valve section n° 3

2. Control valve section n° 1 7. Control valve section n° 4
3. Lift control valve section 8. Manifold
4. Control valve section n° 2 9. Check valve
5. Inlet manifold
10-87
5.6.3 SERVICES CONTROL SECTION
2
B
A
3
R R
Y
4
P
1
6 5 D0005100
1. Spool return device 4. Flow control

2. Check valve 5. Flow control spool
3. Spool 6. Check valve
10-88
5.6.4 DESCRIPTIONS OF COMPONENTS
SPOOL RETURN DEVICE
1
2
D0005040
1. Spool return spring

2. Spool
Check valve (NR)
3 B
4
1
R
2
D0005050
1. Slide 4. Valve seat

2. Ball 5. Spool
3. Check valve spring
10-89
FLOW CONTROL VALVE
1 2
3
D0005060
1. Spring
2. Flow control spool
3. Control shaft
10-90
5.6.5 INLET MANIFOLD (CC version)
DESCRIPTION
The function of the inlet manifold is to send only the required amount of oil to the actuators and to send any excess oil
supplied by the pump to the drain circuit.
The inlet manifold also includes a relief valve that limits the operating pressure of the actuators.
3 HYDRAULIC DIAGRAM
4
1
4
P 3
2
R
2 1
D0005070
1. Pressure compensating valve spool

2. Compensating valve spring
3. Relief valve
4. Relief valve spring
10-91
OPERATION
1. When the actuators are not operated
b
a
1 CONTROL VALVE
D0005080
• When the engine is running and the driver does not operate any of the hydraulic service controls, the pump sends oil
to the inlet manifold (port P).
• As all the actuators are stationary, the oil pressure increases in chamber a and consequently also in chamber b.
• When the oil pressure in chambers a and b exceeds the force exerted by the spring (2), the spool (1) is shifted
downwards, allowing the excess oil from the pump to flow to drain.
10-92
2. When an actuator is operated
b
CONTROL VALVE
a
P
y
5
c 2
D0005090
• When an actuator is operated, the pressure required for its operation is also directed to the channel y (Load Sensing
signal channel) and then sent to chamber c of the manifold.
• This causes the spool (1) to shift upwards and the oil required to operate the load is sent to the control valve.
• When the load pressure balances the force of the spring (4), poppet (5) is shifted to the left, allowing limitation of the
operating pressure.
10-93
5.6.6 LIFT CONTROL VALVE SECTION
DESCRIPTION
• The lift control section is a 1-way hydraulic control valve operated by two proportional solenoid valves.
• The control incorporates an antishock valve that protects the hydraulic circuit and against pressure surges caused by
jolting of the implement during work and transport.
HYDRAULIC DIAGRAM
P Y R
A
P Y R
1 2 3 4 5 7
A R
D0004920
11 10 9 8 6
COMPONENTS 7. DOWN control solenoid valve

1. UP control solenoid valve 8. Flow control spring
2. Check valve 9. Flow control spool
3. Check valve spring 10. Spring
4. Antishock valve 11. UP control spool
5. Antishock valve spring
6. DOWN control spool
10-94
OPERATION
1. When the lift control is in neutral position
• The oil from the pump enters chamber a and from here flows into passage b.
• At the same time the oil flows into chamber c of the flow control (1) through passage d.
• This causes the spool to shift to the right until the connecting passage between chamber a and passage b is closed.
• The pressure in chamber e caused by the weight of the implement mounted on the linkage (e.g.: plough), keeps the
check valve (2) closed, thereby ensuring that the lift maintains its position.
• The chamber e is thus a closed chamber that prevents any uncontrolled movement of the lift.
• The pressure in chamber e also acts on the antishock valve (3) that eliminates any pressure surges caused by jolting
of the implement during work or transport.
.
e 3
A R
c b d a 1 D0004930
10-95
2. When the lift is raised

• When the lift is raised, the electronic lift control energises the solenoid (4) which move the spool (5) to the right.
• The oil in passage b can therefore flow through the check valve (2) into chamber e and from there to the lift cylinders.
• At the same time, the pressure present in passage b can flow into the chamber i and into the passage f and from there
through the channel g into chamber h of the flow control (1).
• As the oil pressure is the same on both sides of the spool, the spool is shifted by the force of the spring (6) and the oil
can flow from chamber a into the passage b.
e 2
4 5
A R
i D0004940
b 1 g a 6 h
10-96
3. When the lift is lowered

• During lifting or when the lift is stationary, the spool (8) is pushed to the right by the spring (9).
• As a result, the passage between the chambers m and n is closed and the pressure in chamber p pushes the spool
(10) to the right.
When the lift is lowered, the electronic lift control energises the solenoid (7) that moves the spool (8) to the left.
The oil in chamber n can flow into chamber m and the pressure in chamber p is reduced.
• Now the force balance coming from the pressure in the chambers e and p influencing the spool (10), is disturbed and
moved to the left. Oil can flow now from e to m.
• As a result, the oil in the lift cylinders is directed to the drain circuit and the lift is lowered.
• As the solenoid is of the proportional type, the more current supplied, the more the spool (8) shifts to the left, thereby
allowing more oil to flow and the lift to descend more rapidly.
• The electronic control obtains float position by energising the solenoid valve (7) and holding it fully open.
• In this condition, the oil in the lift cylinders is sent to the drain circuit so that the lift is free to move up and down and
follow the contours of the terrain.
10 e n m 9 8
A R
p
7
A R
D0004950
10-97
CONTENTS
SECTION 20
CONTENTS
OPERATOR’S MANUAL SERDIA (LEVEL III) ..................... 1 • 9. SERDIA UPGRADE FROM VERSION
• 1. ENTRY AND COMMUNICATION ........................................ 2 2.5 TO VERSION 3.1 ..........................................................57
• • 1.1 OVERVIEW.................................................................. 2 • • 9.1 IMPROVEMENTS AND HELP WITH PROBLEMS
IN COMMUNICATING WITH
• • 1.2 ORDERING ................................................................. 3
NOTEBOOKS/WIN 98 ...............................................57
• • 1.3 SWITCH ON NOTEBOOK AND INSTALL
• • 9.2 NEW ENTRY MASK WITH MEASURED VALUES
SOFTWARE ................................................................ 4
AND COLOURED-CODED INDICATION OF
• • 1.4 USER LEVEL, ACCESS AUTHORIZATION................. 5 CONNECTION STATUS ............................................58
• • 1.5 MAKING A CONNECTION BETWEEN ECU • • 9.3 NEW SWITCH “JOBS“ FOR PERFORMING
(ENGINE) AND NOTEBOOK ....................................... 6 SELECTED SERVICING OPERATIONS,
• • 1.6 PROGRAM START ..................................................... 6 E.G. ADJUSTING CONTROLLER OR ADJUSTING
• • 1.7 OFFLINE MODE.......................................................... 7 OFFSET .....................................................................59
• • 1.8 WORKING WITH THE PROGRAM.............................. 9 • • 9.4 IN- AND OUTPUT ASSIGNMENT IS NOW
• • 1.9 PRINT (OUTPUT) ...................................................... 11 ADDITIONALLY CONFIGURABLE USING
PLAIN TEXT
• • 1.10 PROTOCOL (PROTOKOLL)...................................... 12
(PREVIOUSLY ONLY CODE NUMBERS) ..................60
• • 1.11 END COMMUNICATION .......................................... 12
• • 9.5 UPGRADES IN "PARAMETER SETTING/
• 2. ECU SELECTION .............................................................. 13 CONFIGURATION“....................................................60
• • 2.1 GENERAL ................................................................. 13
• • 2.2 RECOGNITION OF ECUS......................................... 13 OPERATOR’S MANUAL EDS
• • 2.3 IDENTIFICATION DATA ............................................ 13 (Electronic Diagnosis System) ........................................... 61
• 3. MEASURED VALUES ....................................................... 14 • 1. GENERAL INTRODUCTION ..............................................62
• • 3.1 ACTUAL MEASURED VALUES (GENERAL) ............. 14 • • 1.1 FUNCTIONAL SCOPE...............................................62
• • 3.2 RAM VALUES ........................................................... 18 • • 1.2 HARDWARE REQUIREMENTS .................................63
• • 3.3 DATA LOGGER (ONLY EMS) ................................... 18 • • 1.3 STARTING AND TERMINATING OF THE EDS
PROGRAM ................................................................65
• • 3.4 INPUT/OUTPUT ASSIGNMENT ............................... 18
• • 3.5 CAN-Status............................................................... 18 • 2. TRANSMISSION DIAGNOSIS ...........................................67
• • 3.6 EXAMPLE OF A DISPLAYED ERROR • • 2.1 THE MAIN MENU ......................................................67
INFORMATION: ........................................................ 20 • • 2.2 ONLINE HELP ...........................................................69
• 4. PARAMETERS .................................................................. 21 • 3. POWER-SHIFT DIAGNOSISPROGRAMM DEST 38 .........70
• • 4.1 CONFIGURATION .................................................... 21 • • 3.1 PREPARATIONS FOR TRANSMISSION
• • 4.2 OVERALL PROGRAMMING ..................................... 32 DIAGNOSIS WITH DEST 38 ......................................70
• • 4.3 CALIBRATION .......................................................... 32 • • 3.2 DEST 38 PROGRAM DESCRIPTION.........................71
• • 3.3 Error codes POWERSHIFT /DEST 38 ......................81
• 5. ERROR MEMORY ............................................................ 34
• • 3.4 ERROR CODE LIST WITH DESCRIPTION ................83
• • 5.1 GENERAL ................................................................. 34
• • OTHER INFORMATIONS ...................................................89
• 6. FUNCTION TEST .............................................................. 39
• • 3.5 SENSORS AND SOLENOID VALVES AT THE
• • 6.1 GENERAL ................................................................. 39
TRANSMISSION T-7100 ...........................................90
• 7.
EXTRAS ............................................................................ 40 • • 3.6 ELECTRO-HYDRAULIC GEAR SHIFT T-7100 ..........91
• •
7.1 MAXIMUM VEHICLE SPEED .................................... 40 • • 3.7 SENSORS AND SOLENOID VALVES AT THE
• •
7.2 LOGISTIC DATA ....................................................... 40 TRANSMISSION T-7200 ...........................................92
• •
7.3 LOAD SPECTRUM (ONLY EMS) .............................. 41 • • 3.8 ELECTRO-HYDRAULIC GEAR
• •
7.4 MAINTENANCE INTERVAL EXCEEDED SHIFT T-7200 / T-7300 .............................................93
(ONLY EMS).............................................................. 41 • • 3.9 SENSORS AND SOLENOID VALVES AT THE
• • 7.5 OVERRIDE MEMORY (ONLY EMS).......................... 41 TRANSMISSION T-7300 ...........................................94
• 8 WHAT SHOULD YOU DO IF ...? ....................................... 42 • • 3.10 ERROR ANALYSIS ....................................................95
• • 8.1 SERDIA IN GENERAL ............................................... 42
• • 8.2 EMR .......................................................................... 45
20-i
CONTENTS
• 4. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45 .....97

