WORKSHOP MANUAL

Seat and headquarters

V.le Ing. F. Cassani, 15
24047 Treviglio (BG)
Tel. 0363/4211
Telex: 311472 Samtra I

DORADO 55 DORADO 60

DORADO 65 DORADO 70

DORADO 75 DORADO 85

introduction
This publication is intended for the trained technician who must operate on our tractors.

It contains all general information relating to our tractor range, and in particular it highlights the inspection, overhauling
and adjustment procedures as well as the main instructions for dismantling and reassembling operations.

The workshop manual is a natural summary for the mechanic who has attended the vocational training and specializa-
tion courses, which are held every year at our Service School, to permit him to perform a precise and qualified work on
tractor.

Its contents are therefore an exhaustive reference book for the experienced mechanic who desires to refresh his me-
mory on the sequence of the operations to be done. It is then good practice for every authorized dealer mechanic to
have at his disposal this publication, so that it may be consulted quickly when necessary.

We wish to thank in advance for the cooperation all thos people, who will let us have their suggestions in order to make
this publication more complete.

1
 List of contents

Tractor configurations DORADO 55 - 60 - 65 - 70 - 75 - 85 .....................................................................................6

Dimensions and weights...........................................................................................................................................7
Prescribed lubricants and capacities ........................................................................................................................9
Conversion tables ...................................................................................................................................................10
Parts .......................................................................................................................................................................11

1 - ENGINE
Engine section ........................................................................................................................................................12
General characteristics ...........................................................................................................................................20
Timing specifications ..............................................................................................................................................21
Lubrication system - specifications .........................................................................................................................22
Fuel supply system - specifications ........................................................................................................................23
Turbocharger - specifications .................................................................................................................................24
Cooling system - specifications ..............................................................................................................................25
Engine cylinder block ..............................................................................................................................................26
Installing bushings into the camshaft journals ........................................................................................................26
Adjusting backlash between the gear teeth of the auxiliary engine drive ...............................................................27
Support for hydraulic pumps or air compressor located between engine block and timing cover ..........................27
Timing idler gea ......................................................................................................................................................29
Cylinders.................................................................................................................................................................30
Main bearings .........................................................................................................................................................33
Crankshaft ..............................................................................................................................................................35
Connecting rods - connecting rod bearings and bushings .....................................................................................38
Pistons ....................................................................................................................................................................39
Piston rings .............................................................................................................................................................39
Counterweights for 4-cylinder engines ...................................................................................................................44
Engine flywheel ......................................................................................................................................................45
Checking camshaft .................................................................................................................................................48
Checking camshaft bushings ..................................................................................................................................48
Checking timing gear ..............................................................................................................................................48
Cylinder heads - valves - valve rockers ..................................................................................................................49
Cleaning cylinder heads .........................................................................................................................................50
Checking engine compression ...............................................................................................................................53
Oil pump ................................................................................................................................................................54
Checking pressure relief valve ...............................................................................................................................54
Fitting shims between engine oil pan and front support .........................................................................................55
Fuel injection nozzles .............................................................................................................................................56
Mechanical-type engine governor ..........................................................................................................................58
Assembly of the governor unit ................................................................................................................................60
Fitting and adjustment of the external controls of the mechanical governor .........................................................62
Engine governor control assembly .........................................................................................................................64
Electronic engine governor ....................................................................................................................................66
Installing and checking the pick-up.........................................................................................................................68
Installing and checking actuator .............................................................................................................................69
Fitting and checking the accelerator pedal (1st version) .......................................................................................70
Fitting and checking the accelerator pedal (2nd version). .....................................................................................72
Fuel injection pumps...............................................................................................................................................76
Injection pump control system ................................................................................................................................76
Installing injection pump control bar guide supports...............................................................................................77
Engine timing ..........................................................................................................................................................77
Positioning the pumps ............................................................................................................................................80
Fuel prefilter ............................................................................................................................................................83
Fuel filter .................................................................................................................................................................83
Draining water from fuel filter ..................................................................................................................................83
Fan assembly .........................................................................................................................................................85
Turbocharging DORADO 65 - DORADO 85.........................................................................................................88
Engine air filter ........................................................................................................................................................92
Tightening torques ..................................................................................................................................................92
Instructions for engine assembly ............................................................................................................................94
Diagnosing malfunctions ......................................................................................................................................108

2 - CLUTCH
Gearshift clutch.....................................................................................................................................................110
General specifications ..........................................................................................................................................110
Spring specifications to Belleville washer for the clutch engagement ..................................................................110
Cecking clutch ......................................................................................................................................................114
Adjusting clutch control pedal ...............................................................................................................................114
Bleeding air from the hydraulic circuit...................................................................................................................114
Stripping the slave cylinder...................................................................................................................................115
Stripping the master cylinder ................................................................................................................................116

2
 Diagnosing malfunctions ......................................................................................................................................118
Agroshift unit, general specifications ....................................................................................................................119
AGROSHIFT unit detach from the gear box .........................................................................................................122
Assembly of AGROSHIFT unit .............................................................................................................................133
Re-assembly of the Agroshift unit.........................................................................................................................135
Fitting the oil manifolds of the Agroshift unit .........................................................................................................137
Diagnosing malfunctions ......................................................................................................................................142

3 - TRANSMISSION
General specifications ..........................................................................................................................................143
Technical specifications........................................................................................................................................143
Speed change configurations ...............................................................................................................................144
Section through transmission ...............................................................................................................................149
Section through transmission with Agroshift unit..................................................................................................150
Range selector rods and forks..............................................................................................................................157
Removal and refitting operations..........................................................................................................................158
Separating the front gearbox from the engine ......................................................................................................159
Dismantling the gearbox .......................................................................................................................................160
Removal of the gearbox input and P.T.O. shafts..................................................................................................160
Separating the AGROSHIFT unit from the gearbox .............................................................................................160
Removal of the gear train positioned in the front gearbox....................................................................................161
Disassembly of the inversor control rods and forks..............................................................................................162
Dismantling of the gearchange rod and fork assembly ........................................................................................163
Dismantling of the gearchange selector rods and forks assembly .......................................................................164
Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive........................ 165
Removal of the range gear shaft ......................................................................................................................... 165
Examining parts removed .....................................................................................................................................166
Adjusting play of the gearbox shafts by means of the thrust plates on the mini/inversor
shaft and the secondary shaft .............................................................................................................................167
Warnigns related to assembly of the gears of the P.T.O. unit, the range reduction unit and synchronised
P.T.O. shaft ..........................................................................................................................................................171
Assembly of the P.T.O.........................................................................................................................................171
Installation of the range reduction unit, the gear for the front-wheel drive shaft
and the parking brake discs.................................................................................................................................171
Points where sealant is to be used .......................................................................................................................175
Tightening torques................................................................................................................................................176
Bevel drive adjustment .........................................................................................................................................179
Servicing operations .............................................................................................................................................180
Rear power take-off ..............................................................................................................................................181
P.T.O. clutch .........................................................................................................................................................186
Technical specifications........................................................................................................................................186
Correct positions of P.T.O. sensors and cables ...................................................................................................187
Clutch inspection ..................................................................................................................................................189
Checking clutch hydraulic pressures ....................................................................................................................190
Checking the end-play of the front shaft of the P.T.O. clutch ...............................................................................191
Renewal of the rear P.T.O. clutch ........................................................................................................................192
Main operations for removal of the rear P.T.O. unit .............................................................................................193
Diagnosing malfunctions ......................................................................................................................................198

4 - AXLES
Rear axle ..............................................................................................................................................................199
Installing the rear half-shafts ...............................................................................................................................199
Removal and disassembly of the epicyclic reduction unit.........................................................................................202
Fitting lateral stub axles of the wheel ...................................................................................................................203
2WD extendible axle.............................................................................................................................................204
Removing the axle from the front support ............................................................................................................206
Centre steering lever ............................................................................................................................................209
Wheel hub ............................................................................................................................................................210
End float adjustment .............................................................................................................................................212
Front-wheel drive..................................................................................................................................................213
Specifications .......................................................................................................................................................213
Epicyclic reduction unit .........................................................................................................................................217
Side hubs..............................................................................................................................................................219
Tightening torques................................................................................................................................................220
Adjusting bevel gears ...........................................................................................................................................222
Adjustment of the internal control of the mechanical differential lock...................................................................223
Installing the differential assembly into the drive axle ..........................................................................................223
Diagnosing malfunctions ......................................................................................................................................224

5 - VEHICLE
Brakes - General information................................................................................................................................225
Hydraulic pump.....................................................................................................................................................226

3
 Assembly of brake master cylinder ......................................................................................................................228
Checking the front brake disks on 2WD and 4WD front axles and the rear brake disks ......................................229
Adjusting service brake pedals .............................................................................................................................229
Correct installation of inspection cover for parking brake discs ............................................................................230
Checking parking brake pads ...............................................................................................................................232
Bleeding air from the brake hydraulic system.......................................................................................................233
“Separate Brakes” valve .......................................................................................................................................234
Diagnosing malfunctions ......................................................................................................................................238
Hydraulic lift with “load sensing” ...........................................................................................................................239
Installing the lift and front cover plate of the gearbox ...........................................................................................240
Lift mechanism .....................................................................................................................................................240
Checking the safety valves ...................................................................................................................................240
Checking the protrusion of the non-return valve...................................................................................................241
Adjusting the lift ....................................................................................................................................................243
Lift hydraulic circuit ...............................................................................................................................................244
Sensing arm assemblyMontaggio dell'organo sensibile .......................................................................................252
Power-lift distributor valve spring setting specifications .......................................................................................253
Electronic lift .........................................................................................................................................................254
Control panel ........................................................................................................................................................255
Control level or depth control knob .......................................................................................................................255
Mix position/draft control.......................................................................................................................................255
Lowering speed control knob ................................................................................................................................256
Maximum lift height control knob ..........................................................................................................................256
Up/Down control switch ........................................................................................................................................256
Up control .............................................................................................................................................................256
Control/Float mode ...............................................................................................................................................256
Lift status indicator light ........................................................................................................................................256
Remote pushbuttons for lift operation from ground ..............................................................................................256
Calibration of the AUTOMATIC ............................................................................................................................257
Lift operation .........................................................................................................................................................258
Electronic circuit diagram of the ECU ...................................................................................................................259
Calibration of the AUTOMATIC ............................................................................................................................260
Emergency manual lift control ..............................................................................................................................260
List of electronic lift tests ......................................................................................................................................261
Position sensor calibration ....................................................................................................................................266
Precautions for electronic equipment ...................................................................................................................271
Checking the electronics system ..........................................................................................................................271
Checking mechanical components .......................................................................................................................271
Front hydraulic liftSollevatore idraulico anteriore ..................................................................................................272
Hydraulic accumulator and antishock valve for front lift .......................................................................................273
Front power take-off - General information...........................................................................................................275
Section of the P.T.O. ............................................................................................................................................278
Fitting the "RING-FEEDER" rings.........................................................................................................................280
Checking the clutch ..............................................................................................................................................281
Diagnosing malfuntions ........................................................................................................................................282
Spring specifications.............................................................................................................................................282

6 - CONTROLS
Hydrostatic steering ..............................................................................................................................................283
Inspections and checks ........................................................................................................................................284
Steering pump ......................................................................................................................................................284
Directional control valve .......................................................................................................................................284
Check the setting of the pressure relief valve.......................................................................................................284
Bleeding the hydraulic circuit ................................................................................................................................284
Assembly of orbital pump unit ..............................................................................................................................284
Teering wheel shaft and steering cylinders .........................................................................................................285
Instructions for the hydrostatic steering distributor assembly ...............................................................................287
Diagnosing malfuntions ........................................................................................................................................294
Mechanical controls ..............................................................................................................................................295
Electro-hydraulic controls .....................................................................................................................................300
Front P.T.O. clutch engagement control...............................................................................................................300
Rear P.T.O. clutch engagement control ...............................................................................................................300
Differential lock engagement control ....................................................................................................................300
Front-wheel drive engagement control .................................................................................................................300
Rear P.T.O. engagement control ..........................................................................................................................300
Gearbox ................................................................................................................................................................300
Front and rear lift ..................................................................................................................................................300
Hydraulic circuit diagram ......................................................................................................................................301
Solenoid valve - Specifications .............................................................................................................................307
Adjustment of front and rear differential lock control ............................................................................................312

4
7 - BODYWORK
Platform ................................................................................................................................................................313
Cab - General information ....................................................................................................................................314
Cab air filter ..........................................................................................................................................................316
Screen wash .........................................................................................................................................................316
Screen wipers (front and rear)..............................................................................................................................316
Removing the driving platform complete with cab ................................................................................................317
Breakage of the top hood release cable ...............................................................................................................319
High visibility cab roof ...........................................................................................................................................320

8 - SYSTEMS
Ventilation .............................................................................................................................................................321
Heating System ....................................................................................................................................................321
Air conditioning unit for cabs ................................................................................................................................325
Operation and maintenance of the air-conditioning system .................................................................................326
Water dripping from the points at which condensate drain lines are connected to the conditioning unit ............327
Checking system ..................................................................................................................................................329
System safety elements .......................................................................................................................................329
Temperature regulation ........................................................................................................................................329
Charging the system.............................................................................................................................................330
Filling the metering unit ........................................................................................................................................330
Refilling the system with oil ..................................................................................................................................330
Verifying operation of the system after recharging ...............................................................................................332
Directions for tightening air conditioning system pipeline fittings .........................................................................332
Diagnosing malfuntions ........................................................................................................................................339
Hydraulic system ..................................................................................................................................................340
Oil filters................................................................................................................................................................342
Hydraulic pumps ...................................................................................................................................................342
Checking the relief valves of the hydraulic lift system ..........................................................................................342
Stripping the hydraulic pump ................................................................................................................................342
Auxiliary hydraulic spool valves............................................................................................................................345
Checking the pressure relief valve setting............................................................................................................348
Checking the operating pressure..........................................................................................................................348
Conversion of auxiliary spool valves from double acting to single acting operation.............................................348
Checking the surface of the valve spools .............................................................................................................348
Trailer hydraulic braking system ...........................................................................................................................349
Trailer hydraulic braking distributor unit................................................................................................................349
Use of the tractor with CUNA 341/01 hydraulic trailer braking .............................................................................351
Starting .................................................................................................................................................................352
Installing the hydraulic braking valve for trailers equipped with “safety brake” ..........................................................356
electrical system DORADO 55 - 65 (up serial number 1112) 75 - 85.................................................................359
electrical system DORADO 60 - 65 (under serial number 1111) 70...................................................................589
General safety directions......................................................................................................................................590
Jump start utilizing another battery.......................................................................................................................591
Recharge system..................................................................................................................................................593
Heating system..............................................................................................................................................593-594
Heating and conditioning system..........................................................................................................................594
Starting system .....................................................................................................................................................594
Ignition key ..................................................................................................................................................595 - 596
Ventilation control .................................................................................................................................................596
Push button control .......................................................................................................................................596-597
2-Speed windscreen wiper switch ........................................................................................................................598
Work ligths............................................................................................................................................................598
Screen washer switch...........................................................................................................................................598
Beacon push button..............................................................................................................................................598
Push button AGROSHIFT.....................................................................................................................................599
Relay ....................................................................................................................................................................599
Electronic flasher unit ...........................................................................................................................................599
Switch controlling..................................................................................................................................................600
Switch controlling: differential lock - P.T.O. clutch - 4RM - 540 1000 rpm/min P.T.O. speed selector -
Economy P.T.O. - Live P.t.o. - electric starter system.. .......................................................................................600
Switch for emergency brake .................................................................................................................................600
Fuse box ...............................................................................................................................................................601
Instrument panel with digital display .....................................................................................................................602
Operation of the broken belts alarm control unit...................................................................................................604
Engine stop operation with a type 2MH engine control unit .................................................................................606

Electrical wiring.....................................................................................................................................................609

9 - APPENDIX
Engine electronic unit ................................................................................................................................................I
Power lift tester version 1.23a ...........................................................................................................................XLVII
Power lift tester version 1.24a .............................................................................................................................LXV

5
 TRACTOR CONFIGURATIONS:
- DORADO 55 - 60 - 65 - 70 - 75 - 85

DORADO 55 - 60 - 65 - 70 - 75 - 85 2RM WITH PLATFORM

2RM WITH CAB
4RM WITH PLATFORM
4RM WITH CAB

CAB - ventilation
- ventilation + heating
- ventilation + heating + air conditioning

GEARBOX Fully synchronised:

For tractors with driving position with footsteps only

- 16 Forward + 8 Reverse: 4 speeds x 2 ranges + mini-reduction + shuttle
- 24 Forward + 12 Reverse: 4 speeds x 3 ranges + mini-reduction + shuttle

For tractors with driving position with plataform/cab only

- 20 Forward + 10 Reverse: 5 speeds x 2 ranges + mini-reduction + shuttle
- 30 Forward + 15 Reverse: 5 speeds x 3 ranges + mini-reduction + shuttle
- 45 Forward + 45 Reverse: 5 speeds x 3 ranges + shuttle + version AGROSHIFT - -

CONTROLS - electro-hydraulic Agroshift control with 2 pushbuttons located on gear lever

- rear P.T.O. clutch with electro-hydraulic control and mechanical speed selector
- groundspeed P.T.O. with mechanical engagement/disengagement control
- front P.T.O. with electrohydraulic control
- 4WD with mechanical control or optional electro-hydraulic control
- differential locks with electro-hydraulic control
- electronic engine throttle (for tractors equipped with electronic governor)

MECHANICALLY OPERATED REAR POWER-LIFT

- with supplementary rams
- without supplementary rams

ELECTRONIC REAR LIFT

- with auxiliary rams
- without auxiliary rams
- with auxiliary control pushbuttons mounted on fender

HYDRAULIC SYSTEM
The hydraulic system is equipped with two pumps:
Standard:
- 11 cc pump with 27 l/min capacity. Supplies power steering, electro-hydraulic control unit and gearbox
lubrication circuits.
- 14 cc pump with 34 l/min capacity. Supplies auxiliary service control valves and hydraulic lift.
Optional:
- 11 cc pump with 27 l/min capacity. Supplies power steering, AGROSHIFT control unit, electro-hydraulic
control unit and gearbox lubrication circuits.
- 19 cc pump with 47 l/min capacity. Supplies the hydraulic trailer breaking control valve, auxiliary service
control valves and hydraulic lift.

MAIN EQUIPMENT
- front P.T.O.
- economy P.T.O.
- front lift
- electronic lift
- electronic engine governor
- 3-point linkage with hydraulically adjustable right-hand lift rod and stabilisers
- 4-way or 6-way control valves with “Flow Divider”

6
 DIMENSIONS AND WEIGHTS

DORADO DORADO DORADO

55 60 65
2WD 4WD 2WD 4WD 2WD 4WD
Tyres
- front 7.50 - 16 320/70 R 20
- rear 14.9 R 28 420/70 R 28 420/70 R 28
Length
- without front linkage (A) mm 3330 3720 3725 3370
- with front linkage (A) mm 3700 - 4240 3720
Width
- min. (B) mm 1790 1920 1920
- max (B) mm 2230 2320 2320
Ground clearance (D) mm 445 355 345 445 355
Wheel base (E) mm 2105 2056 2105 2056 2105 2056
Max. height
- at safety frame (C) mm 2380 2400 2380
- at cab (standard) (F) mm 2400 2400 2400
Front track
- min. mm 1300 1440 1300 1340 1300 1440
- max mm 1800 1740 1600 1740 1800 1740
Rear track
- min. mm 1400 1400 1500
- max mm 1840 1900 1900
Min. turning radius
without brakes mm 3060 3650 3200 3650 3060 3650
Operating weight
- with driver platform Kg 2400 2800 2360 2530 2400 2800
- with cab Kg 2600 2850 2550 2700 2600 2850
Max. permissible load
- front Kg 1300 2300 - 2300* 1300 2300
- rear Kg 3200 - 3200 3200
- total Kg 4500 5000 - 5000 4500 5000

*: Data applies to reinforced type tyres

7
 DIMENSIONS AND WEIGHTS

DORADO DORADO DORADO

70 75 85
2WD 4WD 2WD 4WD 2WD 4WD
Tyres
- front 7.50 - 16 360/70 R 20
- rear 420/70 R 30 420/70 R 30 480/70 R 30
Lunghezza
- without front linkage (A) mm 3850 3855 3530 3575
- with front linkage (A) mm - 4370 3850 3850
Width
- min. (B) mm 1920 1920 2070
- max (B) mm 2320 2320 2330
Ground clearance (D) mm 365 445 380 465 400
Wheel base (E) mm 2235 2186 2235 2186 2235 2186
Max. height
- at safety frame (C) mm 2430 2400 2420
- at cab (standard) (F) mm 2420 2420 2440
Front track
- min. mm 1300 1340 1300 1440 1300 1440
- max mm 1600 1740 1800 1740 1800 1740
Rear track
- min. mm 1400 1400 1500 1590
- max mm 1900 1900 1900 1910
Min. turning radius
without brakes mm 3300 3800 3200 3800 3200 3800
Operating weight
- with driver platform Kg 2470 2720 2400 2800 2400 2800
- with cab Kg 2660 2890 2600 2850 2600 2850
Max. permissible load
- front Kg - 2300* 1300 2300 1300 2300
- rear Kg - 3200 3200 3200
- total Kg - 5000 4500 5000 4500 5000

*: Data applies to reinforced type tyres

8
 PRESCRIBED LUBRICANTS AND FUELS
(amounts in litres)

Part to be supplied Amt Oil type Product

Multigrade engine oil

6,7 ACEA E3-96
55 - 60 - 65 HP API CF
Engine SDFG OM-1991A AKROS TURBO
MIL-L-2104 E level Special Formula SAME
11 SAE 15W40 (15 ÷ +40 °C)
70 - 75 - 85 HP SAE 10W30 -25 ÷ +30 °C)

Gearbox and
Rear axle
Power-lift 41
Auxiliary Systems
Hydrostatic steering
SDFG OT - 1891
API GL 4 AKROS MULTI
Front P.T.O. 2,5
SAE 10W30

Front - wheel drive

Central axle 6
Side reductions 1,5x2

Brakes control and clutch max. level ATF DEXRON II AKROS MATIC

Lubrication points NLGI 2

LITIO/Ca AKROS GREASE T2

Fuel tank 90 litres

WARNING: The engine oil sump has been replenished after the first 50 work hours.

It is advisable to always use the some type of oil when replenishing.

9
 CONVERSION TABLE FROM

FROM TO multiply by:

inch cm 2.540
cm inch 0.394
foot m 0.305
m foot 3.281
yard m 0.914
m yard 1.094
Eng. miles km 1.609
km Eng. miles 0.622
Sq.in. cm2 6.452
cm2 Sq.ft. 0.155
Sq.ft. m2 0.093
m2 Sq.ft. 10.77
Sq.yard m2 0.835
m2 Sq.yard 1.197
Cu.in. cm3 16.39
cm3 Cu.in. 0.061
Cu.ft. Liter 28.36
Liter Cu.ft. 0.035
Cu.yard m3 0.763
m3 Cu.yard 1.311
Imp.gall. Liter 4.547
Liter Imp.gall. 0.220
US gall. Liter 3.785
Liter US gall. 0.264
pint Liter 0.568
Liter pint 1.762
quart Liter 1.137
Liter quart 0.880
oz. kg 0.028
kg oz. 35.25
lb. kg 0.454
kg lb. 2.203
lb.ft. kgm 0.139
kgm lb.ft. 7.233
lb/in. kg/m 17.87
kg/m lb/in. 0.056
lb./sq.in. kg/cm2 0.070
kg/cm2 lb/sq.in. 14.22
lb./Imp.gall. kg/l 0.100
kg/l lb./Imp.gall. 10.00
lb./US gall. kg/l 0.120
kg/l lb./US gall. 8.333
lb./cu.ft. kg/m3 16.21
kg/m3 lb./cu.ft. 0.062
cu.ft./lb. m3/kg 0.062
m3/kg cu.ft./lb. 16.21
Nm kgm 0.102
kgm Nm 9.81
kW PS 1.36
PS kW 0.736
bar kg/cm2 1.014
kg/cm2 bar 0.981
dm3 l 1
l dm3 1

10
 HOW TO ORDER SPARE PARTS

To ensure perfect tractor efficiency thus avoiding serious drawbacks, and to optimize your investment and the operatio-
nal expenses, the use of “ORIGINAL SPARE PARTS” is recommended.
Spare parts orders must specify the following:

— Tractor serial number and engine serial number (if the engine is concerned).
— Spare part name and reference code.