• • 4.1 PREPARATIONS FOR TRANSMISSION
DIAGNOSIS WITH DEST 45......................................97
• • 4.2 DEST 45 PROGRAM DESCRIPTION .......................98
• • 4.3 ERROR CODES POWER-SHUTTLE /DEST 45 .......113
• • 4.4 DISPLAY POWERSHUTTLE....................................114
• • 4.5 ERROR CODE LIST WITH DESCRIPTION ..............115
• • 4.6 OTHER INFORMATIONS ........................................126
TRANSMISSION T-7100 .........................................127
• • 4.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100 ........128
TRANSMISSION T-7200 .........................................129
• • 4.10 ELECTRO-HYDRAULIC GEAR
SHIFT T-7200 / T-7300 ...........................................130
• • 4.11 ERROR ANALYSIS..................................................131
• 5. AGROTRONIC-HD + ASM ..............................................133
• • 5.1 PROGRAM DESCRIPTION .....................................134
• • 5.2 ERROR CODES OF THE AGROTRONIC-HD..........141
• 6. PREPARATIONS FOR DIAGNOSIS OF THE
INFOCENTER...................................................................144
• • 6.2 CONSTANT VALUES FOR INFOCENTER...............155
• 7. PREPARATIONS FOR DIAGNOSIS OF THE
SPRING-SUSPENDED FRONT AXLE .............................159
• • 7.2 PIN ASSIGNMENT OF THE ELECTRONIC BOX
“SPRING-SUSPENDED FRONT AXLE ” .................164
• • 7.3 ERROR CODES.......................................................165
20-ii
SERDIA OPERATOR’S MANUAL
OPERATOR’S MANUAL
SERDIA (LEVEL III)
20-1
SERDIA ENTRY AND COMUNICATION
1. ENTRY AND COMMUNICATION

1.1 OVERVIEW
Digital electronic engine ECUs have become a normal part of modern engine technology.
These ECUs are designed, at the very least, to fulfil the functions of comparable mechnical modules (e.g. governors), as
well as to provide additional functionality. SERDIA is required in order to make communication with these digital electronic
DEUTZ ECUs possible. With
a) an interface (cable with diagnostics plug and copy protection) and
b) a commercially available notebook (or PC),
SERDIA forms a special tool
.
1.1.1 INTRODUCTION
SERDIA is a software program. Together with the notebook and the interface, it constitutes a tool which serves as an aid
to communication with the engine ECUs.
SERDIA supports DEUTZ ECUs EMR, EMS and MVS. You can also communicate with three different ECUs using just one
software product.
Any changes you wish to make to the ECUs as far as settings, parametrizations, error deletion and calibra-tion are con-
cerned are only possible with SERDIA.
SERDIA runs under the MS Windows®3.11 and Windows95(98) user surface.
You can choose English or German as the user language when carrying out program installation.
The user surface enables the user to call up the functions required simply by clicking on the appropriate buttons.
The menu points listed below are available:
• ECU selection
• Measured values
• Parameters
• Error memory
• Function test
• Extras
20-2
1.1.2 HARDWARE AND SOFTWARE

You should have the following minimum system configuration in order to work with SERDIA:
Hardware:
• Notebook o PC (IBM-AT compatible):.... with 1 serial interface RS 232 (There should be no mouse connected) and par-
allel printer interface
• Grafiphs carde:....................................... VGA/SVGA
• Processor: .............................................. 80486 (or later)
• Frequenz:................................................ 100 MHz
• RAM:....................................................... 8 MB RAM (or later)
• Hard disk (free memory capacity): ......... 15 MB (or later)
• Diskdrive:................................................ 3,5” (1,44 MB)
ECUs (engine):
• EMR (Elektronischer Motor-Regler)........ Electronic engine governor,
ECU TN 0211 1910 e 0211 2017
Software Version N° 12.1.08 and lower
• Diagnostics interface.............................. Serial in ace. with ISO 9141
Interface, connector piece between ECU (engine) and PC:

• Level adaptator for ISO 9141, SAE J1708 e RS 485
• Safety switch with dongle function, copy protection
• Power supply range 12-24 V
• Power supply side: Engine
• Protective switch against incorrect polarity and surge voltage
• Decoupling
Software:
• Operating system ................................... DOS versione 5.0 or later
• User surface ........................................... MS-Windows 3.11 or Windows 95
Installation is also possible under Windows 3.1; however, this creates a specific Windows problem: Conflicts may occur
when accessing serial interface COM1 (see Chapter 8, What should you do if...?). Further information is also given in the
Readme file supplied with SERDIA).
For proper display of the contents of the SERDIA windows under Windows 3.11, you should install the standard screen
driver (VGA).
1.2 ORDERING
SERDIA can be ordered, like the DEUTZ special tools, through:
SAME-DEUTZ-FAHR GROUP S.p.A.

Viale F. CASSANI, 15
24047 TREVIGLIO (BG) - ITALIA
1.2.1 FIRST-TIME USERS

For first-time users, we recommend the SERDIA package Re-order No. 5.9030.740.4/10.
Scope of supply:
• SERDIA software (1 x 3.5' installation diskette)
• Diagnostics interface with implemented user level
• Brief instructions on installation
• A list of tools and modifications usefui when troubleshooting, is included
• Carrying case
20-3
1.2.2 ORDERING SINGLE PARTS

Ser. No. Part Competence level Re-order No.
T7 Installation diskette 5.9030.740.0
T8 Adapter 5.9030.741.0
T9 Interface level III Major overhaul 5.9030.740.2
1.2.3 Adapter
Some OEMs have different diagnostics plugs for certain versions. An adapter is therefore required for the interface from the
12 pole DE UTZ plug to the appropriate OEM plug.
The DEUTZ 12 pole counterpart is available as a genuine DEUTZ part.
A ready-made adapter is available, for diagnostics on engines in DE UTZ Fahr tractors (DEUTZ 12 pole -> DFA 14 pole):
DEUTZ Part No. 5.9030.741.0
1.3 SWITCH ON NOTEBOOK AND INSTALL SOFTWARE

1.3.1 INSTALLING MS WINDOWS®
If you do not already have MS Windows® or Windows95(98) installed on your hard disk, you must do this first of all, fol-
lowing the instructions for installation given for MS Windows® and Windows95(98).
1.3.2 INSTALLING SERDIA

Before you begin installation, you must first make sure that all applications are closed. To be sure, you should therefore
leave MS Windows® and start anew.
In order to operate SERDIA software, you require an interface with a connection to an engine ECU. If this interface is not
available, it is still possible to install SERDIA, but you will only be able to operate it in offline mode. Chapter 1.6.2 Offline
mode tells you which program restrictions this involves.
TO INSTALL:
• Switch on the computer
• Insert the SERDIA installation disk in the 3.5" disk drive (drive A:).
• Start Windows.
With Windows 3.11 (3.1):

• In the main group, open "File manager" by double clicking on the symbol using the mouse.
• Select disk drive A:
• Start "install.exe" by double clicking with the mouse.
• Follow the installation instructions appearing on the screen.
• Remove the installation disk from the disk drive and keep safe.
• After re-starting, open the "SERDIA" program group by double clicking.
• Start "Diagnostics Service" by double clicking.
With Windows 95 (98):

• Open "Desktop" by double clicking.
• Open "3.5 disk (A:)" by double clicking.
• Start "install.exe" (Run Me!) by double clicking.
• Follow the installation instructions on the screen.
• Remove the installation disk from the disk drive and keep safe.
• After re-starting, click on the "Start" button and select the "Programs" folder.
• Start the program "Diagnostics service" in the "Serdia" sub-menu.
20-4
1.3.3 SERDIA UPDATES

You will be informed of software updates by our service information department, as they occur.
There is no automatic exchange against older versions of the software.
When installing the update the target directory should contain the SERDIA version number.
1.4 USER LEVEL, ACCESS AUTHORIZATION

DEUTZ Service has defined three different user levels (I, II, III) for SERDIA users. These levels are specified in the interface.
We make these distinctions in order to prevent unauthorized users from gaining access to the setting parameters (com-
parable to the lead seals on fuel injection pumps).
Access authorization functions in such a way that only certain parameters and function fields are allowed through a filter.
This then allows access to the appropriate user level.
20-5
1.5 MAKING A CONNECTION BETWEEN ECU (ENGINE) AND NOTEBOOK

• Serial communication
• Baud rate = 9600
• Serial port = COM1
An interface forming part of the SERDIA scope of delivery serves as a link between the ECU and the notebook. Despite a
large number of safety measures in the interface and the ECU, such as protection against incorrect polarity, surge voltage
protection and decoupling, the possibility of errors can never be entirely excluded.
For this reason, the connection should be made by adhering closely to the following sequence:
1- Switch off engine, turn off ignition switch (terminal). Do not switch on the notebook yet.
2- Plug the diagnostics plug on the interface into the diagnostics socket on the vehicle/equipment.
3- Connect the other interface side with serial interface RS 232/COM1 . (9 pole plug at the back of your
noteback).
ATTENTION!
On PCs, the COM1 interface may sometimes be occupied by the mouse. If this is the case, you should
connect the interface to the second serial interface (COM2). This must then be configured (see Chapter
8, What should you do if...?).
4 - You can now switch on the ignition (terminal 1 5) and the notebook. For the time being, do not switch on the engine.
5 - You can now start the program SERDIA in accordance with the instructions given in Chapter 1.6 Program start.
1.6 PROGRAM START

Call the program SERDIA under Windows by double clicking.
SERDIA starts up with a main screen and a sub-screen "ECU selection". In this screen, you can only select "OK", "Cancel"
or "Help".
20-6
1.6.1 ESTABLISHING COMMUNICATION WITH THE ECU

Automatic recognition (identification) of the ECU can take up to 60 seconds as the program checks out all the possible in-
terfaces and ECUs one after the other.
• If no ECU or interface is connected, SERDIA will operate in offline mode, see Chapter 1.7.2 DEMO mode.
• If communication with the ECU cannot be established, the system issues an error message, see Chapter Error in es-
tablishing the communication link.
Once communication has been successfully established, the main screen "Diagnostics service" is displayed with the fields
"ECU (electronic control unit)" and "ECU identification". This main screen contains a predefined selection menu.
1.7 OFFLINE MODE

If no ECU/engine and/or interface is available, SERDIA can be operated for training purposes in the password-protected
mode or in the DEMO mode.
The password-protected mode and the DEMO mode are always offered by SERDIA if no successful establishment of com-
munications has been reported.
20-7
Click on "Ignore". The desired mode is selected in the "Confirm" window.
1.7.1 PASSWORD-PROTECTED MODE

If "Yes" is selected in the "Confirm" window, authorized users can enter a password (inquiries at head office) and then read
and print out configuration files without an ECU. However, they cannot alter the files.
1.7.2 DEMO MODE (TRAINING WITHOUT ECU)

If "No" is selected in the "Confirm" window, the user reaches the DEMO mode.
1 - Here, handling of SERDIA can be practiced, without actual figures.
2 - Stored graphics can be read and printed out, provided that the graphics were stored in binary format (file-name ex-
tension ".egr"). See 3.1.2 Graphics.
ATTENTION!
It is not possible to carry out function tests covering the functioning of the ECU.
20-8
1.8 WORKING WITH THE PROGRAM

Brief description:
1) Call SERDIA under Windows
2) Click on ECU selection in the SERDIA main screen
3) Select the ECU you require in the screen "ECU selection"
4) Select the menu point you require in the SERDIA main screen
1.8.1 MAIN SCREEN, MENU SELECTION

A predefined selection menu is displayed in the main screen. Brief description of the buttons:
Menu point ECUs Explanation
ECU selection All Selection of the required ECU.

(Only one ECU can be selected at any time)
Aktuelle Actual measured values All Display of current actual values (also if engine not in operation,
but in this case with U-Blatt)
RAM values Only for level III
Data logger EMS Only Display recorder contents
Input/output assignment All Assignment of the signals used to the ECU pins
CAN-Status
Parameters
Configuration All Read and update configuration data
Overall programming EMR, EMS
Calibration of measured value sensor, e.g. accelerator
Calibration All pedal sensor
Error memory
Error memory All Copy, display and delete error memory
Function test EMR Only Operate actuator
Extras
Maximum speed EMR Only Selection of three different maximum speeds
Logistic data All
Load spectrum EMS Only
Maintenance interval exceeded EMS Only
Override memory EMS Only
Help All General help for the main screen and the associated buttons
20-9
1.8.2 MENU POINT "ECU SELECTION”

It may be the case that one DEUTZ engine is fitted with one or several ECUs (e.g. the combination of MVS with EMS). How-
ever, SERDIA can only communicate with one ECU.
Exception: It is also possible for the list of errors to be read via EMS, and measured values can be read from the MVS.
You must therefore first select the ECU you require from the menu point 'ECU selection'.
For more details, please see Chapter 2, ECU selection.
1.8.3 MENU POINT "MEASURED VALUES” ("ACTUAL MEASURED VALUES")

Selection and display of measured values is also possible from a list of measured values (including input and output val-
ues).
Displayed measured values that have exceeded an upper or lower value (if applicable) are stored in color.
Only those measuring points that are appropriate to the ECU are displayed in sequence, differentiated by the following:
• read measured values
• read ejectronics measured values
• read mcorter data (EMS speda menu)
displayed by:
• designation
• value
• unit
The measured values are rerreshed after a predefined sensor rate. They can be displayed with the engine shut down as well
as with the engine in operation.
For rnore information, please see Chapter 3. Meas,ed values.
1.8.4 MENU POINT "PARAMETERS"

The wide range of possibilities open to you with DEUIZ ECUs means that very specit\c programrning IS requireci in ac-
cordance with each indivtdual applicauon case Changes to parametrization beconne necessary if:
• custonner requiremenis
• abaptation to locai requirements
• replacement installation
The pararneters can only be changed with SERDIA!
This menu point also does away with the neecl br screwdriver setting, as is necessary with analog ECUs. Individuai pa-
rameters (such as dynamic go~ernor characteristics) can uso LE changed 'nithin predefsned limits. Parametrization is car-
ried out in two separate screens, one for configuration and one for calibration. Access to the flelds in the various screens
is controlled from the user level. Fields for which no access authorization exists are not displayed. It is even possible to
swap over entire blocks or parameters from this function field in order to create variants.
For more information. please see Chapter 4, Parameters..
1.8.5 MENU POINT "ECU SELECTION”

The error messages stored in the ECUs can be read from this menu point.
Error messages refer solely to the electrical parts of the engine system, such as the cable harness and the measured value
sensors.
An error message may take the form of: "Broken cable or short-circuit".
Only passive error messages can be cleared, active messages are retained. When the error is corrected, active error mes-
sages are changed into passive error messages. The error message will be retained even if you disconnect the battery/
power supply.
Error messages display information on
• error location
• type of error
• total number of errors (at the error locations)
• frequency
• error status (active / passive)
• environment data at the time the error was detected.
20-10
SERDIA provides help in remedying defects; you may also find it useful to consult the menu points "Measured values" and
"Function test". For more information, please see Chapter 5, Error memory.
1.8.6 MENU POINT "FUNCTION TEST"

SERDIA supports a wide range of function tests, distinguishing between the various actuators (e.g. actuator test for EMR).
Functional checks are a particular help when investigating defects and carrying out maintenance work.
For instance, it is possible to activate and check individual actuator outputs. To carry out this work, you must switch over
to test mode.
Before doing so, the engine must be shut down!
During a function test, the actuators are activated by the tester program while the engine is shut down.
You switch the actuators on and off by clicking on the check box next to the actuator designation in the "setpoint" column.
The reaction of the actuator status triggered by the ECU is displayed under the actual value.
The actuator statuses are always controlled in the ECU. This control function can only be transferred to SERDIA by the
ECU, i.e. if the required actual value is not produced, this is probably due to a wiring error. It can then be helpful to make use
of the combination of the menu points "Error message" and "Function test" in order to track down the cause.
For further information about function testing, please see Chapter 6, Function test”.
1.8.7 MENU POINT "EXTRAS"