TRACTOR IDENTIFICATION DATA PLATE

ENGINE TYPE AND TRACTOR FRAME TYPE

SERIAL NUMBER AND SERIAL NUMBER

11
 1 Engine
Engine section DORADO 55 - 60

Fig. 1 - DORADO 55 - 60 - Cross section of 3-cylinder engine

12
 Engine 1
DORADO 55 - 60 Engine section

ø105
ALESAGGIO
115.5
CORSA

Fig. 2 - DORADO 55 - 60 - Longitudinal section of 3-cylinder engine

13
 1 Engine
Engine section DORADO 65

Fig. 3 - DORADO 65 - Cross section of 3-cylinder TURBO engine

14
 Engine 1
DORADO 65 Engine section

ø105
ALESAGGIO
115.5
CORSA

Fig. 4 - DORADO 65 - Longitudinal section of 3-cylinder TURBO engine

15
 1 Engine
Engine section DORADO 70 - 75

Fig. 5 - DORADO 70 - 75 - Cross section of 4-cylinder engine

16
 Engine 1
DORADO 70 - 75 Engine section

ø105
ALESAGGIO
115.5
CORSA

Fig. 6 - DORADO 70 - 75 - Longitudinal section of 4-cylinder engine

17
 1 Engine
Engine section DORADO 85

Fig. 7 - DORADO 85 - Cross section of 4-cylinder TURBO engine

18
 Engine 1
DORADO 85 Engine section

Fig. 8 - DORADO 85 - Longitudinal section of 4-cylinder TURBO engine

19
 1 Engine
General information

DORADO 55 DORADO 65 DORADO 70 DORADO 75 DORADO 85

DORADO 60
Engine
Type 1000.3-A7 (55HP)
1000.3-A5 (60HP) 1000.3-AT2 1000.4-A5 1000.4-A6 1000.4-AT3
Ciyle diesel diesel diesel diesel diesel
Strokes 4 4 4 4 4
Turbocharging - turbo - - turbo
Injection direct direct direct direct direct
Cylinder No 3 3 4 4 4
Cylinder arrangement in line in line in line in line in line
Bore and stroke mm 105 x 115,5 105 x 115,5 105 x 115,5 105 x 115,5 105 x 115,5
Stroke / bore ratio 1,1 1,1 1,1 1,1 1,1
Displacement cm 3000,44
3
3000,44 4000,44 4000,44 4000,44
Compression ratio 17:1 16:1 17:1 17:1 16:1
Max. output
- for DORADO 55 cv CUNA 56 - - - -
Kw 41,2 - - - -
- for DORADO 60 cv CUNA 60 - - - -
Kw 44 - - - -
- for DORADO 65-70-75-85 cv CUNA- - 62,5 70 75 85
Kw - 46 51 55 63
Peack horsepower speed r.p.m. 2350 2350 2350 2350 2350
Max. torque
- for DORADO 55 Nm 197,1 - - - -
kgm 20,1 - - - -
- for DORADO 60 Nm 204 - - - -
kgm 20,8 - - - -
- for DORADO 65-70-75-85 Nm - 225 243 274,2 314,7
kgm - 22,9 24,8 28 32,1
Max. torque speed r.p.m. 1400 1450 1400 1400 1450
Specific horsepower
- for DORADO 55 cv/l 18,4 - - - -
- for DORADO 60 cv/l 20 - - - -
- for DORADO 65-70-75-85 cv/l - 20,1 17,5 18,7 21,2
Cooling air/oil air/oil air/oil air/oil air/oil
Low idling speed giri/min 650/700 650/700 650/700 650/700 650/700
Peak speed
- for DORADO 55 r.p.m. 2520-2550 - - - -
- for DORADO 60 r.p.m. 2470-2490 - - - -
- for DORADO 65 r.p.m. - 2470-2490 - - -
- for DORADO 70 r.p.m. - - 2510-2530 - -
- for DORADO 75 r.p.m. - - - 2520-2550 -
- for DORADO 85 r.p.m. - - - - 2520-2550
minimum lubricating oil pressure
low idling speed (hot oil) bar ³ 0,5 ³ 0,5 ³ 0,5 ³ 0,5 ³ 0,5
high idling speed (hot oil) bar ³ 3,5 ³ 3,5 ³ 3,5 ³ 3,5 ³ 3,5
Oil filter with replaceable cartrige
n. 1 1 1 1 1
Filtering capacity µ 15 15 15 15 15
Fuel filter replaceable cartridge
Valve arrangement vertical in-line

20
 Engine 1
Timing specification

Timing diagram
X = injection advance value on the cylinder block

A - Top dead centre (TDC)

B - Bottom dead centre (BDC)
C - Injection advance
D - Valve overlap

a - Intake
b - Exhaust
c - Opening
d - Closing

Timing by overhead valves and camshafited

into engine block
valve arrangement vertical in-line
intake valve
-opening before TDC 14°
-closing after BDC 40°
exhaust valves
-opening before BDC 48°
-closing after TDC 12°
clearance between valves and rockers
(cold engine) mm 0,20
injection advance (geometric)
before TDC 55HP - 63HP - 75HP 16°
85HP 13°
piston stroke as to injection
advance mm 2,92 (injection advance 16°)
mm 1,94 (injection advance 13°)

21
 1 Engine
Lubrication system - specifications

Fig. 9 - Lubrication diagram.

engine type 1000.3-A7 1000.3-AT2 1000.4-A5 1000.4-A6

1000.4-AT3
lubrication forced-type, gear pump-driven
by camshaft
oil pump codice 010.5481.4 010.5481.4 010.5441.4/10 010.5441.4/10
pump delivery rate at 2500 engine r.p.m.
(dm /60 sec)
3
l/min 38 ¸ 42 38 ¸ 42 38 ¸ 42 38 ¸ 42
pressure relief valve calibration bar 3,5 ¸ 4,5 3,5 ¸ 4,5 3,5 ¸ 4,5 3,5 ¸ 4,5
piston cooling nozzle calibration bar 1,5 1,5 1,5 1,5
minimum lubricating oil pressure (hot oil)
at low idling speed bar ³ 0,5 ³ 0,5 ³ 0,5 ³ 0,5
at high idling speed bar ³ 3,5 ³ 3,5 ³ 3,5 ³ 3,5
oil sump capacity l 6,7 6,7 11 11
oil radiator code 007.7319.3 007.7319.3 007.7320.3 007.7320.3
type 3 rows type 3 rows type 4 rows type 4 rows type

22
 Engine 1
Fuel system - specifications

fuel supply by diaphragm pump

fuel pump ref. code 2.4519.300.0
pump delivery when pressure inside the circuit changes from 0 to 0.4 bar
and engine is at peak speed (dm /h) l/h
3 100
Injection
- by single-cylinder, immersed-type pump and camshaft-controlled plungers
- manufacturer BOSCH
- type
- for DORADO 60-70 (1^ versione) PFR 1K 90 A 517
- for DORADO 60-70 (2^ versione) PFR 1K 90 A 542
- for DORADO 65 PFR 1K 90 A 543
- for DORADO 55-75-85 PFR 1K 90 A 555
- number of pumps used 3 cylinder engine 3
4 cylinder engine 4
- injection order 3 cylinder engine 1-3-2
4 cylinder engine 1-3-4-2
- plunger diameter mm 9
- injection system residual
calibrating pressure bar 70
injectors
- manufacturer BOSCH
- injector type
- for DORADO 60-70 DLLA 150 S 925
- for DORADO 55-65-75-85 DLLA 155 S 1323
- injector holder type KBEL 100 S 31
- rated calibration pressure bar 180
- injection pipe inside diameter mm 1,5
cylinder pressure at sea level at 150 r.p.m. (with hot oil) measured by
equipment no. 5.9030.500.6/10 bar 25 ÷ 30
dry air filter
- code
- for DORADO 55-60-70 7” 2.4249.610.0
- for DORADO 55-60-65-70-75-85 8" 2.4249.600.0
fuel filter
- with replaceable paper cartridge
- code 2.4319.230.0
- filtering capacity m 1,5 ÷ 2

23
 1 Engine
Turbocharging - specifications

For DORADO 65 - 85 only

The engine is supercharged through a turbocharger, whose characteristics are here you of succession bring again.

Fig. 10 - Turbocharger.

DORADO 65 DORADO 85
type GARRETT T25-45/0.68 A/R 62 GARRETT T25-50/0.68 A/R 76
SCHWITZER S 1A/4808DB/0,81 MM1 SCHWITZER S 1B/5309W6/0,81 GG1
code 007.0720.4 007.1443.4
compressor and turbine with radial wheel
impeller shaft on floating bearings with oil seals
lubrication system linked to engine oil lubrication system
operating revolving speed r.p.m. 55.000 ÷ 85.000
mean pressure in the duct at compressor exit:
- at 1400 engine r.p.m bar 0.25
- at 2500 engine r.p.m bar 0,60
air flow rate under operating conditions:
- at 1400 engine r.p.m m /sec
3
0,06
- at 2500 engine r.p.m m /sec
3
0,10
air temperature inside intake manifold:
- at 1400 engine r.p.m °C 60°C
- at 2500 engine r.p.m °C 90°C

24
 Engine 1
Cooling system - specifications

The cooling system consists of a ventilation unit composed by a fan, a stator and an air conveyor.

This system ensures high thermodynamic efficiency as well as prompt engine power availability after a cold start.

1000.3 A5
1000.3 A7 1000.3 AT2 1000.4 A5 1000.4 A6 1000.4 AT3
fan with blades with blades with blades with blades with blades
fan diameter 250 250 250 250 250
n. blades 13 13 13 13 13

Fig. 11 - Cooling system.

25
 1 Engine
11 Cylinder block

Engine cylinder block

The one-piece engine cylinder block is a particularly sturdy ca-
sting. All oil passages necessary to piston lubrication and cooling
are directly machined in it.

Whenever the engine is stripped, ensure that all passages are not
obstructed. If necessary perform a thorough cleaning by compres -
sed air after the block has been soaked in a water and soda or Diesel
oil bath for some time, and all passage caps have been removed.

It is most important to make sure that neither the piston cooling

nozzles nor the cylinder bottom cooling throats are obstructed as
this could prevent the engine from running smoothly.
Fig. 1 - Engine cylinder block.
If the piston cooling nozzles have been removed, pay particular at-
tention on reassembly so as to avoid any interference with piston
stroke, since this would certainly result in a serious engine dama -
ge. For this reason we recommend using the special tool no.
5.9030.731.4, enabling the nozzles to be correctly positioned.

NOTE: When installing the fitting of the piston cooling nozzle,

apply a small quantity of Loctite 242 to the thread and tighten to a
torque of 3 kgm. Fit the nozzle to the fitting, tightening the retaining
nut to a torque of 2.5 kgm.

The tappet seat surfaces should be completely smooth.

Tappets must be fitted before installing the camshaft and with the
Fig. 2 - Oil chamber for cylinder cooling. cylinder block overturned. After fitting tappets, ensure these can
move freely.

Installing bushings into the camshaft journals

Ascertain the camshaft journal bushings are correctly positioned,
i.e. thoroughly aligned with the oil passages machined in the cylin-
der block.

Bushings should be positioned so that they may recess about 2

mm from the holes in the block, except the last bushing on flywhe -
el side which should be flush with the block wall.

Fig. 3 - Piston cooling nozzles.

Fig. 4 - Piston cooling nozzle assembly with

5.9030.731.4 tool. Fig. 5 - Camshaft journal bushings.

26
 Engine 1
Timing case 11

Adjusting backlash between the gear teeth of the

auxiliary engine drive.
Maximum horsepower drawn should never exceed 30 HP.

Between engine plane and application base fit a number of shims

to allow a 0.1 to 0.2 mm backlash may take place between the
gear teeth.
The pack of shims should be put together by alternating metallic
and isogene shims, the first and the last shims being of isogene
(the first metal shim on engine side shall be 0.5 mm).
After dismantling the timing case gears, provision shall be made
for a new timing keeping to the instructions given on page 77 prior
to reassembly. Fig. 6 - Engine oil thermostat.-I begin closing to
83°C -elegant closing to 100°C.
Make sure the idler gear shoulder rings are not excessively worn;
also check the pin surface and the gear inside face for scoring.

Support for hydraulic pumps or air compressor loca-

ted between engine block and timing cover
The timing cover is made of lightweight aluminium alloy.
To fit the timing cover, it is essential to use tool 5.9030.634.0 to en -
sure a perfect alignment between the oil seal and the crankshaft
and between the mating surfaces of the auxiliary power take-off.
Fit the oil seal A in the timing cover with the locating tabs oriented
towards the inside of the cover. Fig. 7 - Drive gear toothing backlash.
Fit the gasket D and timing cover C to the block. Screw in the cover
bolts but do not tighten at this stage.
Fit the hub B.
Align the mating face of the timing cover with that of the engine
block using tool E 5.9030.634.0, which is to be secured with two
bolts to the engine block.
Tighten the timing cover bolts in the sequence 1-2-3 and then the
all remaining bolts to a torque of 24.5 Nm (2.5 kgm).
Remove the tool E and the strip of excess gasket D.

Fig. 8 - Aligning the timing case with the cylinder

block

Fig. 9 - Timing case stripped components.

27
 1 Engine
11 Timing case

Fig. 10 - Auxiliary drive for either hydraulic pumps or air compressors.

28
 Engine 1
Cylinder block 11

Timing idler gea

Use a magnetic base dial gauge to check for correct tooth

backlash between idler, engine gear and timing gear.

This backlash should not exceed 0.10 mm; otherwise the idler
gear should be replaced by another one having the same thic -
kness as the tooth located on the different pitch diameter, so that a
correct tooth backlash may be established.

Identification among gears is provided with marks of different co -

lours (either RED or YELLOW or GREEN) as illustrated in figure
11.
Fig. 11 - Timing idler gear
To each colour corresponds a well-defined tooth thickness value. A - Identification mark

tooth thickness on the pitch diameter

-0, 088
ref. code 007.1177.0 RED colour =3,829 -0, 044

-0, 053
ref. code 007.1178.0 YELLOW colour =3,829 -0, 009

ref. code 007.1179.0 GREEN colour =3,829 +0, 026

-0, 018

Fig. 12 - Gear toothing

B - Gear tooth thickness.

A - Idler gear
B - Cranshaft driving gear
C - Timing driving gear

Fig. 13 - Idler gear

29
 1 Engine
12 Cylinder

Cylinders

Fig. 2 - Cylinder-to-piston position.

Fig. 1 - Cylinder wear check diagram.

Overall cleaning

After removal, clean the cylinders with water and soda or Diesel
oil; also perform a torough cleaning of the cylinder block parts for-
ming the oil chamber for cylinder cooling.

Checking cylinders

Examine the cylinder surfaces for scoring, ovalization, taper and

excessive wear.

Fig. 3 - Measuring cylinder diameter. An acceptable cylinder wear gives the cylinder a light tapered sha-
pe; but if barrel-shape wear is noticed, the cylinder should be re-
placed.

Measurements are to be taken on each single cylinder at three dif -

ferent levels, and also on to planes perpendicular to each other.

If the diameter measured is above the maximum wear limit, the

cylinders should be replaced.

Whenever the piston rings are replaced because of excessive

wear, also inspect the cylinder internal surface; if this is comple-
tely smooth, cylinder reboring will be necessary to permit the new
piston rings to be properly bedded. Use the special tool to perform
a swift to-and-fro movement along the cylinder internal wall in or -
der to score the inner cylinder surface as shown in figure 1.
Fig. 4 - Cylinder inside roughening with No.
5.9030.349.0 equipment.

30
 Engine 1
Cylinder 12

Using the following equipment:

5.9030.627.0 centesimal dial gauge;

5.9030.433.0 dial gauge base;
5.9030.631.4/10 cylinder pressing tool,

Ensure the piston crown at T.D.C. recesses from the head gasket
bearing surface (see Fig. 6).

Fig. 5 - Cylinder head gasket.

Move the dial gauge base until the gauge feeler lies on the cylinder
surface and take reading from the dial.

Reset the dial gauge.

Place the base so that the gauge feeler lies on the piston head at
T.D.C. and take reading.

Choose the gasket to be fitted according to reading taken (also re- Fig. 6 - Checking piston position at T.D.C.
fer to item D in the table here below).

Fig. 7 - Determining the engine cylinder head ga-

sket thickness.

mm Ø machining Ø max wear

A inside diam. measured half-way along the cylinder mm 105,000 -0

+0, 022
105,100

B roundness error mm 0,020 0,080

C piston recess from the head gasket

bearing face on cylinder mm 0,30 ÷ 0,40

D determination of head gasket thickness X reading gasket thickness

gasket ref. code 0.085.1450.0 mm -0,562 ÷ -0,30 0,5 without locating notches
gasket ref. code 0.085.1451.0 mm -0,290 ÷ -0,11 0,7 with 1 locating notch
gasket ref. code 0.085.1453.0 mm -0,100 ÷ +0,02 0,8 with 3 locating notch
gasket ref. code 0.085.1452.0 mm -0,030 ÷ +0,178 1 with 2 locating notch

31
 1 Engine
12 Cylinder

Fig. 8 - Engine cylinder.

32
 Engine 1
Crankshaft 12

Main bearings

Fig. 9 - Crankshaft and main bearing dimensions. (The scheme is relative to the motor to 4 cylinders).
a crankshaft main journal and big end journal machining.
b crankshaft tail journal machining.
c main bearing inside diameter

Ø machining Ø max. wear

-0, 020
A main journal diameter mm 70,000 -0, 040
69,900
1st grinding
a mm 69,750 -0, 020
-0, 040
69,650
2 nd grinding
a mm 69,500 -0, 020
-0, 040
69,400
max. journal taper allowed mm 0,020 0,050
max. main journal ovality allowed mm 0,005 0,050
0
max. journal boring diameter mm 74 -0, 030
0
B big end journal diameter mm 63,500 -0, 020
63,400
1 st grinding
a mm 63,250 0
-0, 020
63,150
2 nd grinding
a mm 63,000 0
-0, 020
62,900
big end journal cilindricity mm 0,020 0,050
big end journal out-off-roudness mm 0,005 0,050
+0, 018
C mean bearing inside diameter mm 70,000 +0, 068
70,130
+0, 018
1st undersize
a
mm 69,750 +0, 068
69,880
2nd undersize
a mm 69,500 +0, 018
+0, 068
69,650

33
 1 Engine
12 Crankshaft

ø105
ALESAGGIO

115.5
CORSA

Fig.10 - Crankshaft assembly - 3-cylinder engine

115.5
CORSA

Fig. 11 - Crankshaft assembly - 4-cylinder engine

34
 Engine 1
Crankshaft 12

Crankshaft

The crankshaft is in nodular cast iron.

All operations must be carried out in compliance with the following
standards:

1 - Metalloscope inspection of 100% of pieces; cracks are not per-

missible.

2 - When grinding the crankshaft, it should preferably rotate in the

opposite direction to its normal rotation in the engine, but rotation
in the same direction is permissible. During the polishing opera -
tion, however, the crankshaft must rotate only in the same direc -
tion as it normally rotates in the engine.
The surfaces must be polished and totally free of machining
marks.

NB: the permitted values for crankshaft grinding are given on page 33.

3 - The emerging Ø6 mm oilways must be chamfered with a radius

of 1.5 mm, and these chamfers must be free from machining
marks.

4 - Round off all sharp edges.

5 - The crankshaft (complete with ring gear, in the case of

4-cylinder engines) and Ø12 mm dowel, must be balanced both
statically and dynamically. The maximum permissible unbalance
on the end supports is 150 g cm.

6 - Before assembly, degrease and thoroughly clean the

crankshaft, including the oilways.

Fig. 12 - 4-cylinder engine crankshaft

cross-section.

35
 1 Engine
12 Crankshaft

Crankshaft end play is adjusted by two-part spacer rings (see also

specifications table) fitted onto the rear main bearing sides (flywhe-
el side); these are provided with a projection preventing faulty as-
sembly, the rings can be mounted after crankshaft installation too.
Each main bearing consists of two shells each being provided with a
small tongue permitting it to be held in position inside the bearing cap
seat. The upper bearing shell is provided with a cavity for oil flow.
Main bearing caps shall be positioned according to the numbering
printed on their bodies and fixed to the block with two special secu -
ring screws, which can only be replaced with other original screws.

Checking crankshaft
Fig. 13 - Cleaning crankshaft lubricating holes.
After the crankshaft has been thoroughly cleaned examine it carefully.

Meticulously ascertain the main and big end journals do not show
signs of seizure, otherwise rigrinding will be necessary. If the jour-
nals are cracked the crankshaft shall be replaced.
Using a micrometer gauge make sure the main journal diameters
are not below the specifications given in the related table, otherwi-
se a regrinding should be performed.

Checking crankshaft journal out-of-roundness

and tape
With a micrometer gauge measure crankshaft journal taper and
out-of-roundness amounts; if reading exceed the maximum allo -
Fig. 14 - Checking crankshaft dimensions. wances specified a regrinding shall be performed. (Refer to speci -
fication table).

Checking main bearings

Clean main bearings carefully and then examine the internal sur -
faces for indentation, scuffing, scratching or evident antifriction li -
ning wear. If any replace the main bearings.
Check main bearing inside diameters with an internal comparator.
If the diameters are found in excess of the maximum wear limits,
the main bearings shall be replaced.

Main bearings are supplied as spare parts either with normal size
or undersize inside diameters. The inside diameter undersize ran-
ge is 0.25 to 0.50 mm.
Fig. 15 - Checking main bearing inside diameter.
Be very careful when installing the main bearings in order they can
be correctly positioned. The bearing shells provided with a lubrica -
ting hole must be placed in the upper side.

Mounting main bearing caps

The numbers stamped on the main bearing caps must be on the
same side as those stamped on the block.
Carefully check main bearing cap fixing screws for stretching, if so
replace them with original screws only.

The screws are to be tightened progessively to 1,02 kgm (10 Nm)

torque and subsequently to 4,08 kgm (40 Nm) torque then using
no. 5.9030.640.0 tool furtherly tighten each single screw to an an-
gle of 55°±1’.
Fig. 16 - Checking crankshaft end play.

36
 Engine 1
Crankshaft 12

Cleaning crankshaft and cylinder block internal

passages
Cleaning of the lubricating oil passage should be made after all
crankshaft and cylinder block overhauling operations have been
accomplished. This cleaning can be carried out by using Diesel
fuel or compressed air blasted into the passages

Checking crankshaft end play (Fig. 16)

This check is performed with a magnetic base comparator operating as Fig. 18 - Special fixture for piston positioning du-
follows: ring crankshaft installation.
— place the magnetic base together with the comparator onto the
crankcase and then make the comparator feeler contact one of
the crankshaft ends.
— use a lever to move the crankshaft axially towards the compa-
rator side until the comparator hand stops moving.
— reset the comparator and push the crankshaft with the lever to-
wards the opposite side and then take the end play reading
from the comparator dial.

This reading should be 0.10 to 0.27 mm; if higher than specified,

some spacing half-rings with 0.10 to 0.20 mm oversize with re -
spect to the nominal thickness shall be fitted. These half-rings are
regularly supplied as spare parts.
Triangular-section gaskets should protrude as shown in figure 17. Fig. 19 - Mounting one holed main bearing shell
(Dopo il posizionamento nel caso di sostituzione delle guarnizioni, into the cylinder block forging.
tagliare la parte eccedente)
Sigillare la zona lato coppa olio Engine e la zona carter anteriore
con silicone tipo DIRKO TRASPARENT della ditta Erling.

In its rear portion the crankshaft is provided with a 3x30° chamfer. In

addition the surface contacting the sealing ring has undergone a har -
dening process.
The oil seal must be fitted using tool 5.9030.628.0.

Fig. 20 - Fitting the one main bearing shell into

the main bearing cap.

Fig. 17 - Main bearing cap gasket installation. Fig. 21 - Installing the crankshaft main bearing
caps.

37
 1 Engine
12 Crankshaft

Connecting rods - connecting rod bearings and

bushings (Fig. 26)
Checking connecting rod axis parallelism
(using no. 5.9030.651.4 special tool)
Place the connecting rod on the special tool and mount the comparator
by loading the feeler 1 mm against the gudgeon pin.
Move the connecting rod from right to left and reset the comparator to
zero when the comparator hand indicates the maximum reading. Remo-
ve the connecting rod from the tool and replace it after a 180° rotation
along its longitudinal axis. Repeat this operation and note the difference
in reading compared with the previous taken. If the difference is above the
specified tolerances, the rod shall be straightened by hand press.
Fig. 22 - Fitting bushing into the con-rod small
end.
Checking connecting rod bushing and bearings
Check connecting rod bushings and bearings for scoring or scuffing.
Wear amount should not exceed specifications, otherwise they must
be replaced. After fitting the bushing, check that the diameter is as
specified in figure 22.

Checking connecting rod weight

The difference in weight between one engine connecting rod and
another must never exceed 20 gr.
Fig. 23 - Checking con-rod for wear.
Installing connecting rods
The screws are to be tightened progessively to 1,02 kgm (10 Nm)
torque and subsequently to 3,06 kgm (30 Nm) torque then using
no. 5.9030.640.0 tool furtherly tighten each single screw to an an-
gle of 90°±1’
If these bolts are to be reused, check that the difference between
the maximum and minimum diameter measured at the part deno -
ted A (Fig 25) is less than 0,1 mm. If not, the bolt must be replaced.

Fig. 24 - Pulling out/driving in con-rod bushing.

Fig. 25 - Checking the diameter of the connecting

rod clamp bolts. Fig. 26 - Checking con-rod axis parallelism.

Ø machining Ø max wear

connecting rod bearing inside diameter mm 63,500 +0, 035
+0, 075
63,620
1st undersize
a mm 63,250 +0, 035
+0, 075
63,370
+0, 035
2 nd undersize
a
mm 63,000 +0, 075 63,120
+0, 015
connecting rod bushing inside diamete mm 35 +0, 025
35,060
maximum misalignment of the connecting rod smoll
end axis (measured at 49 mm from con-rod centre line) 0,05 mm

38
 Engine 1
Crankshaft 12

Pistons - gudgeon pins - piston rings

Fig. 27 - Piston, piston ring and gudgeon pin dimension.

Pistons

Ø machining Ø max. wear

A piston diameter at 90° of the gudgeon pin axis and
at 10 mm from the bottom base mm 104,9 ± 0,007 104,680
B clearance betwen piston ring and piston
1st piston ring
a mm 0,110 ÷ 0,145 0,250
2 nd piston ring
a mm 0,050 ÷ 0,085 0,150
3 st piston ring
a mm 0,030 ÷ 0,650 0,150
C piston ring and gap
1 st piston ring
a
mm 0,400 ÷ 0,650 1,500
2 nd piston ring
a
mm 0,400 ÷ 0,650 1,500
3 st piston ring
a mm 0,300 ÷ 0,600 1,500
D inside diameter of gudgeon bore
naturally in piston mm aspirated 35 +0, 006
+0, 012
35,020

E gudgeon pin diameter mm 35 34,970

Pistons are specially forged hypereutectic aluminium-silicone-alloy. The

air-fuel mixing chamber machined in piston crown has toroidal shape.
Both the part number and reference A (meaning air) are printed in piston
top, i.e. the piston identification code.

Piston rings
Pay particular attention to the identification marks on the piston rings for
correct assembly.
Inserting the first or the second piston ring upside down will result in either
engine uneven operation or serious damage, even though the piston gro -
ove is the correct one. The figure above illustrates how assembly should
be performed correctly.
Figure 30 on page 41 shows the correct assembly.
Fig. 28 - Measuring piston diameter.

39
 1 Engine
12 Crankshaft

Fig. 29 - Pistons.

40
 Engine 1
Crankshaft 12

Fig. 30 - Instructions for fitting piston rings to pistons.

41
 1 Engine
12 Crankshaft

Cleaning pistons
Descale piston crown and piston ring grooves using an emery
cloth.

Remove any buildups from gudgeon snap ring seats.

After all parts have been thoroughly cleaned and before further
checking is performed, examine them carefully for cracking or da -
mage which may require replacement.

Light scoring o seizing signs can be removed with very fine emery
cloth.
Fig. 31 - Checking clearance between piston
rings and piston ring grooves in piston.

Checking pistons
Measure piston diameter with a micrometer gauge as shown in fi-
gure 28.

If the diameter measured is below the specifications given in table

on page 39, the piston needs to be replaced.

Fig. 32 - Checking clearance between the piston

rings and grooves
Checking gudgeon pin and gudgeon pin seat in pi-
ston
If either gudgeon or related seat diameter measurement differs
from specifications given in table on page 39, the replacement of
the worn-out part is recommended.

Check also gudgeon pin snap rings for proper elasticity or dama-
ge. If they are found not conforming to the operating conditions re -
place them.

Checking piston ring end gap

Both the compression ring and the oil control ring ends installed in
the cylinder should not have a gap exceeding the specifications
shown in tableon page 39.

This check is carried out by inserting the piston rings into the cylin-
der so as the ring end gap can be measured with no. 5.9030.270.0
special thickness gauge, as shown in figure 31.

NOTE - Excessive clearance between piston rings and piston ring

grooves in piston may cause high lubricant consumption as well
as engine power loss.
Fig. 33 - Correct assembly of piston rings. Piston rings must be replaced each time piston is removed or
cylinders are replaced.

42
 Engine 1
Crankshaft 12

Checking clearance between piston rings and pi-

ston ring grooves in piston
This check is to be made with new piston rings, as shown in figure
32, by inserting the piston ring into the groove and then the blade
of no. 5.9030.270.0 thickness gauge. Refer to specifications table
on page 39, for maximum clearance allowance.

If the clearance measured exceeds the maximum allowance, pi -

ston shall be replaced.

Installing piston rings

During cylinder assembly perform a proper orientation of the first
piston ring so that its cut be moved by 60° from the gudgeon pin
axis.

The other piston rings should be inserted with their cuts moved by
120° from each other.

Fig. 34 - Installing piston into cylinder.

Installing pistons into cylinders

Use no. 5.9030.654.0 ring clamping band as shown in figure 34 to
install piston into the cylinder.
Afterwards insert piston and cylinder assemblies into the cylinder
block.

NOTE - Pistons can be taken without removing the crankshaft,

just withdrawing along with the connecting rods directly from the
cylinders after removing both cylinder heads and connecting rod
caps.