SERDIA supports a large number of Extra points; these differ from ECU to ECU. To access these Extra points, you must call
up the sub-menu points, each of which will lead you to its own screen:
• Maximum speed
• Logistics data
• Load spectrum
• Maintenance interval exceeded
• Override memory
For more information, please see Chapter 7, Extras.
1.8.8 Help
In addition to these operating instructions, you may find it useful to consult the on-line "Help" provided by the SERDIA pro-
gram. I.e., click on the button "Help" under Windows.
1.9 PRINT (OUTPUT)

The data for identifying the ECU, and also the data in other windows, can be issued in two different ways.
20-11
1) As a printout. A suitable printer driver has to be selected under Windows. At the top of all printouts, the logistical data
appear:
• Type of ECU
• Date and time
• Interface serial number
• Engine number
• Part number functional data set
• Number of operating hours
2) The ECU data can also be stored as a file. This file can be further processed in Excel.
The following table gives an overview of the possibilities for storing data from the various screens:
• as printable files for further processing, e.g. in Excel
• as configuration files to report changes
• as a graphic file (*.egr) readable in the SERDIA demo mode.
From screen Button Extension Notes
Service Diagnosis Print (File) *. Ecu for further processing, e.g. in Excel
Actual measured values File *. Msw for further processing, e.g. in Excel
Graphics ( ASCII ) *. Agr for further processing, e.g. in Excel
Graphics ( binario ) *. Egr readable in the SERDIA demo mode
Input/output assignment Print (File) *. Ino for further processing, e.g. in Excel
Configuration Print (File) *. Kfg for further processing, e.g. in Excel
Configuration file
Configuration Save in file *. Hex (partial data set, level-dependent)
Overall programming ECU -> File *. Hex Configuration file

(complete data set, Level III and Ilia)
Error memory Print (File) *. Err for further processing, e.g. in Excel
Logistical data Print (File) *. Dat for further processing, e.g. in Excel
1.10 PROTOCOL (PROTOKOLL)

This switch is only provided within the scope of development for configuration of the interface.
1.11 END COMMUNICATION

1.11.1 PROGRAM END
Before you disconnect the notebook from the engine ECU, you should return to the main menu and click on "Close".
If you have modified any parameters, in many cases it is worth checking the current parametrization, for safety's sake.
Proceed by carrying out the following steps:
1. End SERDIA
2. Switch off engine power supply, and then switch on again
3. Start SERDIA again
4. Re-activate the ECU
5. Activate the menu point “Parameters”
6. Click on -> PC” (“SG -> PC”) in the configuration screen.
7. To print out the configuration data, press "Print" (“Print ON”).
8. File the printout with the engine documentation
1.11.2 DISCONNECTING THE ECU

You should only disconnect the engine ECU from the notebook (i.e. interface with cable) after you have left the program
SERDIA by pressing "Close".
20-12
SERDIA ECU SELECTION
2. ECU SELECTION
2.1 GENERAL
DEUTZ engines may be equipped with one or several ECUs (e.g. the combination MVS with EMS). SERDIA, however, can
only communicate with one ECU. Exception: the error list can also be read from the MVS ECU via EMS.
It is therefore necessary to first select the desired ECU from the menu poin "ECU selection".
Recognition of the different ECUs is managed by SERDIA for the user.
Possible ECUs:
EMR (Electronic Engine Governor)
MVS (Magnetic Valve System)
EMS (Engine-Monitoring System)
2.2 RECOGNITION OF ECUS

SERDIA automatically assists recognition of the connected ECUs upon program start. Identification may take up to 60 sec-
onds as the possible interfaces and ECUs have to be polled one after the other.
Following successful recognition the ECU selection screen is automatically overlayed. Only the recognized ECUs are of-
fered for selection. The ECUS which are not selectable are marked by a grey font.
2.3 IDENTIFICATION DATA
2.3.1 EMR IDENTIFICATION

• Meaning of data displayed: DEUTZ part number.
• Product number: Type of selected ECU: 1 = EMR - 2 = MVS - 3 = EMS
• Hardware version number: This number indicates the development status of the ECU.
• Software version number: Number of the EEPROM contained in the ECU. If the digit left from the decimal changes
(e.g. from 2.1 to 3,1), the data set does no longer suit the ECU. In this case it is necessary to consult the headquarters.
• Day, month, year: Date of the latest parameterization on the ECU.
• Service ID: Serial number of the interface used for the previous access. The leading digit indicates the access level.
• Interface serial number: Serial number of the currently used interface.
20-13
SERDIA MEASURED VALUES
3 MEASURED VALUES
3.1 ACTUAL MEASURED VALUES (GENERAL)

The measured values are read cyclically and displayed on the screen "actual measured values"..
Figure: Current measured values of the EMR
ATTENTION!
Values beyond the sensor measuring range are underlayed in colour:
• yellow: above measuring range,
• blue: below measuring range.
De.scription of keys:
Meas. values: (“Actual measured values”):
The window "Measured value selection" is displayed with all measured values available. Measured values to be displayed
can be selected there. In general, the repeat rate of display is increased through a reduced number of measured values to
be displayed. The possible measured values available may vary according to the type of the ECU.
Graphics:
The "Graphics" switch is used to display the pattern over time of the selected measured variables (maximum 5). If more
than 5 variables are selected, an error message appears.
20-14
Collect, time:
The duration of the recording appears in the field ”Collect. time”, in seconds. The lowest value for the dura-tion
of recording is one second. The upper measurement time can be entered as several hours (expressed
in seconds). The basic setting is 10 s. The shortest scanning rate is:
• 40 ms for RAM values
• 60 ms for the other values.
A measurement duration of 10 s gives
• 250 measuring points (10000 ms / 40 ms) with RAM values
• 166 measuring points (10000 ms / 60 ms) with the other values.
Since the program can cover a maximum of approximately 2000 measuring points, before data recording
starts the scanning rate is adjusted automatically as necessary.
The lowest possible scanning rate is determined by the duration of the data transfer from the ECU to the
PC. The more variables are to be displayed at the same time, the longer the data transfer will take and the
lower the scanning rate will be.
File: The current measured values can be stored in a file and reloaded later, for example for further processing in Excel.
Print: The displayed measured values are printed.
Close: Return to the main window "Service diagnosis".
3.1.1 MEASURED VALUE SELECTION
Figure: Measured value selection EMR
In this list you can activate or deactivate measured values for display. You can activate and deactivate individual values by
clicking on the check box; alternatively you select all the values by using one of the switches described below.
Save: The measured values displayed are saved to a file.
Load: A selected measured value is entered from a file.
Delete selection: All measured values are deactivated for display.
Select all: All measured values are activated for display.
OK: The updated measured value selection is adopted and the program returns to a display of the current measured val-
ues.
Cancel: The program returns to a display of the current measured values. Updates to the measured value selection are re-
jected.
20-15
3.1.1.1 MEASURED VALUES EMR

The following table gives an overview of the measured values which can be displayed. Some parameters require con-
figuration for that purpose (see Chapter 4 Parameters), in which case specific measuring points may be assigned to the in-
puts and outputs of the EMR (Menu "Configuration", page 11: assignment inputs/ measured values and page 13:
assignment outputs/measured values). The values required for the parameter configuration are given in the table. The as-
signment can be checked in the menu "Measured values" with the window "Display of inputs and outputs" (see 3.4 Input/
output assignment).
Measured value selection
Parameter
Meas. point designation Unit Description Configuration parameter ✽ value
Battery voltage V Battery voltage - -
Engine speed 1 (camshaft) 2000
Engine speed 1/min Ass(F1 6)Out/Dig/PWM/Freq
Engine speed 2 (crankshaft) 2002
Control rod position mm Control rod position - -
(M9)Cooiant temperature °C Coolant temperature Ass(M9)Analnp3(CoolTemp) 3551
Fuel injection quantity cmm/ Fuel injection quantity - -

Hub
Fuel consumption l/h Fuel consumption - -
(F24)Accelerator pedal
=SWG1 V Accelerator pedal voltage Ass(F24)Analnp1 (Pedal) 3511
Rel. Accelerator pedal % Scanning pos. acceleratorpoti Ass(F24)Analnp1 (Pedal) 3511

= SWG1
(M24)Boost pressure bar Boost pressure Ass(M24)Analnp2(boostPr) 3531
(M21)Oil pressure bar Oil pressure Ass(M21)Analnp4 (OilPress) 3541
(F5)Output:Digital/PWM1 % Torque Ass(F5)Out/Dig/PWM1 2701
(F3)Output: Digita I/PWM2 % Alarm signal oil pressure Ass(F3)Out/Dig/PWM2 3011
(M3)Output:Digital3/PWM3 % Reserve
(F16)Output:Dig/Freq/PWM % Engine speed 1 Ass(F1 6)Out/Dig/PWM/Freq 2000