Fig. 35 - Installing piston and cylinder assembly.

Before installing the cylinder liners, fit the O-ring seals code
2.1539.130.0.

The connecting rod-piston assembly must be assembled with the

piston crown recess oriented towards the tappets (Fig. 36).

The big-end caps must be fitted so that the punched number ap -

pears on the same side as the number on the connecting rod.

Fig. 36 - Correct orientation of piston and con-rod

assembly.

43
 1 Engine
12 Engine section DORADO 70 - 75 - 85

Counterweights for 4-cylinder engines

Specifications
counterweight end play mm 0,1 ¸ 0,43

backlash allowance between

counterweight and crankshaft
crown wheel teeth mm 0,20 ¸ 0,25
+0, 050
bushing inside diameter mm 26 +0, 075

max. wear mm 26,150

Fig. 37 - Counterweight assembly components.

Check counterweight bushing inside surface conditions. Ensure

the inside diameter is not above specifications; otherwise replace
bushings.
With bushing installed perform boring according to specifications
given in the table above.

Installing and adjusting counterweights

Position the weight marked with S in the related support seat, then
place weight D too, so that the engraved teeth coincide as shown
in figure.
Fig. 38 - Counterweight assembly.
Fit gudgeons E and insert spacer washers H.
Be sure the counterweight end play is 0.1 to 0.43 mm.
Complete installation by fixing gudgeons through special pins F
and the weights with securing screw C.

Apply the support and weight assembly underneath the cylinder

block so as the engraved counterweight S tooth engages between
the two engraved teeth of crankshaft crown wheel B. Then fit a
number of shims G until a 0.20 to 0.25 mm backlash between
crankshaft crown wheel and weight S teeth is obtained.

Remove screw C and finally tighten the weight support securing

screws to cylinder block also applying some Loctite 242.

Fig. 39 - Counterweight assembly cutaway-view.

Fig. 40 - Engine-installed counterweights. Fig. 41 - Installed counterwight bushings.

44
 Engine 1
Crankshaft 12

Engine flywheel
Before dismounting the flywheel it is advisable to remove two dia-
metrically opposed screws replacing them with two stud bolts.

To replace the flywheel ring gear operate as follows:

— Immerse the flywheel into a water-filled container. Keep the

flywheel lifted a few centimeters from the container bottom
using some small iron blocks fitted under the ring gear teeth.
The ring gear should be turned upwards and project a few milli-
meters from the water surface.

— Using a flame heat the ring gear all around the toothed sector Fig. 43 - Ring gear position on engine flywheel.
until the flywheel is dropped to the container bottom due to heat
expansion.

— Heat the new ring gear up to a temperature of about 200° C and

position into flywheel housing. Ensure the tooth chamfers are tur-
ned upwards as shown in figure 43.

12" per 75-85HP 57,5±0,2

11" per 60-65HP 60±0,2

26,5±0,1

Fig. 44 - Checking flywheel face coplanarity

27

25,5

Fig. 45 - Removing flywheel ring gear.

Fig. 42 - Machining depths for clutch matching surface of the flywheel.

Checks
Make certain that the sliding surface of the flywheel is not scored;
material can be removed, if necessary, to a maximum depth of 0,5
mm, (surface roughness 1,6 mm).

The flywheel contact surface should thoroughly be in the same

plane as the clutch plate. This can be verified by fitting a magnetic
base comparator as illustrated in figure 44 and rotating the flywhe-
el by hand.
Fig. 46 - Engine flywheel.

45
 1 Engine
12 Crankshaft

Crankshaft removal procedure

— Remove engine from tractor and install on no. 5.9030.002.0 traveling stand for transfer on no. 5.9030.491.4 swivel
bench.
— Remove the oil pan and the oil pump suction rose.
— After detaching the pulley belt take the pulley from the crankshaft along with the pulley hub.
— Dismount engine front case, rear flywheel, engine-to-gearbox connecting flange and sealing ring holding flange.
(In 4-cylinder engines also the counterweight assembly is to be removed).
— Remove big end caps and related bronze bushings.
— Remove main bearing caps and related bronze bushings.
— Remove the crankshaft and take the upper bronze bushings.

Fig. 47 - Rear flange cross-section.

46
 Engine 1
Camshaft 13

Ø machining Ø max. wear

Camshaft cam lift
+0, 05
intake cam mm 6,86 -0, 05
6,30
exhaust cam mm 6,71 +0, 05
-0, 05
6,20
injection cam mm 8 +0, 05
-0, 05
7,50
0
Camshaft journal diameter mm 55 -0, 030
54,950
Camshaft bushing diameter mm 55 +0, 060
-0, 090
55,180
Idler gear bushing diameter mm 40 +0, 025
+0, 064
40,125
Idler gear pin diameter mm 40 0
-0, 025
39,950

The installation of single-cylinder injection pumps besides ensu -

ring an even load distribution on the camshaft has permitted two
bearings per camshaft journal to be mounted in the engine block,
thus minimizing camshaft flexure.

Fig. 1 - Timing system cams:

A bimetallic bushing is inserted in each bearing to ensure very A - Valve cam; B - Injection cam..
smooth camshaft operation. This can be replaced when wear ex-
ceeds the limits specified above.

All these features guarantee precise cam movement thus provi-

ding smooth timing system operation and regular fuel supply as
well.

The camshaft is held in position by a forked plate fitted on engine

front side.
Fig. 2 - Checking cam wear.

The engine oil pump and engine governor driving gear is mounted
at the rear camshaft end.

Prior to installing camshaft, the engine block should be turned up -

side down and the tappets inserted in the related seats in the block
after having been properly lubricated with oil.

Make sure the tappets slide in their seats freely. Fig. 3 - Camshaft fixing forked plate.

47
 1 Engine
13 Camshaft

Checking camshaft
Examine both camshaft journal and cam surfaces: they must be
thoroughly smooth and in perfect operating conditions.

If on the contrary cams show any sizing or scoring, it is convenient

that both the camshaft and the bushings installed in the block be
replaced. Only if a very small evidence of deterioration is noticed,
this might be eliminated using a very fine grain abrasive stone.

To check for wear, place the camshaft on the special

cross-shaped rests and apply a comparator feeler on each single
cam then rotate the camshaft.
Fig. 4 - Installing tappets into the engine block.
Minimum cam lift should never be below specifications, otherwise
the camshaft should be replaced.

Checking camshaft bushings

Carefully examine bushing inside surface; should any seizing or
evident wear of the antifriction lining be found replace the bu -
shings.

If normal conditions are noticed, check the bushing inside diame-

ters by means of an internal comparator. If the bushing inside dia-
Fig. 5 - Installing the engine governor driving meters measured are in excess of the maximum wear limits speci-
gear. fied, these shall be replaced.

Each time the bushings are replaced they must be bored.

Checking timing gear

Be sure the gear teeth are not spalled or excessively worn. Repla -
ce the gear, as necessary.

Fig. 6 - Inserting the camshaft bushings.

Fig. 7 - Camshaft.

48
 Engine 1
Cylinder heads 14

Cylinder heads - valves - valve rockers

Ø machining Ø max. wear
natur. aspirated engines turbo engines
A valve stem diameter intake mm 9 --00,, 013
028 8,98 –0, 04
0 8,940
exhaust mm 9 --00,, 013
028 8,96 –0, 02
8,940
B inside diameter of the valve guides installed in the heads mm 9 9,100
C valve seat angle with respect to valve
intake 29°30’ 0
-15
exhaust 44°30’ 0
-15
44°22’ –7' 30 "

D valve seat width on the valve seat insert

intake mm 0,8 +-00,,15 1,8
exhaust mm 1 +-00,,15 2

E valve recess from cylinder head level

intake mm 1,55 1,7
exhaust mm 2,20 2,35
F valve seat taper intake 60° 0-15
exhaust 45° 0-15
G valve diameter intake 44,2 44,1
exhaust 39,5 39,4

A B
A S

D
D
E E
G C
C G
F
F
Fig. 1 - Main dimensions of valves and valve seat inserts.

Fig. 2 - Rocker support assembly cross-section. Fig. 3 - Engine cylinder head longitudinal section.

49
 1 Engine
14 Cylinder heads

Fig. 7 - Cylinder head cross-section.

Fig. 4 - Tappet assembly.

Fig. 8 - Valve recess from the cylinder head gasket bearing face.

Fig. 5 - Clearance between valves and rockers. Cleaning cylinder heads

Ø machining. Ø max. wear
A Valve springs
a inside diameter mm 27,7
b free spring length mm 53,6
c loaded spring length
Kg 15,85 ± 5% mm 42
Kg 19,60 ± 5% mm 39,6
rocker arm bushing inside diameter
B

(see fig. 10 on page 51)

C

mm 19 +-00,,011
015
19,060
C

cker arm pin diameter

(see fig. 10 on page 51 mm 19 0-0, 011 18,980
clearance adjustment between
Fig. 6 - Main valve spring dimensions. valve and rocker arm (cold) mm 0,20

50
 Engine 1
Cylinder heads 14

Cleaning cylinder heads

Clean the cylinder heads thoroughly by removing any coking insi-
de both exhaust and intake ducts. Also clean cylinder head coo-
ling fins carefully.

Checking valve seats

First descale and clean valve seats and then inspect for either pit-
ting or corrosion in the valve contact area, otherwise a new grin-
ding (if light wear is found) or a replacement shall be provided.

To install new valve seat inserts operate as follows:

chill the valve seat inserts in liquid nitrogen for easier installation in
the cylinder head by running fit.
Valve seat inserts are supplied as finished parts and do not requi-
re any further machining. On installation avoid knocking on the
valve seats to prevent distortion.

NOTE - If no liquid nitrogen is available for valve seat insert chilling

before installation, it is also possible to heat up the cylinder head
to a temperature of 200° to 300°C.
Fig. 9 - Cylinder heads, cylinders, valves and roc-
ker arms.(it has presented in figure the gasket for 4
cylinders.
Checking valves
Descale the valves with the special brush.

Make sure the valve seat is thoroughly intact, otherwise replace.

Check the valve stem for deformation, be sure the stem outside
diameter is not below specifications.
A

Testing valve tightness

B

After grinding the valve seats, test valve tightness as follows: plug
the intake and exhaust ports through the related valves and then
pour in some petrol and check for any leaks (if new valves are in- Fig. 10 - Bushing and rocker arm positions and
stalled a slight dripping is allowed). wear check dimensions.
A - Rocker arm bushing inside diameter.
B - Rocker arm pin outside diameter.

Checking valve guides

Inspect valve guide boring inside surface. It should be thoroughly
smooth and show no evidence either of seizing or scoring.

Use no. 5.9030.020.0 gauge (fig. 17) for measuring the valve gui -
de inside diameter. Excessively worn guides are to be replaced.
When re-installing the valve guides they should protrude 14.5 ±
0.2 mm from the seat in the cylinder head.

Using tool specific for installation will enable this dimension to be

automatically obtained.

Fig. 11 - No. 5.9030.635.0 tool for tappet rod cap

removal.

51
 1 Engine
14 Cylinder heads

Ø 45 Ø 40,5
Ø 36 Ø 31,5

20°

A B

9
9
2,2
0

7
1,
°
45
Ø 40 Ø 39,11

Ø 43,63

Fig. 12 - Valve seat inserts and valve guides. Fig. 13 - Valve seat inserts.

Checking push rods

A S
Examine rocker arm push rods for deformation and the rocker arm
contact ball seat for signs of seizing or roughness, if any, replace.

Make sure also the other push rod end in contact with the tappet
does not show excessive wear or nicks.
29° 30'

44° 30'

30°
25

3.6
°

39,1
43,63

Checking valve springs

Make sure the valve springs have not lost their elasticity.
Fig. 14 - A - Intake valve Also inspect valve springs for rust or damaged lacquering.
S - Exhaust valve.

Checking rocker arms

Ensure the rocker arm working area is thoroughly smooth and no
nicks are shown.

Use a micrometer gauge to measure the rocker arm pin diameter;

reading should not be lower than specifications, otherwise replace.

Check the rocker arm bushing for excessive wear, replace as ne-
cessary.

Check both rocker arms and valves for proper lubrication by run -
Fig. 15 - Using no. 5.9030.012.0 tool to remove ning the engine at idling speed, ensure the oil flow rate is regular;
valves.
should this not be the case the rocker arm bushing should be in-
spected for proper installation or the ducts checked for clogging.

Adjusting valve clearance

This adjustment is to be performed with a cold engine and piston
at T.D.C. at the end of the compression stroke (both rocker arms
shall be in uppermost position and detached from the valve
stems).

Rotate the crankshaft until the above mentioned conditions are

obtained, then use a thickness gauge to take clearance measure -
Fig. 16 - Grinding valve seats.
ment.

52
 Engine 1
Cylinder heads 14

Fig. 18 - Inserting valve guides with the special

Fig. 17 - Checking valve guide wear. tool.

Installing cylinder heads

Cylinder head securing screws should be tightened evenly follo-
wing the cross sequence shown in figure to a 2 kgm (19 Nm) tor-
que, then repeat tightening in the shown sequence to a 5 kgm (49
Nm) torque, finally use n. 5.9030.640.0 equipment to furtherly tig -
hten the cap screws until each of them is locked by an angle of
90°÷ 3’.
Before performing screw tightening, the use of plate A is recom-
mended to align the cylinder heads correctly, as shown in figure 21.

Fig. 19 - Adjusting valve clearance.

Checking engine compression
Run the engine until the operating temperature is attained.
Remove the injection nozzle from the cylinder head and fit the
special engine compression tester.
Ensure the injection pump is in STOP position.
Start the engine and let it turn until the peak pressure in the cylin-
ders is obtained and then check the engine r.p.m.
Be sure the same checking procedure is applied for each single
cylinder so as to provide even measurements.
Cylinder pressure should be 25 to 30 bar at sea level at 150 engine
r.p.m. and with hot oil.
Any difference in readings should be no more than 10%. Altitude
affects engine compression: 4% pressure loss every 300 m above
sea level is usually recorded. To avoid incorrect readings, the bat-
tery should be thoroughly efficient. Lack of compression may be Fig. 20 - Checking cylinder compression.
due either to piston ring or valve and valve seat or cylinder wear.

Fig. 22 - No. 5.9030.640.0 equipment for tighte-

ning the cylinder head securing screws angu-
Fig. 21 - Using alignment plate A to install the cylinder heads and cap larly.
screw tightening order.

53
 1 Engine
15 Lubrication system

Fig. 1 - Oil pump assembly cross-section.

Oil pump
Each time the oil pump is removed or installed, ensure
the gears can rotate freely and there is no evidence of
tool spalling or wear.

Otherwise the whole pump assembly must be repla-

ced.

To perform a complete oli pump efficiency test insert an

oil flow rate meter along with an oil pressure gauge bet -
ween cylinder block and oil filter. Ensure readings cor -
respond to specifications on page 22.

Checking pressure relief valve

Using the special fitting connect the valve to no.
5.9030.520.4 equipment and make sure the valve ca -
librating pressure is 3.5 to 4.5 bar.
If this is not the case the valve should be replaced.

Warning: whenever the oil pan is removed, ensure the

prefilter wire mesh located under the oil rose pipe is
thoroughly clean.
Engine oil pressure can also be checked on the special
dashboard-mounted indicator.

Engine oil level should never be below the minimum le -

vel notch on dipstick.
Fig. 2 - Oil radiator, oil filter and oil pan.

54
 Engine 1
Lubrication system 15

Fitting shims between engine oil pan and front

support
Between engine oil pan C and front support A it is required that
shims be fitted so that a ± 0.1 mm alignment with the engine block
plane may be obtained.

Mount the oil pan onto engine block paying particular attention the
rear planes are thoroughly aligned (engine flywheel side).

With no. 5.9030.272.0 centesimal gauge and no. 5.9030.433.0 gau -

ge base measure the difference in dimension between oil pan C front
plane and engine block plane B. This difference in reading should
be 0.35 to 0.95 mm (make sure the oil pan plane always recesses
from engine block plane).

Install the front support placing a number of shims which permits

both planes to be aligned within a ± 0.1 mm allowance.

WARNING: Reading and shimming should be performed both on

the front right-hand and the front left-hand side of the oil pan as
shown in figure.

Fig. 3 - Measuring the difference in dimension

between oil pan and engine block planes.

Fig. 4 - Positions at which to measure the difference in height between the front face of the sump pan and the engine block.

55
 1 Engine
16 Fuel system

Fuel injection nozzles

Checking fuel injection nozzles

The checks on injection nozzle operating conditions include injec -
tion nozzle spraying efficiency and calibration.

However, it is recommended that the utmost cleanliness rules be

strictly observed and a thorough test on the hydraulic seal of the
different system fittings be performed. As a matter of fact even a
small leakage would invalid the tests carried out.

Fig. 1 - Injection nozzle assembly.

Injection nozzle calibration

Check pressure reading at which the nozzle needle begins to be
lifted from its seat thus determining the injection starting.

This pressure should be within the recommended specifications.

For this reason, each time that calibrating pressure readings differ
from specifications the injection nozzle should be adjusted as re-
quired.

To perform the above checks, the use of a pump connected to the

injection nozzle to be tested by a piping is unavoidable.
(Prior to performing the test the fuel recovery plug should be remo -
ved).

The following procedure shall apply:

Operate the pump lever (fig. 4) a few times to force any air out of
Fig. 2 - Setion of injection system.

Slowly operate the pump lever and notice the pressure reading
right in the moment the injection begins. This pressure should be
180 bar. If readings differing from that specified are indicated, it
will be necessary to adjust the pressure spring by simply adding or
removing the special spring preloading shims.

To gain access to spring adjustment, remove first the lower cap of

the injection nozzle holder and then add or remove shims bewteen
spring and flat cap until the desired nozzle calibrating pressure is
obtained.

Fig. 3 - Spring load adjustment.

56
 Engine 1
Fuel system 16

Checking injection nozzle seat tightness

Checking the injection nozzle seat tightness is very important as
this permits to verify whether there is any fuel dripping from the in-
jection nozzle before the calibrating pressure is reached.

This test is carried out by operating the hand pump until a pressure
reading about 10% lower than the calibration pressure is attained.
Take care this pressure be maintained by oppotunely pressing on
the hand pump lever, so as to compensate the pressure drop
which otherwise would be caused by the fuel dripping between pin
and nozzle holder body.

Under these conditions the injection nozzle should never drip; ot- Fig. 4 - Checking injection nozzle spraying effi-
herwise consult an injection pump specialist. ciency.

WARNING: on refitting, position the injector as shown in figure 56

of page 103.

Fig. 5 - No. 5.9030.618.4 tool used to remove in-

jection nozzle from seat.

Checking injection nozzle spraying efficiency

Connect the injection nozzle to a pump and operate the pump le -
ver repeatedly so that the operating conditions may be reprodu -
ced.

Fuel must be sprayed from the nozzle holes in form of finely atomi-
zed jets, which should all be equal in size. There should be as
many jets as there are holes in the injection nozzle.

Otherwise, clean the nozzles by removing first the residual carbon

deposits from the nozzle holes with a Ø 0.28 mm steel wire and
then clean them thoroughly with a Ø 0.30 mm wire, this having the
same diameter as the nozzle spraying holes.
Fig. 6 - Cleaning injection nozzle with a piano
wire.

Injection nozzle projection from the cylinder head

face plane
3,42 ÷ 3,90 mm
Make sure the injection nozzle projects 3.42 - 3.90 mm from the
cylinder head face plane. Fig. 7 - Injection nozzle projection from the cylin-
der head face.

57
 1 Engine
16 Fuel system

MECHANICAL-TYPE ENGINE GOVERNOR

Fig. 8 - Engine governor assembly longitudinal sections.

Mechanical-type engine governor
The engine injection pump governor assembly is a very advanced
design both for specific operating features and easy servicing.
The engine governor has been developed as a complete unit on
which either repairs or adjustments can be performed after re-
moval from engine.
Besides facilitating operations, also it offers the advantage of be-
ing swiftly replaced or temporarily interchanged with a unit of
same type and specifications, thus preventing the machine from
lying idle in the event of mechanical interventions on it.
The following equipment is also provided with the governor as -
sembly:

Automatic extra fuel supply

Whenever the engine is turned off, extra fuel is automatically sup-
plied to the combustion chamber by this unit; this ensures a
prompt engine starting response. (To be sure this automatic sup-
ply function is not prevented in very cold weather, we recommend
releasing the engine fuel shut-off control - STOP - immediately af -
ter the engine has been stopped).

Engine fuel shut-off

This control permits the engine to be stopped effortlessly, as it di -
rectly operates the pump control rod and no connection to the gov-
ernor assembly is provided.

Anti-hunting
Fig. 9 - Engine governor transmission assembly. This device limits the engine speed variation when this turns at
fast idling speed.

58
 Engine 1
Fuel system 16

Fig. 10 - Engine governor assembly cross-section.

Mounting governor weights (Fig. 11)

Apply Loctite 601 to the crankshaft surface A in contact with support
B, then fit the support to the crankshaft, positioning the two pieces to
allow fitting of dowel F.

Fit the weights C and E to the support by means of plates D inserted

in the groove of the sliding sleeve.

Open weight C against the stop thereby holding the weight whose
plate rests on the coupling and releasing the other one, then move
the coupling against the locked plate. Be sure the dimension read -
ing is 61 ± 0,1 mm as shown in Fig. 11, otherwise add or remove
shims (ref. code 2.1589.160.0 and 2.1589.161.0) to/from the position
indicated by the arrow.

Fig. 11 - Installing weights on the governor shaft.

Before assembly, apply Loctite 601 to the outer surfaces of bush D, tube E and fitting B.
Before assembly, apply Loctite 601 to the outer surfaces of bush G and bush H.
Before tightening nut C, coat the thread with Loctite 270.
Before assembly, apply Loctite 270 to thread of the control lever retaining bolt F.

Fig. 12 - LOCTITE application points.

59
 1 Engine
16 Fuel system

1 - Fit this pin using Loctite

Fig. 13 - Engine governor assembly.

Assembly of the governor unit (fig. 13)

Lower casing
Fit the internal and external STOP control levers and fit the plate and stop screws. Fit bearing A in the casing and fit levers B
and C with complete unit.
WARNING: before fitting lever C, check that 20 mm section indicated in the figure is completely free of burrs or indents.
Insert the shaft complete with the governor weights, securing it to the bearing with the nut.
Fit bearing D and the sliding sleeve and fit eccentric screw E to the casing so that the chasing on the head is positioned
at the top.ent of the actuator
Registrazione dell’adeguatore
Position the governor on the special tool (dis. 5.9030.665.0), taking care to centre the fork with the fixed pin X (fig. 13).
Turn the cam screw E to adjust the distance between the surface of the lower half-casing (without gasket) and the sli-
ding sleeve to obtain a distance of 4.5+0.1. Then lock cam screw E in position.
Upper casing (Fig. 13)
Fit the minimum and maximum accelerator control lever travel stop screws into the upper casing.
Mount bushing G with the relevant O-ring using nut H; install the accelerator internal and external control levers.
Position spring-holder cap I and springs L; secure lever M and inserted coupling N into casing. Install travel stop rod O.

60
 Engine 1
Fuel system 16

Positioning governor lever M

Operate travel stop rod O with an Allen wrench until the distance be-
tween the lower casing edge and the travel stop rod head corner is
about 2 mm, as shown in figure 13.
Connect the upper to the lower casing, first positioning the auto -
matic extra fuel supply unit spring P on coupling N.

Calibrating engine governor

Engine governor calibration is very easy and requires no special
equipment. The procedure recommended permits all lever plays
produced during engine running to be removed, since this adjust -
ment can be performed with engine governor assembled and en -
gine running.
This setting is to be effected when external operations which may
involve engine governor, injection pump or injection pump control
rack replacement are performed.
Important - Whenever the governor is removed from engine, the
cable connected to the battery positive pole should be discon-
nected so that a sudden engine start may be prevented.
Observe the following procedure:
— start the engine and then bring to a 2000æ100 r.p.m. by means
of the hand throttle (avoid subjecting the engine to dragging lo-
ads and ensure it is not hunting).
— Using an Allen wrench (fig. 16) loosen the fuel maximum deli-
very adjusting screw (turn it anticlockwise) until the engine is
about to stop (or keeps on running through the automatic ope-
ration of the extra fuel supply unit stabilizing at 300 to 500
r.p.m.).
Warning: locating this condition requires most accuracy and me -
ticulous operating procedure and namely:
— locate approximately the point where the engine r.p.m. starts droo-
ping;
— screw in the adjusting screw of about 3 turns to permit the engi-
ne to be stabilized at 2000 r.p.m.;
— loosen first the adjusting screw two full turns and then continue loo-
sening by about 30° movements at a time and wait 2 - 3 seconds af-
ter each screw movement until the engine stop point is located.
With the engine stopped, place the contact point of a dial gauge on the
head of screw A (fig. 16), zero the gauge, then screw in the screw the Fig. 14 - Engine-mounted governor unit. (For en-
number of turns indicated in the table, to obtain the gauge reading indi - gine 4-cylinders with governor mechanical type).
cated below:

ENGINE R.P.M. HP TURNS OF THE

NO OF TIGHTENING
TYPE ADJUSTING SCREW

1000.3 A7 2350 55 6,75

1000.3 A5 2350 60 7
1000.3 AT2 2350 62,5 4
1000.4 A5 2350 70 5
1000.4 A3 2350 75 6,75
1000.4 AT3 2350 85 7,1

NOTE: This adjustment can be performed at an engine oil

temperture not less than 80°C. Fig. 15 - Tractor-installed engine governor unit.

Tighten the lock nut.

61
 1 Engine
16 Fuel system

FITTING AND ADJUSTMENT OF THE EXTERNAL CONTROLS OF THE MECHANICAL

GOVERNOR

Accelerator pedal (fig. 16).

Attach the throttle cable A to bracket C and then to lever D, then fit spring P. Adjust the position of screw G to obtain a pe-
dal travel of 75 mm as shown in figure 16 (corresponding to an angle of approximately 32°) and secure in position with
locknut Q.

Hand throttle
Attach the throttle cable B to bracket E by tightening screw N and positioning the locknuts O and then attach the cable to le-
ver V.

Connection of the accelerator pedal and hand throttle cables to the governor.
Attach the throttle cable to bracket H of the governor by way of screw L, and secure with locknuts I;
Connect the throttle cable to bracket M of the governor.
Adjust the freeplay of the throttle cable by turning the screw L (after having undone the locknuts I) so that the cable is
correctly tensioned, then re-tighten the locknuts.
Attach the throttle cable S of the hand throttle to bracket T and then attach it to lever U.
Then apply a force f = 5 to lever F and screw in self-locking nut R until the force applied is no longer capable of moving
±0,5

the lever. Move the hand throttle lever to the “MAX” position and manually push lever F to the end of its travel, then
screw in screw N until the throttle cable is fully tensioned, then tighten locknuts O.

Fig. 16 - Adjustment of the external controls of the mechanical governor.

62
 Engine 1
Fuel system 16

Fig. 17 - Component for control accelerator pedal and manual.

63
 1 Engine
16 Fuel system

Engine governor control assembly

Installing pinion (Fig. 18)

First insert bearing A in pinion B placing a pack of shims C (ref. codes
2.1589.146.0, 2.1589.147.0, 2.1589.153.0) between both until as-
sembly clearance has been fully removed.
Position the preinstalled assembly in support D so that pinion
head rests on tool E as shown in figure 18.