Engine speed2 2002
(F20)Hand throttle
=SWG2 Hand throttle Ass(F20)DigAnalnp(H.thr.) 3521
(F18)lnput:Digital/PWM1 %
(F21)lnput:Digital/PWM2 %
(F19)lnput:Digital %
Outp:0,0,0,0,0,M2, Summary outputs
F15,F4(LSB)
Selector switch Selector switch
Vehicle speed km/h Vehicle speed
✽ See also table with configurable parameters in Chapter 4 Parameters.
20-16
3.1.2 GRAPHICS
Once any desired measured values are selected, up to a maximum of 5, the window "Graphic display" can be opened by
clicking on "Graphics".
The measured values are represented inside the display range (minimum to maximum). The scaling steps for the axes are
set in the column "Delta". By activating the control field "Auto", it is possible to have the program carry out scaling au-
tomatically. Since the program carries out this scaling taking into account the minimum and maximum values for the var-
iables concerned, it is not possible to have automatic scaling with variables which are constant in time. A maximum of two
axes, one on the left and one on the right side of the display area, are shown.
In the columns L (left) and R (right) a representation of an axis can be assigned to a measured variable.
EXPLANATION OF THE FUNCTION SWITCHES:

START: This function switch is used to start recording of the data.
UPDATE: This function switch is used to update the displayed information. This is necessary if there has been a change in
the minimum, maximum or delta values. The update process takes the new values into account.
PRINT ON: By clicking on this switch the transmission to a printer is started. First the printer selection appears, then a com-
ment can be inserted if desired, and then printing starts.
SAVE: The Information from the representation displayed can be saved in a file in two different ways:
• As an ASCII file ('.agr) for further processing in Excel

• As a binary file (*.egr) to represent measurement graphics in OFFLINE mode. See 1.7 Offline mode.
The graphics information saved in a file is read in and displayed.
20-17
3.2 RAM VALUES

Access to the RAM values is not possible for Level III.
3.3 DATA LOGGER (ONLY EMS)

The screen of this menu point is only selectable when an EMS ECU has been selected.
3.4 INPUT/OUTPUT ASSIGNMENT

Inputs and outputs can be configured. This item in the menu displays the current input and output status.
Restriction: Only applies for EMS and EMR ECUs.
3.5 CAN-Status
This window displays the CAN bus activities of the EMR.
Sent: Contains the information Can: TxCounter (0 to 65535, word). The value is increased with each CAN sending message
and indicates the sending activity of the EMR.
Received: Contains the information Can: RxlrCounter (0 to 65535, word). The values is increased with each CAN sending
message and indicates the sending activity of the EMR.
20-18
Bus Off: Counter that indicates how often the EMR has separated from the CAN bus because of constant errors (Can-
BusOffCounter 0 to 255, byte).toma
Status: CanOnline indicates whether the EMR is active on the CAN bus. Via the ISO 9141 interface a value 1 is sent for on-
line and a value 0 for offline. The program SERDIA displays the text "online" (for value 1) or "offline" (for value 0).
Phase: The variable CanSetPointPhase (0 to 255, byte) is sent via the ISO 9141 interface. This variable displays the pro-
cedure with regard to time of the setpoint assignments:
Phase Text
0 0: Engine standstill, Initialization
1 1: Engine standstill, phase! , no CAN error
2 2: Engine standstill, phase2, CAN timeout error
3 3: Engine start, ... until idling speed is recognized
4 4: Engine runs, wait for CAN setpoint
5 5: Engine runs, setpoint preset via CAN is allright
6 6: Engine runs, emergency op., setpoint preset via CAN failed
7 7: This phase doesn't exist
Error information: The EMR sends an error number CanErrorNumber (0 to 255, byte) specifically for CAN bus errors via
the-ISO 9141 interface. A text is assigned in SERDIA to these numbers, which is displayed in the window of the CAN in-
terface.
Code Text
0 0: No fault existing
1 1: Message request not received bei controller object 15
2 2: Invalid controller object
3 3: controller object multi assignment
4 4: CAN active, but no message activated
5 5: Diagnosis object not activated
6 6: Scan rate 0 in diagnosis message
7 7: Scan rate 0 in measure value telegram
8 8: preset engine speed config.6 does not match TSC2 activation
9 9: TSC1 activated, but 'Setpoint eng. speed not set to 6’
10 10: ”GovernConf=6,neither TSC1 nor function shift is activated
11 11: GovernConf=6 & Setp.eng.speed=6', but TSC1 is not activated
12 12: TSC1 activated, but Governor config!=6
13 13: TSC1NotAct&FunctShiftAct& GovernConf.!=6 => ShiftMGovernMode!=0
14 14: TSC1Act&FunctShiftAct&GovernConf.=6'=--'ShiftMaskGovernMode!=0
100 100 Receipt message failed
101 101 Setpoint telegram failed w.eng.idle (repl, value)
102 102 Setpoint telegram missing w.eng.idle due to low battery voltage
103 103 Setpoint telegram missing after eng.start due to low battery
104 104 Setpoint telegram missing after eng,start, repl.value used
105 105 Setpoint telegram missing during eng.open, repl.value used
Time-Out errors of receipt messages require special handling. All of these are reported with an error number
To identify which message causes a Time-Out error, SERDIA proceeds as follows:
• CanRxObjActive indicates the active, i.e. actually received messages in bits.
• CanConf_bits contains the configured receipt messages in bits.
20-19
SERDIA negates CanRxObjActive in bits (inactive message) and then performs an AND combination with CanConf_bits in
bits. As result one obtains in bits the receipt messages which are configured and inactive (CanRxTimeOutBits).
A text is assigned to each bit of CanRxTimeOutBits, which represents the name of the relevant receipt messages. As not
all bits may be used, it is defined in the text by entering "dc" for "don't care" that the text output is suppressed for this bit.
If the text "100 Receipt message failed" is displayed, there is an additional text output of the list of missing receipt mes-
sages.
3.6 EXAMPLE OF A DISPLAYED ERROR INFORMATION:

100 Receipt message failed
Engine Temperature
Engine Fluid Level
Pressure Function shift
Inlet / Exhaust Conditions
VanRxTimeOutBit Text
0 Engine Temperature
1 Inlet / Exhaust Conditions
2 Engine Fluid Level /Pressure
3 TSC1
4 Engine protection
5 Function shift
6 Dc
7 Dc
8 Dc
9 Dc
10 Dc
11 Dc
12 Dc
13 Dc
14 Dc
15 Dc
20-20
SERDIA PARAMETERS
4. PARAMETERS
4.1 CONFIGURATION
Via the menu item "Parameters" in the menu bar, you get to the "Configuration" screen. The configuration procedure is as
follows:
• Scroll with keys "Next" and "Previous" to the page which contains the Parameter to be set (example: "AccPedal
(SWG1)up. ref" on page 10: Setpoint gen. calibration values).
• Click on the field "New value" and enter the necessary numerical value. This must be between the indicated minimum
and maximum.
• Click on "PC->ECU". All configuration data is transmitted to the ECU.
The data is now incorporated in the ECU and can be used for testing the engine setting. It is however lost upon shutting
off the supply voltage.
• Save data record with the key "Save in ECU" (old data is overwritten).
• For checking purposes the data can be read out and displayed with the key "ECU->PC".
• Following satisfactory engine run the data record can be saved with the "Save in file" key on the hard disc or on a dis-
kette.
Figure: Example of a choice of configuration parameters.
EXPLANATION OF THE FUNCTION SWITCH
ECU->PC: The configuration data is read from the ECU and is displayed.
PC->ECU: Updated configuration data is uploaded to the ECU. In order for the uploaded data to be permanent, you must
activate the "Save in ECU" switch for the ECU.
Open file: The configuration data is read and displayed from a hex file.
Save in file:The configuration data is saved in a hex file.

The engine number will be suggested as file name for storage on from SERDIA 2.5. This suggestion is not compulsive; other
file names may be chosen nevertheless.
Then confirm with OK. The file (i.e. the engine data record) is then saved under the name <Engine number> hex.
Save in ECU (applies for EMR only): The configuration data are permanently saved in the ECU. changes to the con-
figuration have to be reported!
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SERDIA PARAMETERS
ATTENTION!
• All changes to the configuration have to be reported!
• The reporting procedure is described in Service Bulletin 0199-99-9287.
Previous: The reporting procedure is described in Service Bulletin 0199-99-9287.