Fit a comparator resting its feeler on pinion end and then set it to
zero.
Remove the tool previously fitted and push the pinion until bearing
A stops against ring F, then take comparator reading.
This reading corresponds to the thickness shims H to be placed in
the position indicated in figure 19.

Tighten the ring nut fully and hit in three different points to prevent
it from becoming loose.

Fig. 18 - Installing pinion and crown whee.

Installing crown gear (Fig. 18 and Fig. 19)

Install cage I with rollers and place as shown in figure.

Insert ring M and crown gear N in the support then tighten ring nut
O to allow for a tooth radial backlash of 0.03 ÷ 0.08 mm; then
tighten screw P ensuring the ring nut remains in position.

Warning: screw P is to be mounted after applying a little amount

of Loctite 270.

Fig. 19 - Install cage with rollers.

Installing the control assembly into the cylinder

block (Fig. 20)
Fit some shims A (ref. code 065.2560.0 - figure 22), so as a 0.06 ÷
0.018 mm backlash between the governor drive gear teeth is ob -
tained.

In any case one shim at least needs to be fitted.

Fig. 20 - Installing the control assembly into the

cylinder block.

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Adjusting anti-hunting device (fig. 21)

This adjustment is to be made only in the event of engine hunting
at engine maximum idling speed.

Loosen bush A until being sure that spring B is not protruding in-
side the governor casing.
Start the engine and run to peak speed.
Screw in the bush so as to bring the spring close to the hunting
system until hunting dampening is felt.

Warning: the engine idling speed variation obtained through the Fig. 21 - Engine anti-hunting system.
anti-hunting device should never exceed 20 r.p.m.

Sealing engine governor

The governor is fitted with sealing points, indicated in figure 23,
with the letters A - B - C - D - E - F.

Before starting any operations during the warranty period consult

the local After-Sales Service.

Installing the governor (fig. 22).

Fit the governor by engaging the control fork A in the pawl B of the pump control shaft and securing it in position with the
relative screws.
Then manually check through the injection pump control rod access window that the control rod moves freely and that
the STOP control operates correctly.

Fig. 22 - Installing the mechanical governor

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ELECTRONIC ENGINE GOVERNOR

General information
The electronic engine speed governor consisting of a REG2MK microprocessor permits an accurate and stable engine
r.p.m. control to be obtained. The system includes an ELECTRIC ACTUATOR, a MAGNETIC PICK-UP acting as a spe-
ed recorder, a PUSH-BUTTON PANEL with LED indication (hand throttle) and a POTENTIOMETER located on the ac-
celerator pedal.

Specifications
power supply 8 to 15 Vdc
card electrical input 35 mA + actuator current
maximum actuator current output 6A
PICK-UP input 0,5 ÷ 4,5 V / 0,5 ÷ 1 mA
operating temperature range -40 to +120 °C
control isochronous or with statism
speed range 600 to 2700 r.p.m.
overspeed set at 3200 r.p.m.
reliability 70 °C

The engine governor receives the speed signal in form of electric signal from a pick-up facing the engine flywheel ring
gear and controls the actuator installed on engine by an electronic control unit.
The control unit is fully digital type and contains the mode of operation defined for each engine model in form of perma-
nent storage programs (EPROM).
Communications towards the control unit may be entered by an EXTERNAL PROGRAMMER equipped with specific
functions enabling certain parameters to be diagnosed and set.

A - Electronic throttle hand control

B - Accelerator pedal with potentiometer
C - Injection control unit
D - Engine speed sensor
E - Electronic actuator

Fig. 23 - Configuration of the electronic engine control system

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OPERATION (1st version): OPERATION (2nd version):

Engine r.p.m. governor consists of the following parts: The engine rpm control comprises the following parts:
— electronic control card on microprocessor; — electronic control unit with microprocessor;
— magnetic pick-up on engine flywheel; — magnetic pickup;
— potentiometer on accelerator pedal; — potentiometer on accelerator pedal;
— hand throttle push-button control panel and self-diagnosis LEDs; — hand throttle with pushbutton controls and diagnostic LEDs;
— magnetic actuator controlling the engine injection pump rack rod. — magnetic actuator that operates the injection pump control rod.

The engine r.p.m. is selected by the operator through the accelerator pedal: The operator controls the engine speed by depressing the accelerator pedal;
the potentiometer connected to pedal supplies the card 1 - 4 V voltage corre- the potentiometer connected to the pedal sends a signal to the ECU in the
sponding to a r.p.m. varying from minimum to maximum r.p.m. available range of 1 to 4 volts, which correspond respectively to the minimum and maxi-
mum engine speeds.
The magnetic pick-up located against the flywheel ring gear teeth generates a
voltage whose frequency is proportional to the engine r.p.m. The magnetic pickup, located adjacent to the teeth of the flywheel ring gear,
generates a signal at a frequency proportional to the engine rpm.
The electronic control unit compares the engine r.p.m. from the pick-up with
the potentiometer reference thus setting up a current in the actuator so that the The ECU compares the information received from the engine pickup and the
desired engine r.p.m. may be established. accelerator position potentiometer and accordingly supplies a current to the
The adjustment constants are preset in governor storage and for this reason actuator in order to bring the engine to the required speed. The regulation con-
cannot be altered. stants are preset in the ECU memory and cannot be altered.
The push-button panel permits further adjusting functions to be selected.

Three push buttons are provided in the push-button panel: Controlling the engine speed
— UP There are three controls by which the operator may adjust the engine speed:
— HOLD/RESET — Accelerator pedal
— DOWN — Hand throttle lever
— Memory buttons
Fig. 24 - Electronic accelerator manual control.
In addition, close to HOLD/RESET push button it is located a special LED
providing signalling and self-diagnosing functions.
Accelerator pedal
This control is permanently activated; the position of the pedal corresponds to the engine speed.
If a memorised speed setting is active or if the hand throttle is in any position other than the minimum position, the accelerator
pedal will have no effect until it is depressed beyond the position corresponding to the speed determined by the other control de-
vices; once this position is exceeded, control priority is returned to the accelerator pedal.
Hand throttle
Moving the hand throttle lever controls engine speed in the same way as depressing the accelerator pedal.
Memory button
Pressing this button simultaneously commands:
— "Isochronous" operation (constant engine speed maintained regardless of varying load conditions).
— Recall of the previously set engine speed from memory

On engine start-up, the "Hold" light is off, and engine speed is determined by the position of the accelerator pedal or hand
throttle lever.
If the button is pressed within 3 seconds of start-up:
— the previously set engine speed is recalled;
— the "Hold" light is illuminated;
— “isochronous" operation is activated.

If the memory button is held pressed for more than three seconds (regardless of whether the "Hold" light is on or off), the follo-
wing condition is obtained:
— the current engine speed is stored in memory;
— the "Hold" light comes on (if off);
— the "Hold" light flashes for 1 second;
— isochronous operation is activated;
— the engine speed (now stored in memory) is maintained.

If the "Hold" light is on and the memory button is pressed within 3 seconds, the following condition is obtained:
Fig. 25 - Tester (SAT 5.9030.730.6) for checking the governor. — control of the engine speed is returned to the accelerator pedal/hand throttle;
— the "Hold" light is extinguished;
— governor droop operation.

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Installing and checking the pick-up isochronous operation: depressing push button HOLD/RESET makes the LED light up and the governor keep the r.p.m.
rigorously constant.
Pick-up engine 1st version operation with statism: if the HOLD/RESET push button is pressed again the LED is switched off and the governor oper-
ates with a r.p.m. droop of about 7% from idling to full-load speed. This engine running mode is useful when driving tractor on
The pick-up should be installed in the following manner: public roads.
Adjustment of a new pick-up fixed-speed hand control: this helps reproduce the hand throttle control.
Screw the pick-up in the 1.5 pitch threaded hole M16 placed on the bell until contacting the ring gear then tighten the locknut.
Adjustment of an operating pick-up functions:
If the pick-up has already been operated, after screwing against the ring gear loosen by 1/2 turn and then lock so as 0.65 ¸
— isochronous operating mode;
0.75 mm gap may be obtained. — speed statism operating mode;
— 600 ¸ 2700 RPM speed adjustment;
— hand throttle digital control;
— dling speed under variable statism of 600 to 1500 r.p.m.;
— speed under variable isochronous operating mode from previous idling
speed to 2500 r.p.m.;
— limitation of the peak horsepower varying with the speed;
— self-diagnosis of protection intervention and faults

protections:
— pick-up signal loss protection;
— actuator terminal short-circuit protection;
— overspeed protection;
— battery polarity reversal protection;
— power supply loss protection;
— microprocessor fault protection.
Fig. 26 - Protection against electronic governor
actual access.

Pick-up engine 2nd version

Installing components
The installation of the various components should be carried out with
battery disconnected.

— the positive of the key subsequently supplying power

to the card is directed towards battery +.
— the card power supply in-series fuse is 7.5 A.

Note: the metal box housing the card is connected to battery

negative through a card-internal connection.

The pick-up should be installed in the following manner:

Position the pickup in its seating and secure with retaining screw.
The distance between the pickup and the pulse wheel must be 0.5 mm; check using feeler gauge 5.9030.270.0.

Fig. 27 - Views of the electronic governor actuator.

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Installing and checking actuator

When installing the actuator take note of the following:
— the actuator lever should move the pump rod freely and without friction;
— a free rod must return in stop position;
— the actuator rod must be matched to the pump rod fork with a slight play.
WARNING:
The actuator is provided with cover A (Fig. 29) to protect the access to the injection pump control rod stroke adjusting
device.

Calibration on a specific test bench:

power supply 2A ± 0,001
rod stroke 11,5 mm

Fig. 28 - Positioning the injection pumps actuator and control rod clevis.

Calibrating the governor actuator

Calibrating the actuator is a most delicate operation.
This should be performed in case of external interventions including actuator replacement.
Operate as follows:
— Turn on the engine and run to 2000÷100 r.p.m. using the hand throttle. The engine should never be subjected to
dragging loads, make sure the red LED on hand throttle control lever is illuminated.
— Remove plug A (Fig. 29) to gain access to the actuator spring for spring load setting and loosen screw B (Fig. 29) un-
til first the engine r.p.m. droops and then the engine stops.
WARNING: locating this condition requires most accuracy and meticulous operating procedure and namely:
— locate approximately the point where the engine r.p.m. starts drooping;
— with engine stationary lock the screw B (Fig. 29) of a number of turns as shown in table below.

ADJUSTING SCREW B
TRACTOR TYPE ENGINE R.P.M. HP TIGTHENING TURN NO.
DORADO 55 56 2,15
DORADO 60 2100 60 3,25
DORADO 65 2100 62,5 3,15
DORADO 70 2100 70 3,75
DORADO 75 2100 75 3,75
DORADO 85 2100 85 3,20

WARNING: when refitting plug A, take care not to alter the position of adjuster screw B.

Fig. 29 - Actuator calibration

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FITTING AND CHECKING THE ACCELERATOR PEDAL (Fig. 31) 1 version. st

Fig. 30 - accelerator pedal potentiometer (1 version).

st

Fit lever A, and fit potentiometer B on support C securing it in position with plate D and pin S.
Connect the electrical circuit as indicated in the figure and hook up to a 5V battery.

Engine idling speed adjustment

Turn screw V2 to obtain a voltage VU =1000 ± 30 mV, then tighten nut E2.

Maximum speed adjustment

Move lever A up against screw V1 and turn this screw to obtain a voltage of VU = 4000 ± 30; then tighten nut E1

Pedal travel adjustment

Attach the sheath of the cable F to bracket G with screw H and position locknuts I. Then connect the other end of the sheath to bracket
T. Then apply spring L. Adjust screw M to obtain a pedal travel of 75 mm as shown in figure 33 (corresponding to an approximate an-
gle of 33°) and tighten locknut N.
Feed cable P through sheath F and connect it to lever R via the clevis Q. Fully depress the accelerator pedal O (maximum throttle po-
sition). Then turn adjuster screw H to move lever A up against the stop screw and tighten locknuts I.
Loosen nut E1, unscrew screw V1 by two turns and then re-tighten nut E1

Putting into operation the electronic governor

Switch on dashboard with the ignition key.
If the LED on the accelerator control card blinks, decode the fault (refer to SELF-DIAGNOSIS section). Depressing push button
HOLD the LED should illuminate, depressing HOLD button a second time the LED should go out.

If the LED does not light up operate as follows:

Make sure the card is properly supplied (12 V, no. 20 fuse in fusebox).
Check for card operation measuring actuator voltage. This voltage should be 0.1 - 0.6V direct voltage. Otherwise, either the card is
not operating or the actuator is disconnected or defective.
After these checks are concluded and being sure all is in good order, start the engine, remove the upper actuator cap and insert a 5
mm Allen wrench on the injection pump control rod drive pin so that the injection pump control rod may be moved to stop position,
when irregular engine running is noticed after starting the engine.
Keep on checking ensuring the pick-up voltage be at least a 10V alternate voltage and the direct current measured on the actuator
with engine running unloaded at low idling speed be 1.5 - 1.7A.

If the engine does not start operate as follows:

Ensure pick-up voltage during starting attempt be at least 3V, otherwise check for pick-up correct installation.
Make sure the battery voltage during starting stage never drops below 5.5V.
Ascertain the actuator current during starting stage is at least 2.5A and the actuator moves the injection pump rod.

Check hand control functions through the push-button panel and the hand throttle LED.
Ensure the pedal potentiometer voltage is 1 - 4V.

Note: The hand throttle control push-button panel LED, besides signalling the HOLD condition also helps in diagnosing malfunctions

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Fig. 31 - Accelerator pedal adjustment diagram (1 version)

st

1 - Hole for use on tractors with platforms 2 - Hole for use on tractors with cab

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FITTING AND CHECKING THE ACCELERATOR PEDAL (Fig. 32) 2 version. nd

Fit lever A, and fit potentiometer B on support C, securing it in position with the screws D.

Connect the electrical circuit as indicated in the figure and connect a 5V battery.

Idle speed adjustment

Turn screw V2 to obtain a voltage U1 10 = 0.5V, then tighten locknut E2.

Maximum speed adjustment

Bring lever A up against screw V1 and turn the screw to obtain a voltage U 90 = 4.5 V, then tighten locknut E1.

Pedal travel adjustment

Attach the outer sheath of the cable F to bracket G with bolt H and fit the locknuts I. Then attach the opposite end of the
outer sheath to bracket T. Fit spring L. Adjust the position of screw M to obtain the pedal travel indicated in Fig. 32 (cor -
responding to an angle of approx. 33*) and tighten locknut N. Feed the cable P through sheath F and attach it to lever R
via clevis Q. Fully depress the accelerator pedal O (maximum throttle position), then turn adjuster screw H to bring lever
A up against the stop screw and tighten locknuts I. Back off the locknut E1, unscrew the screw V1 by two full turns, and
then re-tighten the locknut E1.

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Fig. 32 - Accelerator pedal adjustment diagram (2 version).

nd

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Fig. 33 - Pick-up.

DIAGNOSING MALFUNCTIONS
(Only for engine unit 1st version)
Operating as follows the self-diagnosing system is in a position to diagnose any failures and warn the operator through
the led located on the hand throttle control push-button panel.

FAILURE NO. OF LED BLINKS LIKELY CAUSE

pick-up 4 pick-up failure, pick-up disconnected

actuator 2 actuator short-circuited, actuator disconnected

potentiometer pedal
accelerator 3 potentiometer failure, potentiometer disconnected

overspeed 1 attuatore locked, injection pump locked

storage 5 parameter storage not programmed or defective

WARNING:
Should any failure be found take the number of LED blinks from the control push-button;
This LED blink number will permit the repairing technician to readily perform replacement through the correct spare part
needed.

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Setting the maximum speed to 30 km/h

When so required by local regulations, the maximum speed can be limited to 30 km/h by means of the engine control
unit and a vehicle speed sensor mounted on the gearbox.

Maximum speed is set as follows:

Connect the "ALL ROUND TESTER" and calibrate the engine speed following the normal procedure.
Access menu "1" Engine (enter the password "A5555" if required).
- Press 6 "Wheels" and 1 "Configuration"
The value is factory set for tractors with tyre types 13.6 R 36; if the tractor is fitted with different tyres, select the line cor -
responding to the new tyre to enable the correct parameter.
Consult the table below and enter the appropriate wheel constant value.

55 - 60 - 65 - 70 - 75 - 85 CV
Pneus Parameter
480/65 R 28
14.9 R 32
14.9 R 28
420/70 R 28 1100
14.9 R 30
420/70 R 30 1058
16.9 R 28
480/70 R 28
540/65 R 28 1050
12.4 R 36 1020
540/65 R 30
16.9 R 30
480/70 R 30 1050
13.6 R 28
380/70 R 28 1153
420/70 R 24
14.9 R 24 1192
13.6 R 36 984

Press C to confirm the selection, and then press E twice to exit the programme.

Checking the calibration.

With the tractor stationary, check that the engine speed reaches the maximum rpm;
Then, with the tractor moving, engage top gear and accelerate to maximum speed; in this condition the engine speed
should be between 1700 and 1900 rpm.

NB: the control unit’s diagnostic procedure includes the alarm “speed sensor faulty or not connected”.
This alarm is signalled with six flashes of the LED on the hand throttle.

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Fuel injection pumps

The single-cylinder fuel injection pumps are equipped with a constant-pressure backflow valve (short G.D.V. valve).

The plunger load is evenly distributed over the whole camshaft, since an equal-distance distribution is provided.

The G.D.V. valve keeps pressure inside the injection pipes to a high level during the intermediate pump delivery phases.

This ensures engine smooth running even at low operating speed, higher engine performance as well as more favoura -
ble torque curves, besides suppressing any nozzle dribbles resulting in unburnt gas, poor injection nozzle efficiency and
engine detonation.

Fig. 1 - Injection pump control assembly.

Injection pump control system

The injection pumps are simultaneously controlled by a blank sheet
steel bar which besides ensuring the required stiffness has particu-
lar lightweight properties to prevent excessive friction and inertia
under operating conditions.

This bar controls the injection pumps operating through specially

arranged slots and is connected to the engine governor by a rat-
chet.

The injection pump control bar is guided by a couple of

block-mounted supports provided with slide rings.
Fig. 2 - Mounting positions of the injection pump
control bar guide supports.

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Installing injection pump control bar guide sup-

ports (Fig. 2)
Install supports A with related O-rings, rollers and lockpins using
screws B into the engine block. Insert the injection pump control
bar C into the supports and tighten screws B and ensure that the
bar is free to slide inside the support. (The two supports equipped
with sliding rollers should be placed at both bar ends).

Warning - When the injection pumps are removed operate the en -

gine shutoff control (STOP) so as to bring the rack rod dog back to
the injection pump centre line. This permits it to be passed through
the special aperture in the engine block.
Fig. 3 - No. 5.9030.616.4 engine timing equip-
Check is made visually through the sight windows in the en - ment.
gine block.

Engine timing

Valve timing

This should be carried out before injection pump calibration. Fig. 4 - Equipment mounting position for 1st cylin-
der timing.
Raise the first cylinder piston to upper position; remove the rocker
arm support, remove intake valve spring and drop valve onto pi-
ston head then insert a snap ring into the valve stem.

Fasten no. 5.9030.616.4 equipment on piston head as shown in fi-

gure 4 (the comparator indicating 25 mm stroke reading should be
placed on the engine valve).

After raising piston to T.D.C. position set to zero the comparator fi -

xed to the valve stem. When the concerned cam rest race has
been located also reset the comparator applied to the intake valve
tappet head.

Turn the crankshaft clockwise until a 17.27 mm piston stroke has

been completed. Then rotate the camshaft until a 3.93 ± 0.1 mm Fig. 5 - Injection pump
intake cam lift is obtained.

Fit the timing gear and bring the timing gear marked tooth into con -
tact with both idler gear marked teeth. Press on the gear anticloc -
kwise when tightening the securing screws until any backlash bet-
ween teeth is taken up.

Take the equipment and proceed with the injection pump setting
operations.

Fig. 6 - Timing gear reference marks for engine ti-

ming

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Injection pump calibration (fig. 10)

(BOSCH injection pump equipped with a lock pin
for the control rod)
After valve timing has been successfully concluded undertake this
calibration by using no. 5.9030.617.4/10 equipment in addition to
the equipment already positioned on the first cylinder and excep-
ting the comparator on the valve tappet rod.

To each shim pack add a pack of shims equal to the value stam -
ped on the pumps. (example: +2 must be added a thickness of
0,2mm).
Fig. 7 - No. 5.9030.617.4 /10 injection pump ti-
ming equipment.
Injection pump calibration is to determine a 80.4 mm dimension
between the pumps-to-block fixing surface and the corresponding
cam races, considering the position they find when the injection is
being started; (Fig.10).

Rotate the crankshaft to move the 1st cylinder piston into T.D.C.
position (compression stroke end, valves closed) and set to zero
the comparator attached to the valve stem; the same procedure
as described in valve timing section shall apply.

Rotate the shaft in a counter-clockwise direction until a reading of:

- 2.92 mm is shown on the dial gauge; this value corresponds to a
Fig. 8 - Resetting no. 5.9030.617.4 /10 compara-
tor-equipped tool. timing advance of 16°
For Dorado 55 - 60 - 65 - 70 - 75.
- 1,94mm is shown on the dial gauge; this value corresponds to a
timing advance of 13° For Dorado 85.
Correct positioning takes place when through anticlockwise rota-
tion either the 2.92 mm -or 1,94 mm - set point is exceeded, soon
after coming back to such a dimension through clockwise
crankshaft rotation so that any clearances may be taken up.

Fit the special no. 5.9030.617.4/10 comparator. To reset the com -

parator rest the comparator measuring roll onto a flat surface.

Insert the tool into the first injection pump seat and take measure-
ment reading from the comparator dial to align the bearing face
with the engine block. This reading corresponds to shim pack X.

To each pack of shims X add a number of shims Y being equal to

the dimension stamped on injection pump flange, so as to obtain a
total shim packing (X + Y) to be put between injection pump and
engine block, this permitting a 80.4 mm standard dimension to be
determined.
Fig. 9 - Mounting position of the no.
5.9030.617.4/10 equipment fitted with compara-
tor. Repeat this operation for each injection pump, fitting tool
5.9030.616.4 to the corresponding cylinder.

Warning - Install the injection pump after applying some Silastik

738 silicone between shims, engine block and injection pump.

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Fig. 10 - Installing the injection pumps.

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Positioning the pumps (fig. 10).

Before positioning the pumps, lock the control rod using tool
5.9030.728.0, which is to be positioned with the governor remo-
ved and as shown in figure 10.
Then position each injection pump (interposing a shim pack of the
predetermined thickness), so that the dog engages the fork in the
control rod.

Rotate the pump clockwise until you feel the dog fully engage the
fork, then tighten the retaining screw.

NB: The pump must be positioned with the injection cams in b.d.c.
Fig. 11 - Injection pump plunger identification position.
marks. Remove tool (B Fig. 10), release the pump by removing the lock
pin A (Fig. 10 - tool SAT 5.9030.728.0); fit the governor and the
rear plug (flywheel end).
Check that the rod moves freely and that the STOP control opera -
tes correctly.

Servicing
All the pumps are interchangeable as all the plungers are of the
same type.
N.B: new plungers can be identified from the markings in the posi-
tions shown in figure 11.

Fig. 12 - Injection pump G.D.V. valve. Removal and refitting of an injection pump without replacing
components.
This operation does not require the use of any special tools. Refit
the pump using a shim pack of the original thickness.
Hold the pump control rack in position using lock pin A (fig. 10) to.
To do this, operate the STOP control lever so that the pin engages
the relative notch on the pump control rod rack.
Install the pump (also equipped with a rack lock pin) in the cylinder
block, making sure that the dog engages in the fork of the control
rod; then rotate the pump in a clockwise direction whilst simultane-
ously pushing the control rod through the engine inspection flange
towards the front of the engine.

Removal and refitting of a pump after replacing one or more

components
Before installation the pump must be re-calibrated on a test
bench. Remove any previous timing marks and stamp a new
notch and dimension (Y) on the pump.
Refit the pump using a shim pack (see fig. 17) according to the
new dimension stamped on the pump (always make a note of the
old value stamped on the pump before erasure, in order to facilita-
te calculation of the new shim pack thickness) and follow the in-
structions given in the previous point.

Replacing a pump
The thickness of the shim pack (X +Y) must be corrected by first
removing shims to the thickness indicated on the previous pump
Fig. 13 - Injection pump section and then adding shims to the value indicated on the new pump.

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Replacement of camshaft or cylinder block

In the event of camshaft or cylinder block replacement, the valve and injection pump timing procedures must be repea-
ted, but the injection pumps will not require re-calibration.
Install the new pump in the cylinder block with the control rack locked in position, making sure that the dog engages the
control rod and following the instructions on page 80 (pump positioning).
Replacing the injection pumps control rod
Proceed to refit the new rod following the directions on page 80 (pumps), and complete all operations relative to the po -
sitioning of the injection pumps.

Calibration of injection pumps

TIPO BOSCH PFR 1 K 90 A 517
TIPO BOSCH PFR 1 K 90 A 542
TIPO BOSCH PFR 1 K 90 A 543
TIPO BOSCH PFR 1 K 90 A 555

Injection pump calibration is of crucial importance to the correct

engine running. Injection pump calibration procedure should be
carried out by specialized workshops provided with the following
BOSCH equipment:
— Injection 2.4719.200.0/10
— 2.4719.320.0/10
— Injection pipe Ø6x1.5x267
— Test oil ISO 4113 a temp.40°C
— Fuel supply fuel 0,4 ± 0,05 bar Fig. 14 - Injection pump calibration test bench.
— Camshaft N. 1 686 101 021
(7 mm cam lift) Characteristics of the injection pump
— Outlet with metering orifice Ø 1mm
Nominal prelift for delivery start at X 3 X+3= 2,4 ÷ 2,5
Calibration specifications Spill valve
bar 70
radjustments 60-70HP 65HP 60-70HP 65HP
Depth of delay notch
test r.p.m. from from delivery delivery mm 0,5
Conditions X* in mm X* in mm mm/lift mm /lift
3

Start of delay notch intervention

1° test 300 3,5 -3,5 12,5 ÷ 13,5 12,5 ÷ 13,5 mm X+7
2° test 750 3 3 839 ÷ 89 99 ÷ 105
3° test 1300 3 3 72 ÷ 78 84 ÷ 90
4°test 100 9 9 78 ÷93 76 ÷95

Radjustments 55 -75 - 85 HP
test r.p.m. from delivery
Conditions X* in mm mm/lift
3

1° test 300 -1,9 12,5 ÷ 13,5

2° test 750 0 53.5 ÷ 59,5

3° test 1300 0 50.5 ÷ 55,5

4° test 100 9 91 ÷109

*X Reference position for the pawl of the injection pump determined using
the BOSCH special tool.

Fig. 15 - Injection pump plungers A - no delivery; the fuel flows through the longitudinal slot. B - partial delivery; correct adjustment
opens flow at mid-stroke position. C - full delivery; the plunger stroke corresponds to maximum delivery.

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Synchronisation of injection pumps using the method of balancing the exhaust gas temperatures

1 - Bring the engine up to operating temperature.

2 - Remove the screws in the lower part of the exhaust manifold.
3 - Run the engine at idling speed (700 rpm).

4 - Insert the probe of the digital thermometer 5.9030.667.4 in the hole of the exhaust manifold corresponding to the first
cylinder and allow the temperature reading to stabilise. Repeat this operation for the other cylinders, noting the tempe-
rature readings obtained for each.