Next: Displays data for the next screen page.
Print ON: A print-out is made of the configuration data currently displayed.
4.1.1 EMR
.
1- The following table gives an overview of the possible configuration parameters.
2- Settings that cannot be made while the engine is running are identified by the message ”Stop engine”
3- SERDIA only displays one page at a time.
EMR PARAMETERS CONFIGURABLE WITH LEVEL III

typ
MK 3 TTG Parameter Unit Min. Max. Description
Wert
Page 1: General overview
Engine serial number 0 4,2x109 12345678 8 digits
Number of cylinders 4 8 ace. to engine type
48 1013
No. of teeth eng. speed 2 18 200 129
44 1012
PassLevel 1 (OEM) 0 4,2x109
PassLevel 2 (Service) 0 4,2x109
Page 2: Only for BOSCH EDO inline pumps
RefVal.EDC RackPos 20 mm 0 65535 4000
RefVal.EDC RackPos. 0 mm 0 65535 1800
RefVal.EDCValueRefCoil 0 65535 1800
AutoCalib:Current % 0 100 78,2
AutoCalib:WaitingTime s 0 100 1,0
Page 3: Engine speed settings
Idling speed 1/min 500 4000 770 Idling speed engine ( < rated speed)
Fixed eng. speed 1 1/min 500 4000 1000 Fixed speed setpoint 1
Fixed eng. speed 2 1/min 500 4000 1000 Rated speed engine
Rated speed 1/min 500 4000 2300 Fixed speed setpoint 2
Rated speed limp home 1/min 500 4000 2000 Rated speed upon failure of speed sensor 1
Overspeed 1/min 500 4000 3000 Limit overspeed
Recov. speed overrun 1/min 500 4000 2000 Reset limit overspeed
average:0=1 turn, 1=2 turns 0 1 0 Average speed smoothing
Page 4: Speed governor
SpeedGvnr: P part % 0 100 18/4,0 Gain factor P part (genset/automotive)
SpeedGvnr: I part % 0 100 10/10,0 Gain factor I part (genset/automotive.)
SpeedGvnr: D part % 0 100 10/5,0 Gain factor D part (genset/automotive)
Damping factor w. minor speed fluctuation
SpeedGvnr: damping % 0 100 90/65,1
(genset. /automotive)
Speed governor:
SpeedGvnr: damping range 1/min 0 100 15/80,0
damping range (gensets/ automotive)
Engine speed ramp down 1/min/s 0 10000 100 Max. contr. speed setpoint speed ramp down
Engine speed ramp up 1/min/s 0 10000 10,1 Max. contr. speed setpoint speed ramp up
20-22
SERDIA PARAMETERS
typ
Wert
Page 5: Position governor
Only change the following 10 parameters in consultation with the head office
Posgvnr: P part % 0 100 10 Gain factor P part
Posgvnr: 1 part % 0 100 5 Gain factor I part
Posgvnr: D part % 0 100 5 Gain factor D part
Posgvnr: DT2 part % 0 100 10 Gain factor DT2 part
Posgvnr: Gain % 100 200 180,1 Gain factor with minor speed fluctuation
Posgvnr: gain range mm 0 1 0,25 Gain fluctuation range for gain factor
QuickCurrentDecSteepness 1/min 0 65535 40000
QuickCurrentDecTime ms 0 65535 50
Page 6: Functions
Torque curve variants (2 variants✽),
Perm, values:
Assign config. top curve 0 2 0
0 = torque curve 1
1 = Switching betw. torque curves 1+2
Setpoint eng. speed values (6 variants ✽)
Perm, values:
0 = Only variable speed governing
1 = Switching betw. eng. speeds 1 and 2
Ass spec. eng. speed config 0 6 0
2 = Switching betw. fixed / variable speed
3, 4 = Switching betw.speed variable / save:
(3 = w. setp.speed, 4 = w. actual speed)
5 = two setpoint transmitters
Speed droop selection (4 variants✽)
Perm, values:
0 = constant speed droop
Ass droop config 0 3 0
1 = variable speed droop
2 = switching between speed droop 1 and 2
3 = switching betw.const. / variable speed droop
Type of governing (4 variants✽)
Perm, values:
0 = Variable-speed governing
Ass governor config 0 6 0
1 = Min-max-speed governing
2 = Switching betw.var./min.-max.
speed governingx
For the following 14 functions: On = 1, Off = 0
BoostPressSim (on/off) 0 1 0 Boost pressure simulation
BoostPressMeas (on/off) 0 1 1 Boost pressure measurement
EngSpeed sensor2 (on/off) 0 1 0 Redundant eng. speed sensing
VehSpeedLimit (on/off) 0 1 1 Veh. speed limit
CylinderShutoff (on/off) 0 1 1 Overrun cond. with overspeed
LimpHomeOper 0 1 0 Limp-home upon control rod travel sensor failure
Torque computation (off: referred to torque curve,
Torque Indicator(on/off) 0 1 1
on: torque curve point)
SAME Output (on/off) 0 1 0 Customer-specific output function
QuickCurrentDec (on/off) 0 1 0
BOSCH EDC inline p. (on/off) 0 1 0
TempMonitoring (on/off) 0 1 0 Temperature monitoring
OilPressMon(on/off) 0 1 0 Oil pressure monitoring
20-23
SERDIA PARAMETERS
typ
Wert
Page 7: Monitoring
CoolTempMon.:
°C -30 130 118 Limit engine shutoff (130° = none)
ShutoffValue
CoolTempMon.:
s 0 600 0 Time delay engine shutoff
Shutoff Delay
CoolTempMon.:
°C -30 130 110,0 Reset limit
RecovValue
CoolTempMon.: Fuel qty red. % 0 100 20 Fuel inj. quantity reduction (0% = none)
CoolTempMon.: Red. delay s 0 600 15 Time delay fuel inj.quantity reduction
CoolTempMon.: Alarm limit °C -30 130 113 Limit alarm
OilPrMonitor: shutoff fact % 0 100 80 Factor for limit engine shutoff (0% = none)
OilPrMonitor:
% 0 100 20 Time delay engine shutoff
shutoff delay
OilPrMonitor:
% 0 100 20 Factor for reset value
recov fact
OilPrMon.:
s 0 600 15 Time delay fuel inj. quantity reduction
Power Red. delay
Engine speed position 500...260
1/min 8 Engine speed values
valuesp 0
Oil pressure warning bar 0...0,5 Oil pressure warning limit=fct(speed)
Page 9: Sensor calibration values
The following values are dependent only on the type of sensor used and consequently do not generally need to be changed.
BPSensor: upper err limit digits 0 1023 820 Boost pr. sensor: upper failure trigger point
BPSensor: upper ref (2 bar) digits 0 1023 454 Boost pr. sensor: voltage at 2 bar
BPSensor: lower ref (1 bar) digits 0 1023 219 Boost pr. sensor: voltage at 1 bar
BPSensor: lower err limit digits 0 1023 60 Boost.pr. sensor: lower failure trigger point
OilPrSens.:upper err limit digits 1023 820 Oil pr. sensor: upper failure trigger point
OilPrSens.:upper ref (5 bar) digits 0 1023 511 Oil pr. sensor: voltage at 5 bar
OilPrSens.:lower ref (0 bar) digits 0 1023 102 Oil pr. sensor: voltage at 0 bar
OilPrSens.:lower err limit digits 0 1023 40 Oil pr. sensor: lower failure trigger point
CoolTempSens.:up. err limit digits 0 1023 1020 Coolant temp. sensor: upper failure trigger point
CoolTempSens.:lo. err limit digits 0 1023 10 Coolant temp. sensor: lower failure trigger point
LowerMapBranch
digits 0 26...394 4 values
TempSensor
UpperMapBranch
digits 64...838 6 values
TempSensor.
Page 10: Setpoint gen. calibration values
T1:setpoint sensor 0 255 2 Smoothing time constant SWG
The following 8 parameters can be set with the menu ”Calibration”, see 4.3. - *SWG = setpoint sensor
AccPedal(SWG1)up. err val. digits 0 65535 963 SWG1: upper failure trigger point
AccPedal(SWG1)up. ref. digits 0 65535 922 SWG1: voltage max. position
AccPedal(SWG1)lo. ref. digits 0 65535 103 SWG1: voltage min. position
AccPedal(SWG1)lo. err val. digits 0 65535 62 SWG1: lower failure trigger point
Hand thr. (SWG2)up. err val. digits 0 65535 961 SWG2: upper failure trigger point
Hand thr. (SWG2)up. ref. digits 0 65535 830 SWG2: voltage max. position
Hand thr. (SWG2)lo. ref. digits 0 65535 190 SWG2: voltage min. position
Hand thr. (SWG2)lo. err val. digits 0 65535 61 SWG2: lower failure trigger point
20-24
SERDIA PARAMETERS
typ
Wert
Page 11: Assignment inputs/measured values
(F18) Input: Digital / PWM 1
Ass (F18) Inp/PWM1 0 3999 1
(PWM setpoint)
(F21) Input: Digital / PWM 2
Ass (F21) Inp/PWM2 0 3999 2
(PWM setpoint alternate to F18)
Ass (F24) AnaInp1 (F24) Input: Analog 1
0 3999 3511
(Pedal) (accel.pr. sensor)
Ass (M24) AnaInp2 (M24) Input: Analog 2
0 3999 3531
(boostPr) (boost pr. sensor)
0 3999 3551
(CoolTemp) (coolant temp. sensor)
0 3999 3541
(OilPress) (oil pr. sensor)
Ass (F20) DigAnaInp (F20) Input: Digital / Analog
0 3999 3521
(H.thr.) (hand throttle)
Monitoring delay 0 50 1 ON delay of input monitoring
Page 12: Assignment switch inputs/functions
If the sign is changed, the switch positions (open/closed) are reversed.
1 = Input Digital / PWM 1 (Pin F18)
2 = Input Digital / PWM 2 (Pin F21)
3 = Input Digital (Pin F19)
4 = Input Digital / Analog (Pin F20)
5 = Input AnaInput4 (Pin M21)
Max. 5 inputs can be 6 = F3 is input (only for ECU 0211 2088)
assigned to the total Example:
of 7 switch inputs. AssInpTorque curve switching betw.1 / 2: Entry -3: At Input Pin F19 the torque curve can be
switched:
closed = torque curve 2
open = torque curve 1
Entry 3: At Input Pin F19 the torque curve can be switched:
closed = torque curve 1
open = torque curve 2
AssInp:torque curve 1 or 2 -5 5 3 Switching between two torque curves
AssInp:speed droop 1 or 2 -5 5 2 Switching between two fixed speed droops
AssInp:speed specificationi -5 5 1 Switching between two eng. speeds
AssInp:governor type -5 5 4 Switching between two governor types
AssInp:lower engine speed -5 5 0 Fixing lower eng. speed
AssInp:upper engine speed -5 5 0 Fixing upper eng. speed
AssInp:hold engine speed -5 5 0 Holding eng. speed
AssInp:selector switch -5 5 5 Selector switch
Page 13: Assignment outputs/measured values
PWMfreq. for all inp/outp Hz 50 500 100
Ass (F16) (F16) Output: Digital / PWM / Frequency
-3999 3999 2000
Out/Dig/PWM/Freq (Eng. speed 1)
Ass (F5) Out/Dig/PWM1 -3999 3999 2701 (F5) Output: Digital / PWM 1 (torque)
(F3) Output: Digital / PWM 2