5 - The difference in temperature between one cylinder and another must not exceed 20°C. If the difference exceeds
this value, it will be necessary to adjust the injection pumps.

6 - To adjust the injection pumps, proceed as follows:

Slightly loosen the 3 retaining nuts of the injection pump so that you can rotate the pump by tapping its sides with a
punch while the engine is running (rotate the pump in a clockwise direction to increase the exhaust gas temperature
and counter-clockwise to decrease it).
NB: after adjusting one of the pumps, you will need to re-check the exhaust gas temperature of the cylinders served by
the other pumps.
7 - Tighten the injection pump retaining nuts to a torque of 1kgm (10Nm) and replace t

Synchronisation of injection pumps using the method of balancing the exhaust gas temperatures.
A - Digital thermometer -30 ÷ 250 °C
B - Screws 10x6x15 in their holes in the exhaust manifold.

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 Engine 1
Fuel system 16

Fuel prefilter
Strip the fuel prefilter by releasing holding spring A.
Clean cup B and cartridge C with a compressed air jet and ensure
each single component is fully sound, if not replace.
Should any water be found in the glass cup bottom, loosen secu-
ring dowel D and wait until fuel comes out without air bubbles.

Fuel filter
To replace the filter cartridge, remove the cartridge retaining
screw in the upper body, remove the old cartridge and replace with
a new cartridge of the original type.
Check the seal between the new cartridge and the cover. Position
the cartridge and replace the retaining screw.

Fig. 16 - Fuel prefilters.

Draining water from fuel filter A - holding spring
B - cup
To drain off any water from the filter, loosen the screw in the bot - C - cartridge
tom of the filter housing and drain off all fuel mixed with water. D - dowel
When clean fuel appears, re-tighten the screw.

Fig. 17 - Fuel filters. Fig. 18 - Fuel supply pump.

83
 1 Engine
16 Fuel system

Checking the fuel supply pump efficiency (A.C. pump)

This check can be performed by measuring the pump delivery (see on page 23).

If necessary, carry out inner filter cleaning or replcae any items being part of the assembly under overhaul. Full pump
assembly replacement is recommended only if pump casing cracks are noticed.

Bleeding the air from the fuel supply system

The system air-bleeding operation should be made whenever pipe lines are disconnected or there is air in the fuel
supply system.

Operate as follows:
Be sure the fuel tank is filled, then loosen the bleeding valve located in the fuel filter upper side, press on the fuel pump
hand control lever until the fuel flows out without air bubbles. Tighten the retaining screw.

NOTE: While operating the pump control lever, ascertain that a certain resistance is felt. Otherwise set starter going so
as to locate the pump priming position (camshaft control cam at B.D.C.).

Loosen injector pipes only if necessary, set starter going until fuel free of air bubbles flows out of the loosened pipe fit-
tings. Thereafter tighten fittings to the specified torque.

Fig. 19 - Fuel supply pump control.

84
 Engine 1
Cooling system 17

Fig.1 - Shimming engine pulley. Fig. 2 - Fan assembly.

Fan assembly
No specific servicing is required for fan assembly. Occasionally
check bearings for proper sliding, replace if necessary.

Fitting the fan bearings protection seal (Fig.3)

Position the seal A as shown in the figure; check that the seal is re-
cessed 1.5 mm relative to the face of the hub.

Aligning fan pulley to engine pulley (Fig. 1 and Fig. 2) Fig. 3 - Fan bearings protection seal.

Both pulleys should be thoroughly aligned. Fit a straight rod on the

bigger pulley face and ensure it is aligned to that of the other pulley.
If not, remove or add shims to the crankshaft pulley in the position
indicated by the arrow B (see figure 5).
Any extra shims are to be positioned under the heads of the pulley
retaining bolts.

UMETTARE CON
LOCTITE 242
Aligning alternator pulley to engine pulley (Fig. 5)
Fit the alternator and measure the amount of misalignment using
a straightedge across the face of the crankshaft pulley. Fit shims
of this value between the pulley and the support in position A and
C.

Aligning compressor air conditioning pulley to en -

gine pulley
Fit the compressor air conditioning on the he suport and measure
the amount of misalignment using a straightedge across the face
of the crankshaft pulley.
Fit shims of this value between the pulley and the support until the
obtain the aligning.
Fig. 4 - Fan assembly cutaway view.

85
 1 Engine
17 Cooling system

Fig. 5 - Installing the alternator pulley tightener and aligning engine, fan, alternator pulleys.

86
 Engine 1
Cooling system 17

ADJUSTING OF DRIVE BELT TENSION

Adjusting the belt tension turning screws the regolation, operate as follows:

Turn the adjusting screws until to obtain the belt settling A - B, exerting finger pressure to the middle of the longest sec-
tion; the belt should deflect approximately 20 mm and 15 mm for belts with reference C - D.

NOTE - check with the hand on the middling point of the length tug of the belt.

Front view of engine 3 - Crankshaft pulley

(tractors equipped with heating and air conditioning) 4 - Belt tensioners
1 - Engine fan unit 5 - Air conditioning system compressor
2 - Engine alternator 6 - Heating system alternator

87
 1 Engine
18 Intake and exhaust system

Turbocharging DORADO 65 - 85
The turbocharger assembly covers the function of forcing more air
into the cylinders. This also allows the diesel fuel delivery capacity
to be proportionally increased.

Mixture increase is necessary to obtain greater engine power.

The turbocharger assembly is an extremely simple and rational

design and consists of a turbine and a compressor.

The turbine is operated by the exhaust gases from the engine (in
this way, a part of the gases’ kinetic energy which otherwise would
be wasted is recovered). The turbine drives the compressor,
Fig.1 - Turbocharger. which compresses the air sucked in the cylinder intake duct thro-
ugh the filter.

Tests
A precise test on turbocharger efficiency can only be performed
on a test bed.

Tests performed with turbocharger mounted on engine can only

give approximate results.

Before starting checking operations make sure the engine fuel

supply system is operating correctly.

Fig. 2 - Turbocharger and exhaust manifolds

88
 Engine 1
Intake and exhaust system 18

Checking pressure in the duct at turbocharger exit

(Fig. 3)
Remove the intake pipe plug and fit no. 5.9030.515.0 pressure ga-
uge.

Start the engine and ensure that both peak horsepower speed and
maximum torque speed pressures correspond to the specifica -
tions indicated in related table (pag. 24).

Out of specifications readings may be due to poor air filter effi -

ciency which should therefore be checked.

Also check couplings for distorsion or tearing; replace as neces-

sary. Fig. 3 - Checking pressure inside the intake pipe.

All carbon deposits should be removed using a plastic brush.

Checking exhaust pipes

Be sure the exhaust pipes enable the exhaust gases to be pro-
perly expelled; otherwise remove any carbon deposits.

If after performing the above checks the turbocharger is not opera-

ting smoothly a thorough overhaul shall be carried out.

Removal (Fig. 4 and Fig. 5)

Disconnect the lubricating pipes from cylinder block.

Loosen the pipe-to-turbocharger securing screws and remove to- Fig. 4 - Manifolds-to-turbocharger connecting co-
gether with gaskets. uplings.

Ease-off clamps A and remove coupling B connecting turbochar-

ger to intake manifold, (Fig, 4)

Loosen the two coupling fixing clamps placed between air filter
and turbocharger and remove coupling.

Warning: conveniently plug the turbocharger ducts to prevent any

foreign matters from entering.

Unloose the 4 screws securing the turbocharger A manifolds to

exhaust manifold B as well as the nuts fastening the muffler sup-
port C both to turbocharger and exhaust pipe, then remove the tur-
bocharger, (Fig, 5).

Fig. 5 - Turbocharger separation.

89
 1 Engine
18 Intake and exhaust system

Checking rotor shaft radial play - turbine side (Fig. 6)

Place a dial gauge through the related magnetic base in such a
way that feeler rests on the turbocharger rotor shaft as illustrated
in figure 6.

Set dial gauge to zero and press the hub first downward and then
upward taking the readings shown by the dial hand.

The difference in readings shall result in the rotor shaft radial play
and this shall not exceed 0,46 mm.

Fig. 6 - Checking rotor shaft radial play.

Checking rotor shaft end play (Fig. 7)

Fit the dial gauge through the related magnetic base in such a way
that feeler rests on the turbocharger rotor shaft end as illustrated
in figure 7.

Set dial gauge to zero and move the shaft first to the right and then
to the left taking readings shown by the dial hand.
The difference in both readings shall be the rotor shaft end play
and this shall not exceed 0,16 mm.

If the amount of axial or radial play exceeds the prescribed value,

remove the turbocharger and take it to a specialised service cen -
tre for a general overhaul.

Fig. 7 - Checking rotor shaft end play.

90
 Engine 1
Intake and exhaust system 18

Fig. 8 - Turbocharger assembly components.

Installing turbocharger on engine (Fig. 9)

Secure the turbocharger assembly to its mounting. First fit coupling A to turbocharger assembly and next muffler sup-
port B to the exhaust manifold fixing with the securing screws.
Tighten first support B securing nuts and then the coupling securing nuts A.
Connect the lubricating pipes.
Warning: Never race a cold engine.
Run the engine just above low idling speed for a minute or two so as to allow the oil to warm up progressively (the turbo -
charger si lubricated by the engine oil) thus ensuring the rotor to be thoroughly lubricated.
After some hours’ heavy work, let it run idling for a few minutes before stopping. This is to prevent the rotor from continu-
ing to rotate through inertia without receiving a sufficient lubrication. Since the turbocharger under normal working rate
rotates at very high speeds (55.000 ÷ 110.000 r.p.m.), even a few seconds’ oil lack may lead to irreparable damage.

Fig. 9 - Turbocharger assembly on engine.

91
 1 Engine
18 Intake and exhaust system

Engine air filter

If a blocked air filter indicator switch is to be replaced, make sure the new switch to be installed has same setting specifi-
cations checking the reference stamped on it.
Aspirated engine blocked air filter indicator switch setting is 0.94-0.93 bar.

Fig. 10 - Engine air filter.

Tightening torques

Before tightening all screws should be degreased, cleaned and lubricated with engine oil.

Kgm Nm
engine flywheel securing screws 11 108
rocker arm support securing screws 4 39
injection nozzle bracket fixing nuts 4 39
inejction pipe fixing nuts 2,5 ÷ 3 24 ÷ 29
securing bolts for pressed steel rocker cover 0,5 5
counterweight housing securing screws (4-cylinder engines) 8 78
front pulley securing screws 34 ÷ 36 315 ÷ 350
oil pump securing screws 4 39
oil pan securing screws 3 30
rear oil seal cover retaining bolts 2,5 24,5
front casing retaining bolts 2,5 24,5
main bearing cap bolts see page 36
big-end bearing cap bolts see page 38
tightening the cylinder head bolts see page 53
engine flange retaining bolts 12 120

92
 Engine 1
Intake and exhaust system 18

Engine air filter

Warning
It is important that the warning light, which shall be lit when the air
filter is clogged, is always working efficiently. This check can be
carried out by starting the engine and briefly blocking the air intake
pipe by means of a plug (never touch it with your hands).

The filter cartridge should be thoroughly clean, if not, it shall be

cleaned or washed.

Fig. 11 - Washing the filter cartridge.

Cleaning with compressed air

This method is used when the filter cartridge is clogged with dust.

Direct a compressed air jet at a maximum pressure of 7 bar from

the inside outwards of the filter cartridge, afterwards blow the air
over the whole surface by moving the air jet along the foldings in
the paper until all dust has been removed.

Fig. 12 - Cleaning the filter cartridge with com-

pressed air.
Washing with water
This method is particularly recommended when the filter cartridge
is obstructed by oily substances and consists of washing the filter
cartridge in clean water.

Rinse the cartridge with a jet of water directed from the inside out-
wards at a maximum pressure of 3 bar.

Let the cartridge dry 24 hours at room temperature in a dust-free

environment.

Fig. 13 - Using a water jet to remove any residual

left on the filter cartridge.

Reassembling the cartridge

Clean the inside of the filter body with a dry cloth and make sure
that the cartridge has not become deformed in any way.
Also check that the paper of the filtering cartridge is not torn by in-
troducing a light source into the cartridge interior and visually in-
specting its outside surface to see if any light shows through. If no
light source is available, carefully examine the external surface of
the cartridge folded paper.
Should any holes or tears be found, regardless of their size, the fil -
ter cartridge should be replaced at once.

The inner safety cartridge should never be cleaned but only repla-
ced every six times the main cartridge is cleaned.
Fig. 14 - Using a light source to check the filter
cartridge folded paper conditions.

93
 1 Engine
Assembly

Instructions for engine assembly

— Be sure all plugs have been removed, then carefully clean the cylinder block and the lubricating passages with clea-
ning solvent and afterwards perform drying using compressed air.
— All sealing rings and gaskets should be replaced on assembly.
— The use of proper tools is of prime importance to the correct performance of all mechanical operations.
— Prior to reassembly use some engine oil to lubricate the faces of all components subject to relative motion.
— The use of special grease is needed for some components so as they can be correctly held in position and assembly
operations facilitated.
— Pay particular attention to the direction of assembly of some items by directly referring to the exploded views illustra-
ted.

— WARNING: Before refitting the engine you must lubricate the following parts:
— cylinders (internal surface);
— pistons;
— crankshaft (main journals and crankpins);
— connecting rods (small end bearing for gudgeon pin);
— valves (stems);
— rocker arms (bushes);
— oil pump and governor drive shaft;
— cam shaft (journals and cams);
— oil pump control rod and bevel gear drive.

Fig. 1 - Clean the block, refit all plugs and attach it to the engi- Fig. 2 - Components of the engine oil vapour breather unit;
ne stand 5 9030.491.4. Apply PIANERMETIC DENSO 510
sealant around the plugs on the rear of the engine. Fit the pi-
ston cooling nozzles as indicated on page 22.

Fig. 3 - Fit the breather unit pipe providing oil return to engine Fig. 4 - Install the oil vapour decantation unit in the engine
into the cylinder block; block using the two securing screws;

94
 Engine 1
Assembly

Fig. 5 - Install the piston rings on piston and then connect pi- Fig. 6 - Fitting the piston-connecting rod assembly into the
ston to connecting rod; cylinder;

Fig. 7 - Fit the O-rings on the cylinder; Fig. 8 - Installing the cylinder-piston-connecting rod as-
sembly in the engine block;

Fig. 9 - Orient the piston combustion chamber towards the in- Fig. 10 - Checking for correct cylinder and assembled piston
jection pump side, secure the piston-connecting rod as- positioning at T.D.C. Measure the piston protrusion from
sembly by means of no. 5.9030.631.4/10 equipment, then cylinder and select the suited gasket type to be fitted between
turn the engine upside down; cylinder and cylinder head as shown on page 31.

95
 1 Engine
Assembly

Fig. 11 - Fit the tappet plates into their seats in the block after Fig. 12 - Place the upper crankshaft main bearing shells in
lubricating with engine oil; their seats in the engine block. These main bearing shells are
distinguished from the lower shells as they are provided with
a lubricating hole;

Fig. 13 - Install the crankshaft in the engine block. We recom- Fig. 14 - Fit the two crankshaft half shoulder rings into the rear
mend using a hoist for accomplishing this operation; block support;

Fig. 15 - Oil the crankshaft main journals and big end jour- Fig. 16 - Fit the main bearing shells into the crankshaft main
nals; bearings. (All main bearing shells are provided with a ratchet.
This ratchet should be completely engaged in its seat);

96
 Engine 1
Assembly

Fig. 17 - Oil the crankshaft main bearing shells; Fig. 18 - Fit the big end cap bearing shells in the related seats
and then install the big end caps;

Fig. 19 - Install the intermediate crankshaft main bearing ta- Fig. 20 - Install the main bearing shells in the front and rear
king care the numbers stamped on the bearing correspond to crankshaft bearings. Shoulder half rings shall be secured in
those stamped on the crankcase. (Numbers should all be the rear bearing after applying some grease;
oriented in the same direction);

Fig. 21 - Install the gaskets in the front and rear main bea- Fig. 22 - The main and big end bearings securing screw thre-
rings; then fit bearings easing them into the engine block ads should be covered with LOCTITE 242. Thereafter tighten
using sheet metal slides and tapping gently; the securing screws using tool no. 5.9030.640.0; following
the instructions on pages 36 - 38.

97
 1 Engine
Assembly

Fig. 23 - Protruding gaskets should be cut flush with the engi- Fig. 24 - Using a suitable tool cut the rubber gaskets protru -
ne block at the front and rear side; ding from block oil sump face according to specifications gi -
ven on page 37. Smear some sealant on the rubber gaskets
in the block;

Fig. 25 - Use a screwdriver to fit the screw plug in the position Fig. 26 - Install the socket head screw plugs in the positions
shown in figure; shown in figure;

Fig. 27 - Turn the crankshaft and make sure it can rotate fre- Fig. 28 - Fit the oil pump and after securing to engine block
ely and no interference between pistons and spray nozzles check gears for free sliding. Install the oil pipe rose;
occur, then measure the crankshaft end play;

98
 Engine 1
Assembly

Fig. 29 - Install the camshaft in crankcase. Mount the forked Fig. 30 - Fit the crankshaft rear flange gasket;
flange permitting the camshaft to be positioned. Make sure
the camshaft is free to rotate with a slight amount of end float.
Warning - If the timing gear has been removed or replaced a
new valve timing should be performed;

Fig. 31 - Using a guard ring install the flange. Warning - The Fig. 32 - Place the engine oil pan gaskets;
ring inserted into flange should never be greased. Cover the
securing screws with a sealing compound. Interpose the cop-
per washers and tighten to the specified torque as indicated
on page 98;

Fig. 33 - Install the engine oil pan; Fig. 34 - Place the injection pump control rod guide supports
in the block and lock with the related securing screws;

99
 1 Engine
Assembly

Fig. 35 - Insert the injection pump control rod in the its seat in Fig. 36 - ONLY FOR TRAKTORS WITH MECHANICAL
the cylinder block along with pressure spring and stop cap. GOVERNOR ONLY - Assemble the square transmission
Make sure it is free to move inside the guide supports; controlling both engine governor and oil pump. As to as -
sembly and adjustment procedures see instructions on page
60;

Fig. 37 - FOR TRAKTORS WITH ELECTRONIC Fig. 38 - FOR TRAKTORS WITH MECHANICAL
GOVERNOR ONLY - After inserting a sealing ring on the GOVERNOR ONLY - Install the square transmission in its
stem fit the engine actuator support in the block; seat in the block placing the special backlash adjusting shims
between the gear teeth (see instructions on page 64);

Fig. 39 - ONLY FOR TRAKTORS WITH MECHANICAL Fig. 40 - Only if necessary, determine the shim pack amounts
GOVERNOR ONLY - Fix the square transmission to the to be fit between injections pumps and engine block (see in -
block tightening the related securing screws; structions on page 78);

100
 Engine 1
Assembly

Fig. 41 - If the timing gear has been removed from the shaft Fig. 42 - After smearing the shim faces with some sealing ad-
carry out valve timing for timing the engine as indicated on hesive place the shim packs between pumps and block. Sub-
page 77; sequently perform injection pump installation;

Fig. 43 - After the timing gear has been secured to shaft, fit Fig. 44 - Fit some locating pins or studs to centre the timing
the idler gear taking care the chiselings on teeth be in the case correctly during assembly;
same line. If one of these three gears must be replaced, valve
timing procedure shall be repeated;

Fig. 45 - Place the isogene gasket between engine block and Fig. 46 - The timing case should be installed paying attention
timing case; not to damage the sealing ring lip fitted inside;

101
 1 Engine
Assembly

Fig. 47 - Remove excess gasket from the face used to fix ex- Fig. 48 - Insert all timing case securing screws but do not tig -
ternal applications; hten fully;

Fig. 49 - Fit no. 5.9030.634.0 tool as shown in figure to obtain Fig. 50 - Using a suitable plug fit the pulley hub to the
thorough concentricity between sealing ring and crankshaft crankshaft;
as well as a full coplanarity of the external application fixing
faces, then fully tighten the timing case securing screws. Re-
move the tool;

Fig. 51 - Fit gaskets between cylinder heads and cylinders Fig. 52 - After preassembling the heads install on engine;
(see instructions on page 31);

102
 Engine 1
Assembly

Fig. 53 - Insert the tappet rods, fit the rocker arms and the roc- Fig. 54 - Install the injection nozzles in their seats;
ker arm supports;

Fig. 55 - Using a special tool fit the rod cover pipes and the po- Fig. 56 - Using a plug thoroughly insert the injection nozzles
sitioning springs; in their seats orienting the fuel rejection hole towards the fi-
xing bracket. Install the injection nozzle fixing brackets tighte-
ning the securing screws to the torque specified in the table
on page 92;

Fig. 57 - Adjust valve and rocker arm clearance; Fig. 58 - Oil valve caps and valve springs;

103
 1 Engine
Assembly

Fig. 59 - Fit gaskets between heads and caps. Orientation Fig. 60 - Install pump-to-injector pipes as well as the fuel re -
shall be provided according to “TOP” indication on them; covery pipes from injection pumps and injectors;

Fig. 61 - Install gaskets between heads and intake manifold; Fig. 62 - Install the intake manifold;

Fig. 63 - Install the head caps; Fig. 64 - Fit the exhaust manifold gaskets. Install the exhaust
manifold;

104
 Engine 1
Assembly

Fig. 65 - On turbocharged engines: install the turbocharger Fig. 66 - On turbocharged engines: connect the turbocharger
assembly following the instructions given on page 91; oil delivery and return pipes;

Fig. 67 - On turbocharged engines: place the rubber hose Fig. 68 - For traktors with mechanical governor only - install
connecting the turbocharger to the intake manifold and secu- the engine governor taking care the control frok engages in
re with two clamps; the pump control rod ratchet correctly; make sure it is pro-
perly fit in its seat and then tighten with both securing screws;

Fig. 69 - For tractors equipped with electronic governors Fig. 70 - Fitbthe oil fuel filter and engine oil filters; then fit the
only: fit the actuator assembly; fuel filters and the fuel prefilter. Connect the fuel lines

105
 1 Engine
Assembly

Fig. 71 - Fit the head vapour breather pipe and the rear de- Fig. 72 - On engines equipped with electronic governor, fit
flector; pulse wheel B to the crankshaft pulley A. before fitting the pul -
se wheel, apply Loctite 648 to the contact surfaces of the two
parts.

Fig. 73 - Fit the crankshaft pulley to the crankshaft. Fit the re- Fig. 74 - Fan assembly;
taining bolt with the relative thrust washer, lightly lubricating
the thread with engine oil. Tighten the bolt first to a torque of
60 to 70 Nm (6 to 7 kgm) and then to a final torque of 340 Nm
(34 kgm).

Fig. 75 - Install the thermostarter; Fig. 76 - Install the fuel pump and the fuel filters and when re -
quired the fuel prefilter. Fit the fuel system lines;

106
 Engine 1
Assembly

Fig. 77 - Install the engine oil radiator; Fig. 78 - Fit the injection pump cover; where required, fit the
auxiliary power take-off, interposing shims to obtain the spe-
cified gear backlash (see instruction of p. 29). Fit the engine
flywheel; on engines with electronic governor, fit the speed
sensor pickup in its location of the governor housing and se-
cure with the specific screw.

Reassembling the engine on tractor

To perform engine reassembly on tractor two operators are required.
— Install the clutch assembly onto the engine flywheel.

— Secure two eye-bolts to engine and hook it to a hoist, then lift from swivel bench.

— Position the engine so as it may be centred on the studs inserted in gearbox front part.

Warning: when carrying out these operations take great care to prevent any shock between engine and gearbox.

After truing engine onto gearbox studs, use a suitable spanner to rotate the crankshaft until the gearbox shafts are cen -
tred in both the clutch plate and the engine flywheel flange broachings.
— Tighten all securing screws and nuts to the specified torques.

— Place a suitable stand under the engine (insert a squared wooden piece between both parts and always keep the ho-
ist tension wires taut).

— Bring the front tractor section close to engine and adjust both assembly positions so as to make connection easier.

Between engine oil pan and front support insert a suitable pack of shims so as both parts may contact fully.

Centre the front support onto the engine studs (should it be hard to do so the use of a lever is recommended).

Fill the engine oil pan with oil keeping to the amount, type and specifications as described on page 9.

107
 1 Engine
Diagnosing malfunctions

clean battery con-

check battery charged battery battery terminals tacts and tighten
charge oxidized terminals

engine won’t run when discharged battery recharge battery

started
consult a motor ve-
hicle electrician for
starter failure having the defec-
tive parts replaced

top up fuel level in

tank

check fuel level

inspect fuel filter for clean filter, replace
cleanliness if necessary

a metal noise is out-of-adjustment recalibrate the

heard when engine pumps, excessive pumps
idles advance

engine difficult to start perform air bleed-

or won’t restart after a inefficient injection air in the fuel sys - ing
system tem
stop
defective fuel pump replace defective
or pump control parts
out-of-calibration
injection nozzles calibrate

Check clean or replace

thermostarter

restore correct grind or replace

backlash valves, cylinder
check clearance head gaskets and
Insufficient between valves piston rings
compression and rockers
check valves for ef- replace pistons and
ficient operating cylinders
conditions

check injection perform a new set- check piston rings replace worn-out
pump setting ting and cylinders for parts
wear
make sure there is
clear exhaust smoke no excessive clear- replace worn-out
ance between parts
valves and valve
guides

check injectors for clean scrupulously

proper cleanliness

108
 Engine 1
Diagnosing malfunctions

clean or replace
check air filter car-
tridge for blocking restore calibration
check injectors for according to speci -
proper efficiency fications
dark exhaust smoke

out-of-calibration adjust governor

engine governor and provide a new
calibration

check air filter car- check for proper clean or replace fil- bleed the system
tridge for clogging fuel filter cleanli- ters
ness

make sure no air is bleed the air in sys-

within the fuel sys- tem
poor engine response tem
after a sudden accele-
ration restore correct grind or replace
clearance valves, cylinder
insufficient com- check clearance head gaskets and
pression in the cyl- between valves piston rings
inders and rockers
check valve effi - replace pistons and
ciency cylinders

empty the tank and bleed air from sys-

fill with decanted tem
diesel fuel
make sure neither
engine won’t keep air nor water are in
constant r.p.m. the injection sys- check injectors for
tem correct calibration

check belt tension operate the related

belt tightener

check cooling sys- clean carefully

tem efficiency

retime as neces-
sary
engine overheating inspect pumps for check injectors for restore specified
proper timing correct calibration calibration

measure pressure clean the

in the duct at com- turbocharger
pressor exit

109
 2 Clutch and transmission
23 Clutch

Earshift clutch

General specifications

The clutch, a single stage type, comprises a friction disc, a pressure plate and a diaphragm spring.
The hydrostatic control is self-adjusting: a master cylinder operated by the pedal directs oil to the slave cylinder moun-
ted to the left hand side of the intermediate housing, which in turn operates the clutch release lever.