Ass (F3) Out/Dig/PWM2 -3999 3999 3011
(Warn.sign. KMT)
Ass (M3) Out/Dig3/PWM3 -3999 3999 0 (M3) Output: Digital / PWM 3
(F4) Output: Digital
Ass (F4) OutputDig1 -3999 3999 3200
1 (error pilot light)
(F15) Output: Digital 2
Zuw (F15) OutputDig2 -3999 3999 3013
(Warn.sign. oil pr.)
(M2) Output: Digital 3
Zuw (M2) OutputDig3 -3999 3999 3201
(solenoid)
20-25
SERDIA PARAMETERS
typ
Wert
Page 14: Start behaviour and cold start aid
mm3/ Fuel quantity at start up to idling eng. speed.
Starting fuel quantity 0 200 110
str. Applies to coolant temperature > 0°C
mm3/
Fuel quantity high idle 0 200 10 Fuel quantity at high idle
corsa
mm3/ Initial injection quantity w. boost pressure
Suction fuel quantity 0 200 90
str. simulation
Overfueling 0 20 0
Overfueling recovery 0 25 0
Cold start fuel qty times s 0 600 30 Cold start overfueling time
mm3/
Cold start overfueling 0 50 20,01 Engine start overfueling for T < 0°C
str.
Eng.speed ramp cold start 1/min/s 5 250 100 Max. eng. speed ramp cold start
Max. PreHeatTime s 0 600 10
Min. PreHeatTime s 0 600 0
ColdSt:PreHeatBackupTime s 0 600 2
Max. PostHeatTime s 0 600 10
Min. PostHeatTime s 0 600 0
const. speed droop °C -30 130 0
CoStMaxHeat
°C -30 130 -30
Temp(pre&post)
Page 16: Breakaway characteristics
const. speed droop 1 % 0 80 6 Speed droop 1
const. speed droop 2 % 0 80 0 Speed droop 2
Engine speed position values 1/min 600...20000 8 engine speed values
Variable droop
% Speed droop=fct(engine speed)
= fct(engine speed)
Page 17: Speed-dependent PID control
Engine speed position values 1/min 600...2500 7 Engine speed values
mm3/
Quantity position values 0...100 4 fuel injection quantity values (ref. points)
Hub
P-Part=fct(eng.speed, fuel quantity)
Speed governor: P map % 100...200
(28 values)
I-Part=fct(eng.speed, fuel quantity)
RSpeed governor: I map % 50...100
(28 values)
D-Part=fct(eng.speed, fuel quantity)
Speed governor: D map % 25...400
(28 values)
Page 18: Smoke limitation
Boost pressure position
bar 4,0 4 Boost pressure values
values
mm3/ Fuel injection quantity=fct(eng.speed,boost
fuel injection quantity limit. 68...104
corsa pressure) (20 values)
Page 19: Simulation of boost pressure sensor after failure
Eng. speed pos. values for
1/mm 800...2500 8 Speed values
boost pr. simul
fuel inj. qty limiting for boost mm3/
20 Fuel inj. quantiy limitation =fct(eng.speed, time)
pr. simul. str.
Page 20: Power parameters
Max. torque (fix) Nm 0 64255 500
20-26
SERDIA PARAMETERS
typ
Wert
Page 21: Min/max speed governor
AccelPos. Position pts % 0...41 5 Setpoint generator
mm3/ fuel inj. quantity=fct(eng.speed,
DrivMap: injection qty 0...100
Hub Accel. pedal position) (25 values)
Page 22: Vehicle speed governor
Speed limiting km/ora 0 300 40 Veh.speed limiting
Tacho calibration lmp/m 1 150 130 Tachometer constant
VehSpeedLimit: P-factor % 0 100 10 Governor parameter speed limit
VehSpeedLimit: I-factor % 0 100 10 Governor parameter speed limit
VehSpeedLimit: D-factor % 0 100 10 Governor parameter speed limit
EngSpeed:TachometerFail. 1/min 500 4000 2000 Maximum permissible speed after tachometer fail
Tacho Timeout s 0 100 5
Max. consumption l/ora 0 200 200
Page 23: CAN, general settings
CAN bus (on/off) 0 1 0
CAN time out Mon (on/off) 0 1 0
CAN: EMR Adress
Can: Baud Rate kBaud 0 255 0
Can:Start Time Out s 0 100 10
Can: Rx Obj Mincount 0 255 4
Can: Low Voltage V 0 66 9
Can: Volt Timeout s 0 100 30
Can: Rx Obj Missing No 0 255 4
Can: Config Tel On 0 63 0
Can :Dia Tel On 0 2047 1961
Can: Meß Tel On 0 3 1
CAN-Sensor ON/OFF 0 65535
LC1: Eng Speed
1/min 1500 0 4000
Ptl Ref)
LC1: Eng Speed
1/min 1500 0 4000
Pt2 (Upper)
LC1: Eng Speed
1/min 1700 0 4000
Pt3 (Lower)
LC2: Eng Speed
1/min 0 0 4000
Ptl (Ref)
LC2: Eng Speed
1/min 0 0 4000
Pt2(Upper)
LC2: Eng Speed
1/min 0 0 4000
Pt3(Lower)
Page 24: CAN: (7700)Rec/Send Telegr. Objects (controller setting)
Rec: EngineTemperature 0 15 0
Recilmake/
0 15 0
ExhaustCond
Rec: Eng Qii Level/
0 15 0
OilPres
Rec:TSC1 0 15 8
Rec: EMR Engine
0 15 12
Protection
Rec: EMR function shift 0 15 0
20-27
SERDIA PARAMETERS
typ
Wert
Rec: Request 0 15 15
Rec:Del. active errors 0 15 6
Rec:Del. error memory 0 15 7
Rec: free 0 15 0
Send:EEC1 0 15 1
Send;EEC2 0 15 2
Send: Meas
0 15 10
Value Objeet
Send: Diagnosis Object 0 15 13
Send: Config Object. 0 15 0
Page 25: CAN- (7720)Source Adr.Rec.messages
Engine temperature 0 255 0
Inlet/Exhaust conditions 0 255 0
Engine fluid level/pressure 0 255 0
TSC1 0 255 3
EMR: Engine protection 0 255 3
EMR function shift 0 255 0
Request 0 255 0
Del. active errorsi 0 255 3
Del. error memory 0 255 3
Free 0 255 0
Page 26: CAN: (7850)Priorities: Object Telegr.
engine temperature 0 7 0
engine fluid level/pressure 0 7 0
TSC1 0 7 3
EMR:Engine protection 0 7 3
Request 0 7 6
Del. active errors 0 7 6
Del. error memory 0 7 6
free 0 7 0
EEC1 0 7 3
EEC2 0 7 3
Page 27: CAN: (7865)Priorities: Diagnosis Telegr.
Active errors 0 7 6
EMR status Diglnputs 0 7 0
EMR status DigOutputs 0 7 0
Engine fluid level/pressure 0 7 6
Engine configuration 0 7 0
Number of errors 0 7 6
Passive errors 0 7 6
Error Environment Data 0 7 6
Engine hours 0 7 6
20-28
SERDIA PARAMETERS
typ
Wert
Page 28: CAN: (7880)Priorities: Config. Telegr.
EMR: Controfler Config. 0 7 0
EMR: Analoglnput 1 Config. 0 7 0
EMR: AnalogInput 2 Config. 0 7 0
EMR: Analoglnput 2 Config. 0 7 0
EMR:PWM-Output Config. 0 7 0
EMR:Dig. Output Config. 0 7 0
Page 29: CAN: (7888)Priorities: Meas. Values Telegr.
Fuel economy 0 7 6
EMR measured values 0 7 0
Page 30: CAN: (7750)SendRepeatRate: ObjectTelegr.
engine temperature ms 0 15000 0
Inlet/Exhaust conditions ms 0 15000 0
engine fluid level/pressure ms 0 15000 0
TSC1 ms 0 15000 80
EMR: Engine protection ms 0 15000 100
EMR function shift ms 0 15000 0
Request ms 0 15000 0
Del. active errorsi ms 0 15000 0
Del. error memory ms 0 15000 0
free ms 0 15000 0
EEC1 ms 0 15000 80
EEC2 ms 0 15000 200
Page 31: CAN: (776S)SendRepeatRate: DiagnosisTelegr.
Active errors ms 0 15000 1000
EMR status Dig lnputs ms 0 15000 0
EMR status Dig Outputs ms 0 15000 0
Engine temperature ms 0 15000 1000
engine fluid level/pressure ms 0 15000 500
Inlet/Exhaust conditions ms 0 15000 500
engine configuration ms 0 15000 0
Page 32: CAN: (7788)SendRepeatRate: MeasValueTelegr.
Fuel economy ms 0 15000 100
EMR measured values ms 0 15000 0
Page 33: CAN: (7900)PDU IdentPart Object Telegr.
engine temperature 0 65535 0
TSC1 0 65535 0
EMR:Engine protection 0 65535 65283
Request 0 65535 59904
Del, active errors 0 65535 65235
Del, error memory 0 65535 65228
free 0 65535 0
EEC1 0 65535 61444
EEC2 0 65535 61443
20-29
SERDIA PARAMETERS
typ
Wert
Page 34: CAN: (7915)PDU IdentPart Diagnosis Telegr.
Active errors 0 65535 65226
EMR status Diglnputs 0 65535 0
EMR status DigOutputs 0 65535 0
engine configuration 0 65535 0
Number of errors 0 65535 65230
Passive errors 0 65535 65227
Error Environment Data 0 65535 65229
Engine hours 0 65535 65253
Page 35: CAN: (7930)PDU IdentPart Config. Telegr.
EMR: Controller Config. 0 65535 0
EMR:AnalogInput1 Config. 0 65535 0
EMR:AnalogInput2 Config. 0 65535 0
EMR:PWM-Input Config. 0 65535 0
EMR:PWM-Output Config. 0 65535 0
EMR:Dig.Output Config. 0 65535 0
Page 36: CAN: (7938)PDU IdentPart Meas.Values Telegr.
Fuel economy 0 65535 65266
EMR measured values 0 65535 0
Page 37: CAN: (7960)Fault codes of rel. fault messages
Setpoint generator 1 0 65535 91
Boost pressure sensor 0 65535 102
Coolant temperature sensor 0 65535 110
Oil pressure sensor 0 65535 100
Electronics temperature 0 65535 171
EngSpeedSensorl EngRun 0 65535 190
EngSpeedSensor2 EngRun 0 65535 190
RackTravelSensor not vibr. 0 65535 200
Oversp. only during shutd 0 65535 190
Actuator deviation excessive 0 65535 209
Coolant Temp.high(alarm) 0 65535 110
Coolant Temp. high
0 65535 110
(shutdown)
Oil pressure low (alarm) 0 65535 100
Oil pressure low (shutdown) 0 65535 100
PWM Input 2 0 65535 204
PWM Input 1 0 65535 205
Fault data set 0 65535 206
Fault hardware parameters 0 65535 210
Fault CAN 0 65535 203
Fault CAN, voltage too low 0 65535 207
Fault shutdown solenoid 0 65535 208
Fault EDC AutoRegulation 0 65535 202
20-30
SERDIA PARAMETERS
typ
Wert
Page 38: CAN: (7740)SwitchoverRelease: Governor, speed droop, limiting curve, preset engine speed
Shift mask: setpoint speed 0 63 8
Shift mask: limiting curve 0 7 0
Shift mask: speed droop 0 7 0
Shift mask: governor mode 0 7 0
Page 39: CAN: (7662)EMR-fault message via OiagTelegr. (on/off)
Boost pressure sensor 0 1 1
Coolant temperature sensor 0 1 1
Oil pressure sensor 0 1 1
Electronics temperature 0 1 1
Eng Speed Sensorl
0 1 1
Eng Run
Eng Speed Sensor 2
0 1 1
Eng Run
Rack Travel Sensor not vibr. 0 1 1
Oversp. only during shutd. 0 1 1
Actuator deviation excessive 0 1 1
Coolant Temp. high (alarm) 0 1 1
Coolant Temp. high
0 1 1
(shutdown)
Oil pressure low (alarm) 0 1 1
Oil pressure low (shutdown) 0 1 1
PWM Input 2 0 1 1
PWM Input 1 0 1 1
Fault data set 0 1 1
Fault hardware parameters 0 1 1
Fault CAN 0 1 1
Fault CAN, voltage too low 0 1 1
Fault shutdown solenoid 0 1 1
Fault EDC Auto Regulation 0 1 1
✽ See also system description EMR, Chapter 3 System functions.
20-31
SERDIA PARAMETERS
4.2 OVERALL PROGRAMMING