Technical specifications DORADO 55-60-65 DORADO 70-75-85 DORADO

55-60-65-70-75-85
(USA) 6 blades
Type of clutch single disc dry single disc dry single disc dry
organic facing organic facing cerametallik facing
Type of operation hydrostatic with automatic take-up of free travel
Disc p/n 009.6913.3 009.6924.3/20 009.9770.3
Disc diameter mm 279,4 310 310
Minimum permissible thickness of disc mm 6 6 9,7
+0, 3 +0, 3
Thickness of friction disc mm 8,5 -0, 3 8,5 -0, 3 10 +-00..22
Type of facing material on friction disc TEXTAR T385 TEXTAR T385 UA 330 DX
Type of master cylinder Benditalia 3/4"
Type of oil AKROS MATIC

Spring specifications to Belleville washer for the

clutch engagement
Load on the pressure plate Nm 11000

CAUTION:For DORADO 60-70 In the event the transmission be-

ing split to gain access to the clutch assembly, the pickup (A, fig. 1)
must be removed to avoid its being damaged by the teeth of the
engine flywheel.

IMPORTANT: If there are signs of scoring on the surface of the

flywheel, the surface must be machined smooth following the di-
rections of page 45.

Fig. 1 - Engine rpm pickup. (1 version) DORADO

st

60-70)

IIMPORTANT: In the event of the friction disc being removed, care must be taken during refitment to position
the components correctly, as indicated, since the disc is not symmetrical.

110
 Clutch and transmission 2
Clutch 23

Fig. 2 - Clutch unit for DORADO 55 - 60 - 65 Fig. 3 - Clutch unit for DORADO 70 - 75 - 85

111
 2 Clutch and transmission
23 Clutch

Clutch unit for DORADO 55 - 60 - 65 - 65 - 70 - 75 - 85 (USA) 6 blades

112
 Clutch and transmission 2
Clutch 23

Fig. 4 - Components of clutch assembly

113
 2 Clutch and transmission
23 Clutch

Fig. 5 - Checking clutch disk thickness. Fig. 9 - Installing clutch assembly through n. 5.9030.256.4/10 equipment.

Cecking clutch
Check the disk lining for signs of chipping and the disk friction face
for scoring which may prevent the clutch from operating properly.
Check that the sliding surface of the engine flywheel is not scored;
if signs of scoring are evident, machine the surface as indicated on
page 45.
Check the disk thrust plate for scoring or bluish areas caused by
tempering and also ensure the diaphragm-type spring has not lost
its efficiency; if so the whole clutch assembly shall be replaced.
Be sure the clutch disk is free to move in its housing and the friction
lining securing rivets are duly riveted.
Fig. 6 - Clutch assembly hydraulic operating cyl-
inder. Should any wear be found on the thrust bearing or the diap-
hragm-type spring, an exhaustive check over the spring operating
conditions installed in the disk thrust lever operating cylinder (see
Fig. 6) shall be performed; replace if necessary.
On reassembly ascertain dimension A (see Fig. 6) between the
operating cylinder fixing face and the push rod contacting the en -
gagement lever is 195 mm.
NOTE: To facilitate correct clutch disk assembly the use of no.
5.9030.256.4/10 centering tool is recommended.
Warning: With engine running, never ride the clutch pedal with
your foot to prevent the clutch disk from being damaged because
of overheating.
Important: The thrust bearing is prelubricated, and must never on
any account be cleaned with fuel oil or other solvents as these will
render the prelubrication treatment ineffective.
Fig. 7 - Checking operating cylinder inside spring
efficiency.
Adjusting clutch control pedal
Make sure the distance between pump fixing surface and fork hole
centre is 106 1 (Fig. 15) otherwise loosen nut A and operate adju-
sting stay rod B (Fig. 15).

Bleeding air from the hydraulic circuit

Operate the clutch pedal several times, then keeping the clutch
pedal in fully depressed position, slightly unscrew and soon after
tighten the air bleeding screw valve again (this being located on
thrust lever operating cylinder).
This operation should be repeated as many times as the oil flows
out of the bleeding screw valve without air bubbles.
Fig. 8 - Bleeding the air from the clutch hydraulic
circuit.

114
 Clutch and transmission 2
Clutch 23

A Bleed screw D Spring G Push rod

B Hydraulic pipe fitting E Seal ring H Rubber boot
C Slave cylinder body F Piston

Fig. 10 - Clutch operating cylinder

Stripping the slave cylinder (Fig. 10)

Remove the boot H. Withdraw the piston F carefully from the cylinder
C, blasting with compressed air at low pressure to assist removal.
Remove the spring D from the cylinder and loosen the bleed screw
A.
Remove the seals E fom the piston F.
CAUTION: When cleaning the components of the cylinder, use
only specifically formulated brake and clutch fluids (see page
110). Do not use petrol, paraffin or other mineral oils as these will
damage parts in rubber.

Inspections
— Check both internal and external piston surfaces for scratching.
Replace if required.
— Make sure the seal ring grooves are duly clean; blow the groo-
ves with compressed air if necessary.
— Inspect seal ring, dust boot conditions as well as spring effi-
ciency, worn-out parts should be replaced.
— Ensure the air bleeding hole is free from impurities. A - Control lever
B - Dust boot
Notes on refitment C - Pushrod
— When reconnecting the transmission housing, check that the clutch D - Union
fork remains correctly positioned and free to rock on its fulcrum pivot. E - Piston
F - Seal ring
This can be ensured by removing the side plug from the flange of the
G - Cylinder casing
intermediate housing and viewing the fork through the hole. In the
H - Spring
event of the fork pivot being unseated, reposition correctly with the
aid of a screwdriver inserted through the hole vacated by the plug.
— Before refitting the slave cylinder, fill with the recommended oil Fig. 11 - Clutch operating cylinder cutaway view.
so as to facilitate the subsequent bleeding procedure.
— Once all components are correctly and securely in place, bleed
the hydraulic circuit.

115
 2 Clutch and transmission
23 Clutch

A Hydraulic pump F - Spring M - Spacer ring R - Snap ring

B - Delivery pipe union G - Spring holder N - Piston S - Guard boot
C - Delivery pipe H - Screw O - Seal ring T - Nut
D - Clamp I - Shoulder ring P - Rod U - Yoke
E - Union L - Seal ring Q - Support disk

Fig. 12 - Clutch hydraulic pump parts.

Stripping the master cylinder

Referring to figure 14, remove the protective boot E, dislodge the circlip B and withdraw the rod D together with the
disc C.
Remove the piston together with the spacer, the seal, the backup washer and the spring beneath.

Fig. 13 - Clutch pump control positioning. Fig. 14 - Pump control seal ring.
A - Locknut A - Pump D - Rod
B - Yoke B - Snap ring E - Guard boot
C - Support disk

116
 Clutch and transmission 2
Clutch 23

Inspections and checks

WARNING: To clean and wash the hydraulic pump components use only the oil type recommended for brakes and
clutch (see page 110). Never use petrol, kerosene or other mineral oils to prevent damaging the rubber parts.
Inspect both internal and external piston sliding surfaces for scratching. Replace if required.
Make sure the seal ring grooves are duly clean; blow the grooves with compressed air if necessary.
Inspect seal ring, dust boot conditions as well as spring efficiency, worn-out parts should be replaced.
Inspect all pump internal compartments, apertures and passages and make sure these are properly clean and free from
foreign matters.
Check that the spring is neither lazy nor deformed; replace if necessary.

Reassembly
Reassemble the cylinder, repeating the disassembly steps in reverse order and observing the following directions:
— Lubricate surfaces engaged in relative sliding contact, using the recommended oil (see page 110).
— Verify correct operation of the cylinder, making certain that the piston is able to complete its full stroke unimpeded.
In the event that the fork linking the master cylinder with the pedal has been removed, check that with the push rod fully
extended, the distance between the reference surface of the cylinder and the centre of the hole in the fork is as indicated
in figure 15.
If not (referring to fig 13), remove the boot, loosen the lock nut A and screw or unscrew the fork B to obtain the prescri-
bed clearance, then retighten the lock nut and reposition the boot.

Fig. 15 - Section view of clutch master cylinder

Clutch greasing points. Fitting the P.T.O. shaft oil seal

Apply Molikote Gn-plus at all the points indicated in the figure Before fitting the oil seal 2.1529.517.0 apply Loctite 222 to
with letter A. the outer face A indicated in the figure.
Fit part B with Loctite 270.
Fit pin C with Loctite 601.

117
 2 Clutch and transmission
Diagnosing malfunctions

lubricant in clutch renew the front ge- clean oil seal con- replace disk
housing arbox oil seal and tact surfaces with
the rear engine oil petrol
seal

clutch worn check condition of check condition of fit new clutch as -

clutch slips clutch disk the spring disk sembly

thrust bearing stic- clean surfaces and replace thrust bea- clean or replace the
king apply grease ring disk

clutch disk surfa- clean the friction

ces dirty surfaces

clutch disk surfa- replace clutch disk

ces dirty
clutch jerks clutch disk warped

clutch disk worn replace clutch disk

plate seals loose replace clutch disk

difficulty in enga - clutch disk warped replace disk

ging gears when
engine running

check the stroke of

clutch fails to disenga- hydraulic pump the clutch control
ge inefficient piston and replace
any worn parts

clutch disk stuck to clean contact sur-

flywheel faces with a wire
brush and petrol

worn parts in clutch replace parts

engagement me -
clutch noisy when di- chanism
sengaged

118
 Clutch and transmission 2
Agroshift 27

Agroshift unit
The Agroshift unit is composed of an epicyclic speed reducer and three oil-immersed multiple disc clutches
(LOW - MED - HIGH).
The unit is located between the clutch-coupled shaft and the gearbox.
The speed reducer is engaged and disengaged selectively by way of the three clutches, which are operated elec-
trohydraulically from a button mounted to the knob of the shift lever.

Selecting the control, the MED clutch releases as the force of the belleville discs is overcome by hydraulic pressu -
re; at the same time, the HIGH clutch engages, locking the planet carrier of the epicyclic train to the relative housing so
that drive is transmitted to the range input shaft with no speed reduction whatever.
Selecting the control, the MED clutch releases as the force of the belleville discs is overcome by hydraulic pressu -
re; at the same time, the LOW clutch engages, and the shaft carrying the sun wheel is locked to the structure of the tran-
smission housing. As a result, the planet carrier is made to rotate as one with the epicyclic housing and drive is transmit -
ted to the layshaft at a speed reduction of 0.687 (the ratio between the annulus and the sun wheel gear teeth).
Selecting the control, the Agroshift unit is isolated from hydraulic pressure altogether and the belleville discs are
able to engage the MED clutch, with the result that the shaft in mesh with the larger planet wheel is locked to the tran-
smission housing. This gives a reduction of 0.825, by reason of the compound ratio between the planet wheels and the
flange of the speed reducer in mesh with the range input shaft.

Technical specifications

Clutch
maker SAME DEUTZ - FAHR GROUP
number of friction discs 7 4 2
diameter of friction discs 129,5 129,5 129,5
overall thickness of assembled friction
discs complete the intermediate discs mm 25,2 ÷ 25,4 17,50 ÷ 17,60 11,70 ÷ 12,14
number of intermediate discs 3+1 2+1 2+1
disc lubrication pressure bar 5 5 5
maximum pressure bar 16 16 16
piston thrust Kg 1986 1986 1986
Nm 19463 19463 19463
Epicyclic speed reducer
- LOW 1 + (30/66) = 1,4545
- MEDIUM 1 + (21x18) : (66x27) = 1,2121
- HIGH 1

SLOW MEAN FAST

Fig. 1 - Range selection indicators mounted to the instrument panel. Fig. 2 - Plate indicating selection of electro-
hydraulic control.

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 2 Clutch and transmission
27 Agroshift

Fig. 3 - Diagram illustrating operation of the AGROSHIFT system.

Parts in movement Parts locked to transmission housing In rotation (idling)

Fig. 4 - Diagram showing engagement of AGROSHIFT with MED range selected.

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 Clutch and transmission 2
Agroshift 27

Parts locked to transmission housing

Parts in movement Oil circuit for operation of clutches In rotation (idling)

Fig. 5 - Diagram showing engagement of AGROSHIFT with LOW range selected.

Parts locked to transmission housing

Parts locked to epicyclic Oil circuit for operation of clutches In rotation (idling)

Fig. 6 - Diagram showing engagement of AGROSHIFT with HIGH range selected.

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 2 Clutch and transmission
27 Agroshift

AGROSHIFT UNIT DETACH FROM THE GEAR BOX

Fig. 7 - Detach the driving platform (or the cab, if fitted) from Fig. 8 - Detach the front part of the tractor complete with en -
the tractor. gine from the gearbox.

Fig. 9 - Detach the front gearbox from the rear gearbox. Fig. 10 - Remove the upper cover from the front gearbox.

Fig. 11 - Remove the internal clutch control from the front Fig. 12 - Remove the solenoid valve block from the front
gearbox. right-hand side.

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 Clutch and transmission 2
Agroshift 27

Fig. 13 - The Agroshift solenoid valve block is removed by Fig. 14 - Remove the hydraulic lubrication pipe of the
pulling it outwards after having disconnected the pipes and Agroshift unit by first disconnecting the part on the outside of
removed the retaining screws. the gearbox.

Fig. 15 - Disconnect the delivery line from the Agroshift unit Fig. 16 - Using a drift as shown in the figure, drive the
by unscrewing the union. Agroshift unit out of the front of the gearbox.

Fig. 17 - Remove the Agroshift unit from the front end of the Fig. 18 - After having removed the Agroshift unit, proceed
gearbox. with its disassembly, if necessary. Then remove the epicyclic
reduction unit.

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 2 Clutch and transmission
27 Agroshift

Fig. 19 - Remove the planet carrier flange from the epicyclic Fig. 20 - Remove the circlip and the thrust washer. On
reduction unit. re-assembly, the thrust washer must be fitted with the lubrica -
tion channels facing inwards towards the planet carrier flange

Fig. 21 - The play adjustment shim for the Agroshift shafts is lo - Fig. 22 - To dismantle the Agroshift unit, remove the circlip in -
cated between the housing and the epicyclic reduction unit. dicated in the figure.

Fig. 23 - Remove the circlip indicated in the figure using a pair Fig. 24 - Remove the thrust washer.
of bent nose pliers.

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 Clutch and transmission 2
Agroshift 27

Fig. 25 - Unscrew the screws securing the LOW clutch hous - Fig. 26 - Remove the retaining screws.
ing to the Agroshift unit.

Fig. 27 - It is advisable to mark the relative positions of the Fig. 28 - Using a screwdriver, separate the housing from the
parts prior to disassembly. unit.

Fig. 29 - Remove the LOW clutch disc pack (7+7). Fig. 30 - Inspect the clutch discs for wear.

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 2 Clutch and transmission
27 Agroshift

Fig. 31 - Remove the circlip securing the hub of the LOW Fig. 32 - Remove the hub of the LOW clutch.
clutch.

Fig. 33 - Remove the circlip located behind the hub of the Fig. 34 - Proceed with the disassembly of the housing of the
LOW clutch. MEDIUM-LOW" clutches.

Fig. 35 - Using a drift, separate the MEDIUM-LOW housing Fig. 36 - Detach the MEDIUM-LOW housing from the unit.
from the rest of the unit.

126
 Clutch and transmission 2
Agroshift 27

Fig. 37 - Remove the Belleville springs from the MEDIUM Fig. 38 - Remove the discs from the MEDIUM clutch.
clutch.

Fig. 39 - MEDIUM clutch discs (4 friction discs+3 Fig. 40 - The control piston of the LOW clutch may be re-
counterdiscs+2 thrust plates). moved from the “MEDIUM-LOW” bell-housing using a press
of the type illustrated below.

Fig. 41 - This piston can be removed by removing the circlip of Fig. 42 - Remove the LOW clutch shaft.
the piston return spring located on the opposite end of the
housing.

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 2 Clutch and transmission
27 Agroshft

Fig. 43 - Check that the oil ways in the shaft are not ob- Fig. 44 - The LOW clutch control piston can be removed from
structed. the housing using a press of the type illustrated below.

Fig. 45 - This piston can be removed by removing the circlip of Fig. 46 - Remove the circlip securing the HIGH clutch discs.
the piston return spring located on the opposite end of the
housing.

Fig. 47 - Remove the thrust washer of the HIGH clutch. Fig. 48 - Remove the HIGH clutch disc pack (2 friction discs +
2 counterdiscs + 1 thrust plate).

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 Clutch and transmission 2
Agroshift 27

Fig. 49 - HIGH clutch discs. Fig. 50 - HIGH clutch control piston.

Fig. 51 - Separate the HIGH clutch housing from the MEDIUM Fig. 52 - Remove the MEDIUM clutch hub and then the rela-
clutch housing using a press to compress the springs and re - tive housing.
move the circlip.

Fig. 53 - “ VESPEL” seals of the HIGH clutch housing. Fig. 54 - Remove the HIGH clutch housing.

129
 2 Clutch and transmission
27 Agroshift

Fig. 55 - Remove the Belleville return springs of the HIGH Fig. 56 - Examine the condition of the “VESPEL” seals on the
clutch control piston from the MEDIUM shaft. HIGH clutch housing.

Fig. 57 - If necessary, remove the circlip and remove the Fig. 58 - Remove the piston from the MEDIUM clutch hous -
bearing from the MEDIUM clutch housing. ing.

Fig. 59 - Examine the condition of the seal ring of the piston Fig. 60 - Proceed to dismantle the LOW clutch control piston
from the MEDIUM clutch housing. with the aid of a press.

130
 Clutch and transmission 2
Agroshift 27

Fig. 61 - Remove the circlip securing the springs. Fig. 62 - Remove the assembly from the press and remove
the Belleville springs.

Fig. 63 - Disassembly sequence for the 5 Belleville washers. Fig. 64 - Remove the piston.

Fig. 65 - Groove for O-ring in the LOW clutch housing. Fig. 66 - Examine the condition of seal ring of the piston from
the LOW clutch housing.

131
 2 Clutch and transmission
27 Agroshift

A - Cover I - Seeger T - LOW sun wheel

B - LOW clutch L - Clutch hub U - Planet carrier
C - LOW clutch control piston M - Thrust plate V - Thrust washer
D - Clutch housing N - Bearing Z - Ring gear
MEDIUM - LOW O - Thrust plate X - Planet gears
E - LOW clutch belleville springs P - MEDIUM clutch control piston J - LOW shaft
F - MEDIUM clutch belleville springs Q - HIGH clutch housing Y - MEDIUM shaft
G - Actuator disc R - HIGH clutch control piston W - Secondary shaft
H - MEDIUM clutch S - HIGH clutch K - Reduction unit shaft

Fig. 67 - Agroshift unit

132
 Clutch and transmission 2
Agroshift 27

Assembly of AGROSHIFT unit

Fig. 68 - Components of AGROSHIFT unit

The AGROSHIFT unit requires that the basic gearbox, with respect top the standard version, is equipped with a secon -
dary shaft A and a range input shaft B, of specific type.

Warning: no special tools are required to re-assemble this unit, just an M8x1.25x30 screw to hold the central shaft C in
position during AGROSHIFT play adjustment.

Assemble the unit as follows:

— Fit the input ring gear D to the secondary shaft, securing it with circlip E;
— Separately assemble LOW gear F with the planet carrier flange G . When fitting gear F, the planets must be positio -
ned so that their punch marks are aligned with the position reference marks on the carrier flange, (Fig. 69).

Timing reference countermark

Fig. 69 - Timing the epicyclic speed reducer of the AGROSHIFT unit.

133
 2 Clutch and transmission
27 Agroshift

Timing marks on gear teeth of the epicyclic reduction of the AGROSHIFT unit.

Fig. 70 - Pre-assembly of parts on MEDIUM shaft. Fig. Pre-assembly of MEDIUM-LOW clutches.

134
 Clutch and transmission 2
Agroshift 27

RE-ASSEMBLY OF THE AGROSHIFT UNIT.

Fig. 72 - Assemble the HIGH clutch. Fit the bearing with the Fig. 73 - Fit the LOW shaft, the relative roller bearings, and
relative snap rings in the MEDIUM clutch housing; fit the hub position the snap ring.
securing it with the relative circlip and fit the three service
circlips to the housing. Fit the O-ring seals to the piston , then
fit the piston.

Fig. 74 - Fit the MEDIUM clutch discs. Fig. 75 - Apply Loctite 510 sealing compound to the housing
contact surfaces as shown in the figure.
WARNING: when applying sealing compound take care not
to obstruct the oil ways.

Fig. 76 - Fit the circlip and check that the shaft has certain Fig. 77 - Fit the MEDIUM clutch thrust washer with outlets ori-
amount of play. ented towards the circlip.

135
 2 Clutch and transmission
27 Agroshift

Fig. 78 - Join the two housings together; the studs will locate Fig. 79 - Note that a small space will be left between the two
in the 3 holes to ensure the correct relative positions of the housings; this is to allow preloading of the Belleville springs
two housings. Rotate the shaft during this operation so as to when the screws are tightened.
centre the clutch discs.

Fig. 80 - Fit the LOW clutch, first positioning the circlip on the Fig. 81 - Then fit the clutch hub and position the second
shaft as indicated in the figure. circlip.

Fig. 82 - Then install the discs of the LOW clutch. Fig. 83 - The disc pack is completed with a final friction disc,
the tabs of which do not engage the splines on the hub, and
therefore, when refitting the cover, it is advisable not to rotate
the shaft so as to allow the disc tabs to mesh correctly with the
hub.

136
 Clutch and transmission 2
Agroshift 27

ADJUSTMENT OF END FLOAT IN THE AGROSHIFT UNIT (fig. 84)

Screw one M8x1,25x30 bolt finger tight into the cover W (fig 84), so as to hold the centre shaft of the H-M-L unit in posi-
tion during the adjustment.

Measure dimensions X and Y with a gauge then calculate (X - Y - 1 mm) , which gives the thickness of the thrust washer
K to fit.

Example: values measured X = 191,88 Y = 188,24

(191,88 - 188,24 - 1) = 2,64 ~ 2,6 mm (2.1599.727.0/10 washer required)

IMPORTANT: the thrust washer must be selected from those available to give either the exact thickness, or the next
thickness down from the value calculated.
washer p/n:
2.1599.725.0/10 thicknesst 2.2 mm
2.1599.726.0/10 thicknesst 2.4 mm
2.1599.727.0/10 thicknesst 2.6 mm
2.1599.728.0/10 thicknesst 2.8 mm
2.1599.729.0/10 thicknesst 3 mm
2.1599.730.0/10 thicknesst 3.2 mm
2.1599.731.0/10 thicknesst 3.4 mm
2.1599.732.0/10 thicknesst 3.6 mm
2.1599.733.0/10 thicknesst 3.8 mm
2.1599.734.0/10 thicknesst 4 mm

— Fit a shim of the predetermined thickness on the LOW shaft with the relative circlip
— Fit the epicyclic reduction unit in the gearbox and then fit the AGROSHIFT clutches unit, applying Silastic sealing
compound to the contact surfaces.

Fig. 84 - Location of the preassembled AGROSHIFT unit in its housing.

137
 2 Clutch and transmission
27 Agroshift

A - pressure regulator valve F - solenoid control valves

(operating pressure 16 bar) G - electro-hydraulic control unit
B - gearbox lubrication oil H - anticavitation valve for safety steering
pressure setting valve (setting 5 bar) I - bistable valve
C - anticavitation valve for safety L - safety steering valve
steering (30 l/min.) M1 - pressure gauge with scale 0 - 40 bar
D - oil pump (capacity 10 to 27 l/min.) M2 - pressure gauge with scale 0 - 40 bar
E - suction filter (25 micron) M3 - pressure gauge with scale 0 - 10 bar
T - lubrication

Fig. 85 - Hydraulic diagram illustrating operation.

138
 Clutch and transmission 1
Agroshift 27

Fig. 86 - Electrohydraulic control unit for AGROSHIFT system.

PROCEDURE FOR CHECKING THE H-M-L CONTROL UNIT INLET PRESSURE

Referring to Fig. 86:
1 - Connect pressure gauge 5.9030.514.0 (0 ÷ 40 bar) at position M1.
2 - Connect pressure gauge 5.9030.515.0 (0 ÷ 10 bar) at position M2.
Start the engine and throttle up to the revolutions indicated in the table; now verify that the inlet pressures are as prescribed.
NB: Pressure tests should be conducted using oil at a temperature of 80 °C.

A - Test fitting for testing pressure of LOW clutch hydraulic circuit

B - Bistable valve
C - Valve body
D - Non-return valve
E - Non-return valve
F - Oil pressure regulator valve
G - Lubrication pressure control valve
H - Delivery line to P.T.O.
I - Delivery line to differential lock
L - P.T.O. lubrication pipe
M - P.T.O. disk lubrification manifold
N - Manifold for P.T.O. clutch oil pipe
O - Secondary shaft and Agroshift lubrification pipe
P - Pipe from radiator oil to the gearbox
Q - Delivery line to front-wheel drive engagement piston
M1 - Pressure gauge with scale 0 - 40 bar
M2 - Pressure gauge for P.T.O. lubrication pipe
M3 - Pressure gauge with scale 0 - 40 bar for pressure at P.T.O.

139
 2 Clutch and transmission
27 Agroshift

A - Gearbox lubrication oil pressure

control valve (5 bar)
B - Non-return valve 30 l/min
C - Sequence valve
(operating pressure 16 bar)
D - Non-return valve
T - Return
L1- P.T.O. clutch line
L2- Secondary shaft and Agroshift
lubrication

Fig. 87 - AGROSHIFT pressure control valves assembly

140
 Clutch and transmission 2
Agroshift 27

Fig. 88 - Hydraulic control circuit.

141
 2 Clutch and transmission
Diagnosing malfunctions

replace the defecti-

ve parts
check the clutch
assembly hydraulic
system
examine piston and replace
manifold seal rings defective parts
clutch slips
remove any roug-
check piston for hness preventing
free stroke piston from sliding
freely

check the clutch replace the clutch

plates for wear disks

inspect the control replace defective

mechanism parts

replace the disks

inspect the disks burnt disks

clutch won’t remove any roug -
jammed disks hness preventing
disengage disks from sliding
freely

piston jammed in relpace the piston

seat

142
 Transmission 3
Gearbox 31

General specifications

The basic transmission utilizes 5 speed synchromesh gearbox with 2 or 3 speed ranges.

A shuttle, fitted as standard, makes the tractor easy to handle and manoeuvre.

Options include Creeper, and Underdrive (in place of or in addition), giving a total of:

For tractors equipped with driving position with footplates only

16 FWD + 8 REV: 4 gears x 2 ranges + mini-reduction + reverser shuttle
24 FWD + 12 REV: 4 gears x 3 ranges + mini-reduction + reverser shuttle

For tractors equipped with platform or cab

20 FWD + 10 REV: 5 gears x 2 ranges (L-V) + mini-reduction + reverser shuttle
30 FWD + 15 REV: 5 gears x 3 ranges (SR-L-V) + mini-reduction + reverser shuttle.
45 FWD + 45 REV: 5 gears x 3 ranges (SR-L-V) + reverser shuttle + AGROSHIFT

Each version is also available with 30 or 40 km/h top speed.

Technical specifications

number of speeds 16 AV + 8 RM 20 AV + 10 RM
gearbox ratios
1st gear 19/59 = 1/3,1053 19/59 = 1/3,1053
2nd gear 24/47 = 1/1,9583 23/50 = 1/2,1739
3rd gear 34/42 = 1/1,2353 29/44 = 1/1,5172
4th gear 41/32 = 1/0,7805 35/38 = 1/1,0857
5th gear - 41/32 = 1/0,7805
shuttle forward 29/37 = 1/0,7838
reverse 23/19 = 1/0,8261
range ratios low (19/50)x(22/46)= 1/5,5024
high 1
rear axle ratios bevel gear pair 30 km/h 8/39 = 1/4,8750
40 km/h 9/33 = 1/3,6667
epicyclic final drive (12/12+69) = 1/6,7500

overall ratio 30 km/h 1/30,3750 -

40 kmIh 1/25,3125 1/25,3125
backlash between crownwheel
and pinion teeth mm 30 km/h 0,17 - 0,23
mm 40 km/h 0,20 - 0,27
Mini-reduction 32/34 = 1/0,9412
Super-reduction (19/50)x(22/46)x(19/50)x(20/48) = 1/34,7520
axial play of the secondary shaft mm 0,09
axial play of the gears of the change,
of the reverser and mini-reduction mm 0,15 ÷ 0,30
reference distance for adjustment
of bevel gear pai rmm 2,5 ± 0,1

143
 3 Transmission
31 Gearbox

Speed change configurations

Speed range Gearshifting Reversing NO. OF SPEED

Control Control Control (forward + reverse)

16 + 8

24 + 12

20 + 10

30 + 15

45 + 45

DURING TRANSPORT OPERATIONS ON PUBLIC ROADS BOTH BRAKE PEDALS MUST BE

OBLIGATORILY COUPLED BY MEANS OF THE SPECIAL LOCKING LATCH. IN ANY CASE,
ALWAYS OBSERVE LAWS AND REGULATIONS IN FORCE.

144
 Transmission 3
Gearbox 31

* see technical characteristics of gearbox on p. 143 * see technical characteristics of gearbox on p. 143
** see technical characteristics of 4wd front axle on p. 217 ** see technical characteristics of 4wd front axle on p. 217

Fig. 1 - Ratios of 4-speed x 2 range transmission with mini-reduction (16 FWD + 8 REV). Ratios of 4-speed x 2 range transmission with mini-reduction and super-reduction (12 FWD + 12 REV).

145
 3 Transmission
31 Gearbox

* see technical characteristics of gearbox on p. 143 * see technical characteristics of gearbox on p. 143
** see technical characteristics of 4wd front axle on p. 217 ** see technical characteristics of 4wd front axle on p. 217

Fig. 2 - Ratios of 5-speed x 2 range transmission with mini-reduction (20 FWD + 10 REV). Ratios of 5-speed x 2 range transmission with mini-reduction and super-reduction (30 FWD + 15 REV).

146
 Transmission 3
Gearbox 31

* see technical characteristics of gearbox on p. 143

** see technical characteristics of 4wd front axle on p. 217

Fig. 3 - Ratios of transmission with 3 ranges (Super-reduction) + AGROSHIFT (45 FWD + 45 REV).

147
 3 Transmission
31 Gearbox

Assemble the front and rear gearboxes and the rear hydraulic lift,
after having applied PIANERMETIC 510 to surfaces A
and LOCTITE 636 to bushes B.

Fig. 4 - Front and rear gearbox.

148
 Transmission 3
Gearbox 31

Fig. 5 - Longitudinal section through transmission.

149
 3 Transmission
31 Gearbox

Fig. 6 - Longitudinal section through transmission with Agroshift unit.

150
 Transmission 3
Gearbox 31

Fig. 7 - Rear axle longitudinal section.

151
 3 Transmission
31 Gearbox

B
A C
A

Fig. 8 - Inversor lever (A -Side view and B -Front view) - C - Range reduction lever. X - Version with Mini-reduction Y - Version without Mini-reduction

152
 Transmission 3
Gearbox 31

Fig. 9 - Gear lever. Fig. 10 - Front view of gearbox with Agroshift.

153
 3 Transmission
31 Gearbox

Fig. 11- Views of the gearbox.

154
 Transmission 3
Gearbox 31

Asse ruota

97080.2

127 +0.2

M16x1.5

3.2
1.5
0.25-0.75

0.4
70.7 ±0.1

Fig. 12 - Electro - hydraulic control for front-wheel drive engagement/disengagement.

155
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31 Gearbox

Fig. 13 - Gear selector rod. A - bolts securing hubs to rod. Fig. 14 - Gear selector rod. B - C - bolts securing hubs to rod.

156
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Gearbox 31

Range selector rods and forks

Correct positioning of the gearbox, shuttle and range control levers.

Fit the gearbox, shuttle and range control levers so that the grooves are oriented as shown in the figure.

Fig. 15 - Range selector rod. D - bolt securing hub to rod. Fig. 16 - Correct positioning of the gearbox, shuttle and range control levers.

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31 Gearbox

REMOVAL AND REFITTING OPERATIONS — Disconnect the bracket located in the central part of the cable/pipe duct positioned above the engine, and disconnect the
oil delivery line to the oil cooler from the hydrostatic steering control valve (this pipe is to be disconnected at its middle
part).

— Disconnect the front hydraulic lift delivery line from the cock located at the rear of the tractor above the lift.
Removal of the front gearbox without removing the platform
— Position tool 5.9030.002.0 (mobile stands on tracks) to support the front and rear gearboxes, then remove all the screws
connecting the two gearboxes together.
— Place wedges under the front axle support and remove the rear wheels;
— Put the gear lever in neutral and loosen the two screws securing the relay hub complete with the lower rod which enters
the gearbox and then remove the hub.
— Disconnect the 3 pipes (supply, return and breather) and disconnect the electrical lead of the fuel level sensor;
— Put the inversor control lever in neutral and loosen the screw securing the lever in the control rod housing; remove the two
— Loosen the screws securing the fuel tank supports and remove the tank.
relay hub retaining screws and remove the hub itself.
— Disconnect the rear brake pipes which pass over the two gearboxes, collecting the oil in a suitable container (all the oil in
the brake oil reservoir will drain out). — Loosen the hex socket screw (or the two hex socket screws if the tractor is fitted with a minireduction unit) securing the
gear control rod (see fig. 28 page 160).
— Remove the two screws securing the platform to the front silent-blocks, and raise the front of the platform a few centime-
tres using a hoist or a support with adjustment screw; — Holding the rear gearbox in position, move the front wheels to separate the two gearboxes (time required 3,5 4 hours)
this operation is necessary in order to access and loosen the two upper gearbox retaining screws.

— Remove the guard from the front-wheel drive transmission shaft, then release the sleeve coupling the transmission shaft WARNING: under no circumstances undo union B Fig 19 (hex head), located on the left-hand side of the gearbox.
to the gearbox, by removing the snap ring securing the lock pin and then removing the pin.
This union holds the oil manifold D Fig. 19 for engagement of the front-wheel drive transmission shaft. If this union is remo-
— Slide the sleeve towards the front of the tractor in order to disengage the transmission shaft from the gearbox output shaft. ved, the manifold would rotate downwards, thereby making it necessary to dismantle the gear hub in order to reposition it and
refit the union.
— Using a pair of long-nose pliers, remove the circlip from the gearbox output shaft, thereby allowing the shaft to be
withdrawn from the front gearbox. The delivery pipe C Fig. 19 of the front-wheel drive engagement actuator is connected at the opposite end, inside the gear-
box, to the group of solenoid control valves for the hydraulic services E Fig. 19; if this group is to be removed, undo union A
— Disconnect the oil delivery and return lines from the oil cooler located under the platform and to the right of the rear gear - Fig. 19, to prevent deformation of the internal pipe.
box (relative to the driving position). The return line is connected to the AGROSHIFT solenoid control valves as the oil re-
turning from the cooler in the front engine compartment supplies the electro-hydraulic AGROSHIFT control circuit.

— Disconnect the oil line between the AGROSHIFT control unit and the electro-hydraulic services control valve group, then
remove the AGROSHIFT solenoid control valve block, after having disconnected the electrical leads from the solenoid
valves.

— Disconnect the lubrication line from the solenoid valve block for electro-hydraulic controls to the gearbox.

— Remove the tool box positioned on the right-hand side of the tractor under the driving platform.

— Unscrew the oil drain plug located under the rear gearbox (a container of at least 33 litres will be required to collect the oil).

— Disconnect all electrical leads from the starter motor and the lead connected to the engine oil pressure switch.

— Unplug the bulkhead connector for the wires to the group of dashboard warning lights.

— Detach the retaining strap of the brake/clutch oil reservoir, disconnect the level sensor lead and remove the reservoir (the
reservoir will remain connected to its delivery lines).

— Detach the throttle and engine stop Bowden control cables from the governor.

— Disconnect the two oil delivery-return lines from the hydrostatic steering cylinder in the area above the engine and near
the dashboard.

Fig. 17 - Gearbox removal.

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Gearbox 31

Fig. 18 - Separate the rear gearbox from the front gearbox

Separating the front gearbox from the engine

(this operation is necessary in order to access the AGROSHIFT unit)

— Remove the engine pick-up from the top of the gearbox (in the area of the spacer housing).

— Place wedges under the front axle support.

— Disconnect the fuel delivery pipe in the area between the front gearbox and the engine.

— Disconnect the two front brake pipes and the differential lock control pipe.

— Support the front gearbox on a stand.

— Remove the 10 screws securing the front gearbox to the engine flange, then detach the gearbox.

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31 Gearbox

· Dismantling the gearbox.

— Remove the 8 screws securing the top cover and then remove the cover itself.

— Remove the gearbox clutch control located in the spacer housing as follows:
—
— Remove the thrust bearing.

— Remove the lock pin and withdraw the control lever.

— Undo the union and remove the oil delivery pipe to the AGROSHIFT unit.

— Unscrew the 2 screws and the 2 nuts securing the AGROSHIFT unit;

— Remove the 2 retaining screws of the AGROSHIFT control valve unit, (one of these screws also secures the fuel
prefilter with the relative pipe).

NOTE: one of the screws has an extension with a small plate to support the clutch control lever; these parts are to be re -
moved together with the screw.

· Removal of the gearbox input and P.T.O. shafts

— Remove the circlip attaching the gearbox input shaft to the inversor shaft coupling sleeve.
Withdraw the 2 shafts from the front of the spacer housing (the shafts should be withdrawn together to prevent damage
to the seal ring positioned between them).

NOTE: To replace the seal on the gearbox input shaft, it will be necessary to remove the cab or platform to gain access
to the upper cover of the gearbox, from which the seal housing may be accessed.

· Separating the AGROSHIFT unit from the gearbox

— Using a copper drift, tap the housing of the AGROSHIFT unit in order to extract from the front part of the spacer hou-
sing;
(if the purpose of this operation is solely to inspect or replace the hydraulic clutches, it will not be necessary to remo-
ve the epicyclic reduction unit from the gearbox or to remove the cab/platform).

— If instead the epicyclic reduction unit is to be removed, simply withdraw it from the front of the gearbox, then remove
the calibrated thrust washer and the circlip, and then remove the housing complete with the ring gear.

— The AGROSHIFT clutch units are to dismantled on the bench.

NOTE: for instructions on dismantling the AGROSHIFT unit, see page 118.

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 Transmission 3
Gearbox 31

· Removal of the gear train positioned in the front gearbox

WARNING: On tractors equipped with Agroshift, first follow the instructions to remove the Agroshift unit and the gear-
box input and P.T.O. shafts.
For the following operations the driving platform or cab must be removed in order to gain access to the upper gearbox
cover.

Before proceeding with the removal of the gear train, it is necessary to remove the selector rods and forks. These opera-
tions are only possible after having separated the rear gearbox from the front; before separating the two gearboxes, re-
move D fig. 5 on page149.
Detach the front gearbox from the rear gearbox. To do this, it will be necessary to remove the 5 speed relay hub together
with the intermediate support, located on the right-hand side of the rear gearbox. Remove screw A (fig. 14) screws B
(fig. 15) and screw D (fig. 16).

NB: Remove the selector rod detent balls and springs by unscrewing the relative plugs located on the right-hand side of
the gearbox. Then proceed with the separation of the two gearboxes.
The 3 gearbox shafts (inversor, primary and secondary) and the gear selector and inversor control rods and forks will
remain attached to the front gearbox. To remove these rods, it will first be necessary to remove the 3 shafts by removing
the 3 circlips A - B - C fig. 5 on page 149 and then moving all 3 shafts simultaneously backwards to disengage them from
their housings; the first shaft to be detached will be the primary shaft, followed by the secondary, and then the input shaft
located at the uppermost part of the gearbox is to be withdrawn. Each selector rod will come away together with its shaft.

E M16x1.5

A
D C B
Fig. 19 - Oil pipe from the solenoid control valve to the hydraulic actuator responsible for engaging/disengaging front-wheel drive.
A Pipe union on solenoid valve end B Pipe union on actuator ende C Connection pipe.
D Manifold E Solenoid valve assembly

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31 Gearbox

Fig. 20 - Retaining screws of the gear rods to be

removed prior to detaching the front gearbox from
the rear gearbox.
A retaining screw of the inversor control
rod hub
B retaining screws of the gear control
rod hubs.

C Range gear control rod.

D Gearchange control rod.

E Inversor/minireduction control rod.

Disassembly of the inversor control rods and forks

Disengage the fork from the sleeve and rotate it so that the hole in the fork is aligned with the retaining pin; then, using a
drift as shown in figure 23, tap the pin out of the hole.
On tractor equipped with a minireduction unit, repeat the above operations to remove the second selector fork.

Fig. 21 - Components of inversor rod and fork assemblye for Fig. 22 - Rod and fork for gearbox without minireduction.
gearbox with minireduction.

Fig. 23 - Removal of the fork retaining pin. Fig. 24 - Removal of fork from control rod.

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 Transmission 3
Gearbox 31

Dismantling of the gearchange rod and fork assembly.

Fig. 25 - Detach the rod with forks from the secondary shaft Fig. 26 - Remove the screw securing the rod hub and remove
by moving it laterally the hub from the rod.

Fig. 27 - Disengage the 1st gear selector fork from the sleeve Fig. 28 - Withdraw the gearchange control rod.
and rotate it to align the hole on the fork with the retaining pin.
Then, using a suitable drift, drive the pin out of the hole.
Detach the 2nd and 3rd gear selector forks and sleeves in the
same way.

Fig. 29 - Remove the sleeve located on the rod between se- Fig. 30 - Rotate the 4th and 5th gear the two forks. so that the
lector fork. hole on the fork is aligned with the retaining pin, then using a
drift and a hammer as shown in figure 23, drive the pin out of
the hole (the figure shows the components of the selector rods
and forks assembly).

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31 Gearbox

Dismantling of the gearchange selector rods and forks assembly

Fig. 31 - Unscrew the 6 retaining screws and remove the Fig. 32 - Unscrew the guide screw of the central sleeve lo -
cover giving access to the gearchange selector rods and cated between the 2 forks. (NB. Loctite has been applied to
forks assembly. Then using a spanner, unscrew the guide these screws; we recommend that they are heated using an
bolt of the super-reduction control fork. oxyacetylene torch to facilitate removal).

Fig. 33 - Unscrew the guide screw of the L-V selector fork. Fig. 34 - Access the front compartment of the gearbox extract
the rod by pulling the hub.

Fig. 35 - Remove all the parts mounted on the rod, recovering Fig. 36 - Parts comprising the selector rod and forks them
them from the lateral access hole. from the lateral access hole assembly for the super-reduction
unit and range gears.

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 Transmission 3
Gearbox 31

Removal of the shaft with the actuator for engagement/disengagement of the front-wheel drive

Separate the rear gearbox from the front gearbox, (it is first necessary to remove circlip (A fig 37). Unscrew union B ( fig
19 page 161) located on the left-hand side of the rear gearbox and remove the front shaft complete with the front-wheel
drive actuator..

IMPORTANT: Only unscrew union B fig. (19 page 161) located on the left-hand side of the rear gearbox when the two
gearboxes are separated, as refitting is only possible in this condition.

Disassemble the unit, removing the circlip securing the oil manifold and the circlip securing the thrust plate of the helical
spring; then disassemble the unit into its component parts, inspecting for wear the two oil seals (on the shaft and in con -
tact with the control piston) and the areas in contact with the oil manifold.
WARNING: the valve located inside the shaft must be positioned as shown on page 173.

A DE F G CB
Fig. 37 - Front-wheel drive output.

Removal of the range gear shaft

Separate the rear gearbox from the front gearbox, (it is first necessary to remove circlip A fig. 37) remove the right rear
wheel support and the cover on which the electro-hydraulic control valves are mounted, detach the oil pipe for 4WD di-
sengagement by undoing union B (fig. 19 on page 163) located on the solenoid valve mounting on the right-hand side of
the gearbox. Remove the cover supporting the internal parking brake control.
Then remove the synchronised P.T.O. shaft by removing the retaining flange mounted on the rear of the gearbox and
remove the synchronised P.T.O. engagement sleeve mounted on the 4WD shaft, which can be accessed through the
space left void by removal of the wheel support.
Remove circlip B fig. 37 and thrust plate C fig. 37, which can be accessed through the space created by removal of the
wheel support.
Working through the aperture created by removal of the cover on which the electro-hydraulic control valves are moun -
ted, remove circlips D - E - F - G fig. 37 and pull shaft towards the front of the gearbox.

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31 Gearbox

Examining parts removed

Gearbox case
Gearbox case should show no cracks, bearing seats must not be
worn or damaged.

If seriuos damage or excessive wear is occured replace the parts

concerned.

Whenever the gearbox is disassembled clean all sealing surfaces

removing old adhesive and applying some new on all surfaces
evenly when reassembling.
Fig. 38 - Equipment 5.9030.002.0 for the disman-
tling the gearbox.
Shafts
Examine shafts for excessive wear and shaft splines for pitting,
these should allow the gears to slide freely.

Gears
Examine gear teeth for wear or damage and make sure these
work on the whole contact surface.

Check also the gear-mounted bushings for seizing: if so replace

them.

Synchronizers
Fig. 39 - Visual control of the tooth of the gears. Check the ring inside tapered portion for excessive wear or dama -
ge and be sure the gear part being frictioned by the synchronizer
does not show signs of scoring which may prevent the gear from
meshing correctly.

To check the synchronizer ring for wear, measure the distance

+ 0, 3
from the friction cone; reading should be 125
, - 0,15 mm with a new
synchronizer or drop to zero when the ring is maximally worn.

Bearings
Bearings should be in perfect conditions without showing excessi-
ve radial or end play.
Holding the bearings pressed by hand and making them simulta-
neously turn in both directions of rotation a free sliding as well as
Fig. 40 - Unit synchronizer.
no roughness at all should be felt.

Examine the taper roller bearings for proper working conditions,

these should be neither worn nor overheated, replace as soon as
poor working efficiency is suspected, as an abnormal bearing
operation may result in either gear tooth seizure or noisy gearbox.

Warning: oil leakages from the clutch-disk-to-gearbox shaft or

the engine-flywheel-to-P.T.O.-clutch shaft may be stopped when
the assembly procedure is performed with the utmost care and
operating in such a way that the splined parts are prevented from
damaging the O-ring and also providing a thorough cleaning of the
parts prior to being installed.

Fig. 41 - Checking slide of the bearing.

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 Transmission 3
Gearbox 31

ADJUSTING PLAY OF THE GEARBOX SHAFTS BY MEANS OF THE THRUST PLATES ON

THE MINI/INVERSOR SHAFT AND THE SECONDARY SHAFT

· MINI/INVERSOR SHAFTS

Circlip position for measurement of distance “X”

Adjusting the play of the minireduction gear mounted on the inversor shaft.
Obtain an play X of 0.15 0.30 mm of minireduction gear (z=35) by selecting the thrust plate R of the appropriate thic-
kness from among those available:

cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0

Play X is to be measured by pushing the spacer B in the direction indicated by the arrow up to the point where the
synchroniser is pushed up against point Y, while simultaneously pushing the forward speed gear (z=37) in the direction
indicated by the arrow up against circlip A.

Circlip position for measurement of distance “X”

Adjusting the play of the forward speed gear on the inversor shaft (version with minireduction).
Obtain an play X of 0.15 0.30 mm of the forward speed gear (z=35) by selecting the thrust plate R of the appropriate
thickness from among those available:

cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0

Play X is to be measured by pushing the gear (z=23) in the direction indicated by the arrow so that the synchroniser is
pushed up against point Y, while simultaneously pushing the minireduction gear (z=35) in the direction indicated by the
arrow up against circlip A.

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31 Gearbox

· REVERSE SHAFT

Circlip position for measurement of distance “X”

Adjusting the play of the reverse gearwheel mounted on the shuttle shaft.
Obtain play X of 0.15 to 0.30 mm of reverse gearwheel (z = 23) by selecting and fitting a thrust washer R of suitable thic-
kness from those available:

cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0

Play X is measured by pushing the forward gearwheel (z=37) in the direction indicated by the arrow, thereby pushing
the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

· SECONDARY SHAFT 1st SPEED

Circlip position for measurement of distance “X”

Adjusting the play of the 1st speed gear (z=59).

Obtain an play X of 0.15 0.30 mm of the 1st speed gear (z=59) by selecting the thrust plate R of the appropriate thic-
kness from among those available:

cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0

Play X is to be measured with a feeler gauge while pushing spacer B in the direction indicated by the arrow so that the
synchroniser is pushed up against point Y, while simultaneously pushing the 2nd speed gear (z=50) in the direction indi-
cated by the arrow up against circlip A.

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 Transmission 3
Gearbox 31

· SECONDARY SHAFT 2nd/3th SPEED

Circlip position for measurement of distance “X”

Adjusting play of 2nd speed gear cluster

Obtain play X of 0.15 0.30 mm of the 2nd speed gear cluster by selecting a thrust washer R of the appropriate thic-
kness from among those available:

cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0

Play X is to be measured using a feeler gauge while pushing the 3rd speed gear in the direction of the arrow, thereby pu-
shing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

Circlip position for measurement of distance “X”

Adjusting play of 3rd speed gear

Obtain a play X of 0.15 0.30 mm of the 3rd speed gear by selecting a thrust washer R of the appropriate thickness from
among those available:

cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0

Play X is to be measured using a feeler gauge while pushing the 3rd speed gear in the direction of the arrow, thereby pu-
shing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

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31 Gearbox

· SECONDARY SHAFT 4th/5th SPEED

Circlip position for measurement of distance "X"

Adjusting the play of the 4th speed gear cluster.

Obtain a play X of 0.15 to 0.30 mm of the 4th speed gear cluster by selecting and fitting a thrust washer R of the appro-
priate thickness from those available:
cod. 008.0251.0 010.0629.0 010.0630.0 010.0631.0 010.0632.0
Play X is to be measured using a feeler gauge while pushing the 3rd speed gear in the direction of the arrow, thereby pu-
shing the synchronizer up against point Y and pushing the circlip A as indicated in the detail.

SECONDARY SHAFT INPUT SHAFT AND INVERSOR SHAFT

Shimming the front bearing of the secon- Fitting the bush joining the input shaft to the inversor shaft
dary shaft Fit bush A oriented as shown in the figure to facilitate subsequent
Fit shims of appropriate thickness to reduce removal.
end-float between the shaft and the bearing
to the minimum possible amount. By fitting
the correct shims you can obtain a maxi-
mum play of 0.09 mm.

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 Transmission 3
Gearbox 31

Fitting the spacer determining the stroke of the valve for hydraulic disengagement of front-wheel drive.
To allow correct disengagement of the front-wheel drive, bush A must be installed as shown in the figure above.

WARNINGS RELATED TO ASSEMBLY OF THE GEARS OF THE P.T.O. UNIT, THE RANGE
REDUCTION UNIT AND THE SYNCHRONISED P.T.O. SHAFT
Assembly of the P.T.O.
Install:
— The synchronised P.T.O. output shaft (to be installed after the range reduction unit);
— The P.T.O. output shaft and relative gears;
— The rear P.T.O. Shaft.

Installation of the range reduction unit, the gear for the front-wheel drive shaft and the par-
king brake discs
— Position on the bottom of the gearbox the L-V range reduction unit (complete with bushes and roller cage) and the
super-reduction gear (complete with roller cage).
— Slide the shaft, complete with circlip, through the front end of the gearbox, and fit the previously positioned gears
onto the shaft.
— Fit the thrust washer and 2 circlips.
— Position the drive gear of the front-wheel drive complete with parking brake discs.
— Fit the ball bearing for the rear end of the shaft, inserting it in its housing in the gearbox.
— Insert the thrust washer and position the circlip.
— Position the bearing and the bearing circlip in the housing;
— Fit the thrust washer and the circlip;
— Install the synchronised P.T.O. shaft in the rear end of the gearbox, and fit the control sleeve to the shaft.
— Fit the bevel pinion and the gears of the range reduction unit with the relative synchroniser;
— Fit the differential housing complete with the crown wheel and the internal differential lock control.

Warnings:
The spacer installed on the rear output shaft is fitted with an O-ring on the outer surface and an internal oil seal.
To remove this spacer requires the use of a puller to be attached to the spacer using the two holes provided.
At each dismantling of the pins of the brake and clutch control levers, check the bushes for wear.

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 3 Transmission
31 Gearbox

Fig. 42 - Range gearbox

Fig. 43 - Removal of the groundspeed P.T.O. sleeve. Fig. 44 - Removal of the circlip securing the shaft.

Fig. 45 - Gears on range gearbox shaft. Fig. 46 - Checking the oil seals on the 4WD shaft.

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 Transmission 3
Gearbox 31

Fig. 47 - Range gearbox synchronizer. Fig. 48 - Secondary shaft cover plate

Range gearbox synchronizer. Fitting the secondary shaft cover plate. Fit the cover A
Warning: the synchronizer hub must installed so that the applying LOCTITE 601 around the hole of the front gearbox
indicated by the arrow is positioned as shown in the figure. casing indicated X in the figure.
B - secondary shaft

Fig. 49 - Fitting the transmission speed sensor pickup.

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 3 Transmission
31 Gearbox

Fitting the baulk ring of the synchronizer for Fig. 50 - it the 50x90x20 ball bearing, indicated A in the figure, without the
the 1 speed gear mounted on the secon-
st
retaining ring.
dary shaft.
Should it be necessary to restore the correct
play X of 0.15 to 0.30 mm of the 1 speed
st

gear (z=59), it is possible to select a

synchroniser baulk ring of suitable thic-
kness from the two available, as shown in
the figure.

Fig. 51 - Bearing for 4WD shaft. Fig. 52 - Position the groundspeed P.T.O. cover plate as indicated
in the figure.

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 Transmission 3
Gearbox 31

Points where sealant is to be used

Fig. 53 - Rear gearbox.

Apply LOCTITE n° 601 to the base of studs A (n° 9) - B (n° 1) - C (n° 1), as shown in the figure, prior to assembly.

Fig. 54 - Fitting the wheel support.

Apply PIANERMETIC 510 sealant to the surfaces indicated with the letter L in the figure; apply SILASTIK sealant to the surfaces indi-
cated with the letter S.

175
 3 Transmission
31 Gearbox

11"

12"

Fig. 55 - Correct installation of the support tube for the clutch control sleeve.
Position the gearbox vertically with side A facing upwards. Apply Loctite 601 to the seat of the tube and fit the tube.
Wait about 1 hour before returning the gearbox to the horizontal position.