ATTENTION!
• Complete programming (i.e. access to all parameters) is only possible on level III.
Saving data contained in the ECU:
• With "ECU -> file" read data from ECU. The "Save file under" window is shown.
• Save data under any name as Hex-File (file name.hex).
Complete programming of ECU:
• Click on key "Programming" and the "Open" window is shown.
• Select desired Hex file and open.
• " Click on key "Save in ECU".
Of the configuration data only that operating data is shown which was read from the ECU (2nd column) or from a file (3rd
column. Prior to uploading of the configuration data to the ECU, the operating data can be edited in the 4th column. This
data is also uploaded when uploading the configuration data to the ECU.
Figure: Menu complete programming (“Overal programming”)
EXPLANATION OF FUNCTION[ SWITCH:

ECU->fi!e: The configuration data is read from the ECU, displayed and can be saved as HEX file.
Programming: Updated configuration data is uploaded to the ECU, In order for the upload to be permanent, you must op-
erate the "Save in ECU" switch on the ECU.
Save in ECU (only applies for EMR): The configuration data are permanently saved in the ECU
Restriction: Only applies for EMR and EMS.
4.3 CALIBRATION
The accelerator pedal and the hand throttle potentiometer (if any) must be calibra-ted in combination with the EMR (not ap-
plicable for gensets).
Important prerequisites:
• Engine shut off
• Supply voltage (ignition/terminal 15) switched on
• Accelerator in frame
20-32

Agrotron 110 mk3

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SAME DEUTZ-FAHR DEUTSCHLAND GmbH

AGROTRON 106 MK3

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GENERAL SAFETY RULES

HOW THE MANUAL IS STRUCTURED

Section 10 Contains technical descriptions and information regarding the mechan-

Section 40 Contains information and diagrams regarding the machine's electrical

HOW TO CONSULT THE MANUAL

1. Removal and refitting of assembled units

1 :.......................................................................Technique to be applied during refitting

3. List of special tools

HOW TO USE AND UPDATE THE MANUAL

1. UPDATING THE MANUAL

Consecutive page number

20-5-2 Existing page

3. SYMBOLS USED IN THE MANUAL

Symbol Meaning Notes Symbol Meaning Notes

Weight of main assemblies.

SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS

1. Precautions for removal operations

2. Precautions for refitting operations

3. Precautions to be taken on completion of removal/refitting operations

indicated with the symbol

WIRE ROPES - SLINGS

WIRE ROPES POLYESTER SLINGS

8 650 620 500 25 500 400 860 700

NOTE. Lifting capacities are calculated with a safety coefficient.

30° 60° 90° 120° 150°

STANDARD TIGHTENING TORQUES FOR NUTS AND

BOLT SIZE 8.8 10.9 12.9

THREADLOCKERS, ADHESIVES, SEALANTS AND

FUNCTION DESIGNATION DESCRIPTION

ucts; after drying, promotes uniform curing of threadlockers.

FUNCTION DESIGNATION DESCRIPTION

Silastic 738 One-part silicone adhesive/sealant, ready for use.

One-part silicone adhesive/sealant, shrinking, ready for use.

Loctite 601 Anaerobic, fast-curing, high-strength adhesive.

Loctite 986/AVX Anaerobic sealant/retaining compound for metal cylindrical parts.

SYMBOL CODE DESCRIPTION NOTES

T1 00239496 Tool for removal of steering unit inner gasket

T2 00239497 Tool for removal of steering unit dust seal

T3 00239498 Tool for mounting of steering unit inner gasket

T4 00239499 Tool for mounting of steering unit dust seal

T5 5.9030.743.1 Test lead for checking sensors with multimeter

T6 5.9030.743.0 Test lead for checking sensors with multimeter

T7 5.9030.740.0 SERDIA installation disc

T8 5.9030.741.0 Adapter cable

T9 5.9030.740.2 Interface level III

T10 5.9030.742.0 EDS software pack

1. TRANSMISSION................................................................. 1 3. HYDRAULIC FRONT AXLE SUSPENSION..................... 48

• The transmission can be divided into the following three sections:

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1.1 TRANSMISSION (Power Shift version)

1.1.1 MAIN COMPONENTS

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18. Left brake cylinder

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24. Left axle casing

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