Tightening torques
Degrease and clean all bolts/screws before tightening.
Kgm Nm
crown wheel retaining bolts 7÷8 68 ÷ 78
differential flange retaining bolts 6 58
bolts securing differential cage to half-shafts 6 58
rear carrier retaining nuts
(on assembly apply PIANERMETIC 510 sealant to threads) 9,2 ÷ 10,3 90 ÷ 100
P.T.O. shaft retaining nut 10 ÷ 12 98 ÷ 115
gearbox-engine flange bolts 9 ÷ 12 88 ÷ 107
bevel gear retaining nut 28 ÷ 30 274 ÷ 294
nuts securing gearbox to intermediate transmission casing 10 ÷ 12 98 ÷ 107
hex socket screws for reduction unit ring gear
(on assembly apply LOCTITE 242 to screws) 7÷8 68 ÷ 78

176
 Transmission 3
Gearbox 31

IMPORTANT INSTRUCTIONS

Fig. 56 - Positioning of the 4WD shaft complete with engage - Fig. 57 - After positioning the pipe, connect the oil manifold
ment/disengagement system. After positioning the shaft, by inserting union A from the left-hand side of the gearbox.
connect the oil manifold to solenoid control valve (located on The PICK-UP speed sensor must be installed in hole B indi-
the mounting on the right-hand side of the gearbox) using the cated by the arrow (see instructions on page 175).
specially shaped pipe.

Fig. 58 - The pipe connecting the hydraulic control of the Fig. 59 - The AGROSHIFT unit is to be installed in the gear-
front-wheel drive must be connected to the solenoid valve box and the shaft end-float adjusted with the shaft engaged
block at the external fitting indicated by the small arrow. with the epicyclic reduction unit.

Fig. 60 - End-float is to be adjusted by fitting a shim of appro - Fig. 61 - Checking shim thickness using a micrometer.
priate thickness following the instructions given on page 133.

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 3 Transmission
31 Gearbox

Fig. 62 - Fitting the shim to adjust end-float of the AGROSHIFT Fig. 63 - Positioning the epicyclic reduction unit of the
shaft. AGROSHIFT in the front gearbox.

Fig. 64 - Fitting the epicyclic reduction unit inside the housing Fig. 65 - AGROSHIFT unit installed in the gearbox.
previously attached to the gearbox output shaft.

Fig. 66 - Oil seal on shaft between clutch and gearbox. This Fig. 67 - Positioning the P.T.O. clutch unit inside the ge -
seal can be renewed by accessing the inside of the front arbox.
gearbox.

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 Transmission 3
Differential gear 35

Bevel drive adjustment (see figs. 1 and 3)

Install the pinion in the gearbox together with the bearings pack A (without interposing shims); position gear B and tig-
hten ring nut to a torque of: 28 30 Kgm (275 294 Nm).

Fit the differential housing without the crown wheel; shim up the tapered bearings D and E so that they rotate freely in
the housings yet a slight preloading can be felt; then add a 0,1 mm. shim to the pack in order to preload the bearings.

Adjust the distance F between the differential housing and the head of the pinion, interposing shims in the position G in-
dicated in figure 1; the exact measurement for this adjustment is obtained by adding or subtracting the value stamped
on one of the pinion teeth to/from the base value of 2.5 mm.

Secure the bearings pack by inserting a circlip (select one from those supplied in thicknesses of 2.8 3.6 mm. (see figu-
re 1) which fits perfectly in the seating preventing any bearing play.

nstall the crown wheel in the differential housing and, with a dial gauge, measure the crown wheel/pinion backlash; the
correct value range is 0,17 0,23 mm for tractor in the version 30 Km/h and 0,20 ÷ 0,27 mm for tractor in the version 40
Km/h (see figure 4 on page 180). If the measured backlash does not come within this range, remove shims from pack D
and add them to pack E, to move the crown wheel nearer to the pinion, or vice versa to move it further away.

NB.: On completion of the bevel drive adjustment operations, loosen off the ring nut, apply Loctite 270, then tighten to a
torque of 28 30 Kgm (275 294 Nm) and then stake the pinion retaining nut.
Tighten the crown wheel retaining screws to a torque of 7 8 kgm (68 78Nm).

Fig. 2 - Value stamped on a tooth of the pinion.

C - SNAP RING
2.1419.056.0/10 99x2,8
2.1419.057.0/10 99x2,9
2.1419.058.0/10 99x3,0

2.1419.059.0/10 99x3,1
2.1419.060.0/10 99x3,2
2.1419.061.0/10 99x3,3
2.1419.062.0/10 99x3,4
2.1419.063.0/10 99x3,5
2.1419.064.0/10 99x3,6

Fig. 1 - Shimming the bevel pinion. Fig. 3 - Shimming the crown wheel.

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35 Differential gear

Fig. 4 - Checking the backlash between the crown wheel and pinion.

Servicing operations
Installation of the bevel drive without renewing any parts.
New adjustment is not required; make sure that the same shims packs are refitted in the same places, and check that
the distance between the head of the pinion and the differential housing is as prescribed.

Renewal of crown wheel bearings

Shim the bearings to obtain a preloading of 0,1 mm; then adjust backlash between the crown wheel and pinion.

Renewal of pinion bearings

The bevel drive will require adjustment.

Installing the rear differential lock

The rear differential lock system does not require any adjustment.

Fig. 5 - Parts comprising the differential unit. Fig. 6 - Rear differential lock control.

180
 Transmission 3
Power take-off 36

Rear power take-off

Rear P.T.O. gears

The rear P.T.O. shaft, directly coupled to the engine, is equipped with a selector allowing selection of P.T.O. speeds of
540/1000 rpm or, on request, 540-750-1000 rpm.
The selector is of the sliding sleeve type. The selector is mechanically controlled and can only be operated when the
moving parts are stationary. The P.T.O. output shaft rotates in a counter-clockwise direction, as viewed from the rear of
the tractor.

Fitting the rear P.T.O. output shaft

Before installing the studs, remove any oil/grease from the threads, then apply “LOCTITE 242".

Technical characteristics

P.T.O. speeds
540 r.p.m. DORADO 55 - 60 - 65 14/53 = 1/3,7857
540 r.p.m. DORADO 70 - 75 - 85 13/50 = 1/3,8462
750 r.p.m. DORADO 55 - 60 - 65 16/50 = 1/3,1250
750 r.p.m. DORADO 70 - 75 - 85 15/46 = 1/3,0660
1000 r.p.m. DORADO 55 - 60 - 65 - 70 - 75 - 85 20/46 = 1/2,3000

P.T.O. r.p.m. engine r.p.m. P.T.O. r.p.m. P.T.O. r.p.m.

power take-off
engine r.p.m. at max P.T.O. r.p.m engine r.p.m. at fas engine r.p.m. at fas
horsepower speed idling speed idling speed

for 55 - 60 - 65 HP
540 r.p.m. 620/2350 3,7857 (657/2490) ÷ (665/2520) (171/650) ÷ (184/700)
(2045 engine r.p.m.)

for 70 - 75 - 85
540 r.p.m. 611/2350 3,8462 (647/2490) ÷ (655/2520) (169/650) ÷ (181/700)
(2077 engine r.p.m.)

for 55 - 60 - 65 HP
1000 r.p.m. 1022/2350 2,3000 (1082/2490) ÷ (1095/2520) (282/650) ÷ (304/700)
(2033 engine r.p.m.)

for 70 75 - 85 HP
750 r.p.m. 752/2350 3,1250 (797/2490) ÷ (806/2560) (208/650) ÷ (224/700)
(2343 engine r.p.m.)

for 55 - 60 - 65 - 75
- 85 HP
750 r.p.m. 766/2350 3,0660 (812/2490) ÷ (822/2520) (212/650) ÷ (228/700)
(2300 engine r.p.m.)

Synchronised P.T.O. P.T.O. revolutions for each wheel revolution 14,7400

181
 3 Transmission
36 Power take-off

Fig. 1 - 540 - 1000 r.p.m. selector.

Fig. 2 - 540 - 750 - 1000 r.p.m. selector

182
 Transmission 3
Power take-off 36

ADJUSTMENT OF THE P.T.O. CONTROL LINKAGE

Disconnect tie-rod B from lever D.
Move control lever A and lever D to the 540 rpm position.
Turn fork C to adjust the length of tie-rod B so that the hole in the fork is perfectly aligned with the hole in lever D; then screw in fork C
by a 1/2 turn and connect tie-rod B to lever D.

Warning: after adjusting the tie-rod, move the control lever to neutral position and check that the P.T.O. output shaft rotates freely
when turned manually.

NB: For versions with 3-speed P.T.O., check also that output shaft turns freely when the control lever is in the second neutral positi -
on.

2-SPEED VERSION 540 – 750 R.P.M.

WARNING: on assembly, position the lever indicated with the

arrow so that head of the lock screw is facing the front
of the tractor.

2-SPEED VERSION 540 – 1000 R.P.M.

Fig. 3 - P.T.O. controls and output shafts (2-speed version) for 55 - 60- 65- HP models

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35 Power take-off

Fig. 4 - P.T.O. controls and output shafts for 55 - 60 - 65 HP models (3-speed version)

184
 Transmission 3
Power take-off 36

9 kgm
(90 Nm)

Fig. 5 - P.T.O. controls and output shafts for 70 - 75 - 85 HP models (3-speed version)

185
 3 Transmission
36 Power take-off

P.T.O. clutch

General characteristics

The P.T.O. clutch is a wet-type multidisc clutch and is operated by hydraulic pressure.

The oil required for the P.T.O. hydraulic control is drawn from the gearbox and filtered before it arrives at the gear pump
located on the right-hand side of the gearbox.

The clutch control is electro-hydraulic. The electro-hydraulic system controls the circuit by means of a solenoid valve,
which supplies oil under pressure to the clutch control piston. In both cases, the driving discs and driven discs are forced
together, thereby transmitting drive to the output shaft.

The P.T.O. clutch brake is operated mechanically by the piston during the return stroke determined by the helical clutch
release spring. Three pins connected to the piston press against the brake counter disc.

Fig. 6 - Cross section view of the P.T.O. clutch.

186
 Transmission 3
Power take-off 36

Technical specifications
P.T.O. Clutch

Clutch oil-immersed multiple disc with axial piston

number of friction discs 5
diameter of discs 105
thickness of assembled friction discs
minimum mm 27.32
maximum mm 29.90
number of intermediate discs 5
disc lubrication pressure bar 5
P.T.O. clutch relief pressure setting bar 11
+2
P.T.O. pressure control valve bar 16 0

restrictor valve mm 1.1

Correct positions of P.T.O. sensors and cables

A - 3-speed P.T.O. for 70-75-85 HP models B - 3-speed P.T.O. for 55-60-65 HP models C - 2-speed P.T.O.

Springs technical data:

Piston return spring

diameter of wire mm 6
external diameter mm 52,5
spring relaxed mm 50
spring compressed kg 82 (808 Nm ) mm 28
) mm
kg 98 (978 Nm 23,4

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 3 Transmission
36 Power take-off

WARNING: to prevent oil leaks between the oil delivery and lubrication manifolds, apply Loctite 542
to the threaded parts.
CORRECT INSTALLATION OF PINS ON P.T.O. CLUTCH CONTROL PISTON
Insert the three pins and install the three grub screws, applying IDRAULERMETIC 542 to the threads, and tighten
up against the pins; then unscrew each screw by a 1/4 turn to obtain a clearance of 0.25 between the pins and the
piston.

Fig. 7 - Rear P.T.O. control.

188
 Transmission 3
Power take-off 36

Clutch inspection
Inspect the contact surfaces of the clutch friction discs. If worn or torn, the discs must be replaced.
Inspect the control piston and replace if scored.

Inspect the clutch hub. If depressions are worn into the tops of the splines on which the friction discs slide, the hub must
be replaced.

Check the efficiency of the piston return spring. The spring characteristics should match those specified in the relative
table; if not, replace the spring.

Examine the seals of the clutch control piston and the clutch brake piston and the brake disc. Replace if worn.

At each assembly of the P.T.O. clutch, carefully clean the oil ways in the clutch housing; use a compressed air jet if ne -
cessary.

Checking clutch disc clearance

With new discs installed, check that clearance A (Fig. 8) is 0.5÷2 mm .
If the clearance exceeds the maximum value, fit one shim (code 2.1599.499.0) in the position indicated by the arrow.

Warning: Apply IDRAULERMETIC 542 to the threads of the three screws A before fitting; fully tighten the screws and
then back off each screw a 1/4 turn to obtain a clearance of 0.25 mm between the head of the pin and the piston.

Fig. 8 - Checking clutch disc clearance.

A - If the clearance exceeds the maximum prescribed value, fit one shim code 2.1599.499.0

189
 3 Transmission
36 Power take-off

Checking clutch hydraulic pressures

Connect the mini fitting code 009.2923.4 (with M4 12x1.5 threaded fitting) to the electro-hydraulic control unit as shown
in figure 9.
Connect tool 5.9030.517.4 to the fitting and attach the pressure gauge 5.9030.514.0.
Operate the control valve and check that the pressure gauge shows a reading of approximately 16 bar.
For instructions on measuring pressure and relative values see the chapter “electro-hydraulic controls”.

Fig. 9 - Checking the operating pressure in the P.T.O. clutch control circuit.

190
 Transmission 3
Power take-off 36

Checking the end-play of the front shaft of the P.T.O. clutch

On the front shaft of the P.T.O., install circlip A and thrust washer B code 2.1599.761.0; position the shaft in the clutch
unit and push it towards the front of the tractor so that it rest up against the oil seal shown in figure at C, then check that
clearance between the thrust washer B and the clutch hub is not less than 1 mm.
If the clearance is less than 1 mm, remove thrust washer B.

Fig. 10 - Checking the end-play of the front shaft of the P.T.O. clutch.

Installing the waterproof seals rear

P.T.O. output shaft and synchronised P.T.O.
Fit the seal using a suitable installation tool;
the seal is to be oriented as shown in the figure
and pressed in to the full depth of the tool.
The measurements indicated here are to be
used to construct the oil seal installation tool.

Fig. 11 - Installation of the waterproof seals.

191
 3 Transmission
36 Power take-off

Fitting the P.T.O. shaft

In the event of interference between shaft B

and flange A, heat the flange to allow cou -
pling. Before fitting plate D, apply Pianerme -
tic 510 to the surfaces E of shaft B. Tighten
bolt C to a torque of 68 Nm (7 kgm).

Fig. 12 - Fitting the P.T.O. shaft with interchangeable

output shaft (on certain models only).

RENEWAL OF THE REAR P.T.O. CLUTCH

The P.T.O. clutch unit can be removed without having to remove the driving platform.

proceed as follows:
— Remove the top link;
— Detach the lift rods of the 3-point linkagefrom the lift arms;
— Detach the lift control rods from the control levers;
— Disconnect the oil delivery pipe to the auxiliary control valves from the rear pump;
— On models with 4-way control valves, detach the oil pipe from the lift control valve to the auxiliary hydraulic control
valves. On models with 6-way control valves, detach also the pipe from hydraulic control valves to the upper gearbox
cover plate (for 4-way control valves);
— Disconnect the control levers of the hydraulic control valves from the relay levers connected to the control valves, by
removing the relative cotter pins and retaining pins;
— Remove the 3 screws securing the hydraulic control valve from the support bracket;
— Disconnect the fuel tank breather pipe in the area above the lift;
— Remove the 10 screws and the two nuts securing the lift unit to the rear gearbox;
— Attach the lift unit to a hoist and lift it clear of the tractor (when removing the lift unit, take care not to damage the thre-
ads on the two studs);
— Unscrew the screws securing the P.T.O. access cover (located above the gearbox) and remove this cover;
— Using a suitable lever, push towards the front of the tractor the sleeve coupling the P.T.O. clutch output shaft to the
P.T.O. rear shaft;
— Loosen the two screws and remove the rear shaft bearing stop plate;
NOTE: when removing this plate, take care that the spacers positioned underneath it do not fall into the gearbox.
— Unscrew the 3 retaining screws and remove the top flange located at the rear of the gearbox. Then withdraw the bea-
ring together with the upper 540 rpm gear.
NOTE: when withdrawing the gear, take care that the roller bearing located in the gear does not fall into the gearbox.
— Disconnect the pipe supplying oil for lubrication of the inversor shaft and to the oil-bath for the P.T.O. clutch discs, lo-
cated on the right-hand side of the gearbox, by undoing the relative union; then remove the union of the oil supply
pipe to the P.T.O. clutch;
— With the aid of a lever, push the P.T.O. shaft a few centimetres to the rear;
This will only be possible if the shaft is positioned in such a way that there is no interference between the teeth of the
gear and those on the shaft;
— Slide the sleeve onto the rear shaft after having first pushed the bearing located in the wall of the gearbox back a suf-
ficient distance;
— Push the clutch unit together with the front shaft and the output shaft to the rear, so as to be able to withdraw the front
shaft to the front P.T.O. unit;
— Extract the complete clutch unit, disengaging it from the rear shaft;
— Inspect the clutch discs and renew them if necessary, removing the large circlip and the spacer.

WARNING: on re-assembly, after having positioned the clutch unit complete with the front shaft, refit the two oil unions
in order to ensure that the unit is positioned correctly, then insert the rear shafts and complete the assembly.

192
 Transmission 3
Power take-off 36

MAIN OPERATIONS FOR REMOVAL OF THE REAR P.T.O. UNIT.

Fig. 13 - The rear P.T.O. clutch may be removed without hav - Fig. 14 - Remove the lift and the front cover of the rear gear-
ing to remove the cab from the tractor. box to gain access to the P.T.O. clutch unit.
Disconnect the controls of the auxiliary control valves.

Fig. 15 - Release the rear shaft of the P.T.O. towards the rear. Fig. 16 - Remove the circlip on the front clutch shaft.

Fig. 17 - If necessary, push the rear shaft support bearing for - Fig. 18 - Disconnect the oil supply pipes and remove the com-
ward and withdraw the sleeve coupling the 2 rear shafts of the plete P.T.O. clutch unit from the gearbox.
P.T.O. together.

193
 3 Transmission
36 Power take-off

OPERATIONS FOR REMOVAL OF THE REAR P.T.O. UNIT

Fig. 19 - Withdraw the front shaft from the clutch unit. Fig. 20 - Check that the clutch hub slides freely in its housing.

Fig. 21 - Check the condition of the lube pipe and nozzle for Fig. 22 - Remove the circlip securing the clutch discs.
the hydraulic pumps drive gears.

Fig. 23 - Remove the clutch discs. Fig. 24 - The complete disc pack can be extracted along with
the clutch hub.

194
 Transmission 3
Power take-off 36

Fig. 25 - Inspect the piston; note the three pins of the clutch Fig. 26 - Remove the thrust washer from between the spring
brake, which is engaged by the action of the clutch release and the clutch hub.
spring in the absence of hydraulic pressure.

Fig. 27 - Inspect the clutch discs for wear. Fig. 28 - Examine the condition of the counter disc.

Fig. 29 - Examine the teeth of the clutch hub. Fig. 30 - Remove the circlip securing the hydraulic manifold of
the clutch unit.

195
 3 Transmission
36 Power take-off

Fig. 31 - Remove the shoulder plate. Fig. 32 - Remove the lube pipe for lubrication of the hydraulic
pump gears.

Fig. 33 - Completely disconnect the lube pipe. Fig. 34 - Remove the clutch oil supply manifold.

Fig. 35 - Check the manifold oil ways and check the manifold Fig. 36 - Remove the snap rings and check for signs of wear.
for wear.

196
 Transmission 3
Power take-off 36

Fig. 37 - The two holes at the front of the manifold as shown in Fig. 38 - Examine the seals on the oil supply fittings.
the figure serve for lubrication of the clutch discs, while the
large hole to the rear of these supplies the oil to operate the
clutch control piston.

Fig. 39 - Dismantle the two oil supply fittings and examine Fig. 40 - Remove the brake disc of the clutch unit.
them.

Fig. 41 - Remove the circlip securing the brake disc thrust Fig. 42 - Extract the two thrust plates together with the brake
plate. disc.

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 3 Transmission
36 Power take-off

Fig. 43 - Examine the clutch brake disc pack. Fig. 44 - Check the three pressure pins for wear.

Diagnosing malfunctions
replace the springs
of incorrectly cali-
check the hydraulic brated valves
system of the sole -
noid valve block
check the seals on if necessary, repla-
the piston and ma- ce the defective
nifold parts
the clutch slips

check that the pi - eliminate any roug-

ston slides freely hness preventing
free movement

check the clutch replace the plates

plates for wear

check the control replace the defecti- replace the plates

linkage ve parts

incomplete control plates burned eliminate any roug-

valve stroke, sole- check the plates hness preventing
the clutch fails to di- noid valve faulty plates jammed free movement
sengage

piston stuck replace the piston

198
 Drive axles - axles 4
Rear axle 44

Rear axle

Fig. 1 - Rear axle.

Installing the rear half-shafts (fig. 2)

— The half-shafts are fixed to the planet gear carrier flange of the epicyclic reduction unit by means of a plate inserted
in the flange and attached to the internal face of the half-shaft by a screw.

— The correct position of the half-shaft in the trumpet housing is determined by the shim pack A indicated in figure 2.

To install the half-shafts, proceed as follows:

— secure the half-shaft in a vertical position to prevent its rotation;

— press the rings of bearings B and C into the respective housings in the trumpet housing; (before installing the ring of
bearing C, position the cover underneath to retain the grease);

— then fit spacer I, oil seal D and bearing E to the half-shaft. Slide the trumpet housing onto the half-shaft, fit oil seal H
and bearing F, then position the planet carriers;

— secure the assembly by way of the plate and screw G, interposing a shim pack A between the plate and the half-shaft
to obtain a rolling drag torque of 8 to 12 Nm;

— apply LOCTITE 270 to screw G and tighten to a torque of 18 kgm (177 Nm).

199
 4 Drive axles - axles
44 Rear axle

Fig. 2 - Fitting of rear stub axles.

Fig. 3 - Fitting of rear stub axles. Fig. 4 - Halfshaft securing plate.

A - Planet carrier housing
B - Spacer

200
 Drive axles - axles 4
Rear axle 44

Fig. 5 - Fitting of bearing to halfshaft.

Fig. 6 - Fitting of O-ring to stub axles.

201
 4 Drive axles - axles
44 Rear axle

Removal and disassembly of the epicyclic reduction unit

Unscrew the three screws securing the planet carrier B ( Fig. 7) to the half-shaft.

Then remove the spacer and the flange, and recover the underlying shim pack.

Remove the epicyclic reduction unit and disassemble it into its component parts as follows:

1 - using a hammer and drift, remove the pin securing journal A of planet gear B (Fig. 8).

2 - withdraw the journal and remove the planet gear together with the roller cage and the two thrust washers.

3 - Remove bearing A from the flange of epicyclic reduction unit B, using a suitable puller (Fig. 9).

Fig. 7 - Removing the spacer.

A - Flange
B - Planet carrier

Fig. 8 - Epicyclic reduction unit. Fig. 9 - Removing the bearing from the epicyclic reduction unit flange.
A - Journal
B - Planet

202
 Drive axles - axles 4
Rear axle 44

FITTING LATERAL STUB AXLES OF THE WHEEL

Fig. 10 - Before installing the trumpet housing, position slee- Fig. 11 - Position the inner half-shaft in the differential hou-
ve A of the synchronised P.T.O.. sing.

Fig. 12 - Fit the differential housing support flange and then Fig. 13 - Install the thrust plate of the brake disc. The side
install the brake piston and brake disc. shown in the figure is to be positioned in contact with the bra-
ke disc.

Fig. 14 - View showing the side of the brake disc thrust plate
to be positioned in contact with the ring gear of the epicyclic Fig. 15 - Fit the trumpet housing with the aid of a hoist.
reduction unit.

203
 4 Drive axles - axles
42 2 W.D. extendible axle

2WD extendible axle

General information

The wide sideways front axle swinging obtained through excellent anchoring, not only makes it possible to operate the
tractor nimbly on steep slopes but also permits the axle to be easily removed from the tractor when any repair is to be
performed. End play check is the only operation required on axle reassembly.

The telescopic-type axle is extremely rugged and enables the tread to be adapted to any work requirements without re-
moving the hydrostatic steering cylinders.

Fig. 1 - Extendible front axle pivot system.

Tecnical specifications

front axle DORADO 55 - 60 - 65 - 70 - 75 - 85

tread
- minimum mm 1300
- base mm 1400
- maximum mm 1600
toe-in mm 2÷4
wheel caster angle 3°
axle swinging angle 10°
tyre inflating pressure
bar 2,4
Kg/cm² 2,40
lubricating grease type NGLI 2 LITIO / Ca
steering angle 70°

204
 Drive axles - axles 4
2 W.D. extendible axle 42

Fig. 2 - Front axle assembly parts.

1 steering track rod 11 shoulder ring 21 wheel hub 31 shims

2 clamp 12 bushing 22 spacer ring 32 pin
3 sleeve 13 seal ring 23 internal bearing 33 disk
4 ball-and-socket joint 14 bushing 24 retaining ring 34 lower taper roller bearing
5 external steering lever 15 side LH axle 25 wheel shaft 35 centre steering lever
6 ubricating nipple 16 cover 26 O.ring 36 upper taper roller bearing
7 snap ring 17 seal ring 27 axial bearing 37 cover
8 thrust ring 18 castellated nut 28 pin 38 spacer ring
9 seal ring 19 shoulder ring 29 centre axle
10 power steering cylinder 20 external bearing 30 axle securing pin

205
 4 Drive axles - axles
42 2 W.D. extendible axle

Removing the axle from the front support

Fig. 3 - Place some suitable vessels beneath the steering Fig. 4 - Loosen both securing screws of pin A to axle support
control cylinders, then loosen unions A of control cylinders C B.
from hoses B side.

Fig. 5 - Using a hammer and light-alloy punch tap on rear end Fig. 6 - By way of both levers A withdraw pin B forward and re -
of pin A. cover the shims interposed between flange and front support.
Ensure the securing pin surface shows no flattening, craking
WARNING: Keep the two shim packs separated so that the or chipping, replace the pin if necessary.
correct position can be restored on reassembly.

Fig. 7 - Remove the axle from the front support by tapping a Fig. 8 - Ensure that bushes A of the centre axle are not worn,
few times the axle centre portion with the hammer. checking for well-evident indentations, remove the bushes by
Lower axle A very slowly and make sure that it does not touch hammer and punch if necessary.
other parts in the process, then remove shoulder rings B.

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 Drive axles - axles 4
2 W.D. extendible axle 42

Carry out installation according to the following procedure:

— Use very fine abrasive paper to remove any signs of — Place rear shoulder ring D and push the pin almost
oxidation from both pin and front support; fully inward;

— Fit shims G adjusting as instructed on page 216 and

— Bushes and pin should be properly lubricated with then fasten front axle pin securing screws H;
the specified grease type;
— Top up the oil in the hydrostatic steering system and
— Coat the front support shoulder rings with grease to bleed the air from the system (see chapter on hydro -
make positioning easier; static steering).

— Making use of a hammer and light alloy punch tap

on spacer F so as it may be moved toward the front
side;

— Insert pin E into the spacer and fit front shoulder ring
B;

— Lift the axle and insert the pin into bush C;

A Front carrier
B Front thrust plate
C Axle bushes
D Rear thrust plate
E Pin
F Spacer
G Shims
H Bolt

Fig.9 - Front axle longitudinal section.

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 4 Drive axles - axles
42 2 W.D. extendible axle

A Snap ring
B Thrust ring
C Seal ring
D Power steering cylinder
E Grease nipple
F Pin
G Castellated nut

Fig. 10 - Assale anteriore

— Check steering rod ball-and-socket joints for dama-

A Castellated nut ge or wear and make sure the are able to rotate fre-
B Ball-and-socket joint
C External steering ely and without excessive play inside their seats.
lever
— Ensure the rubber ball joint guard is intact, otherwi-
se replace the ball joints.

— Examine the operating rods for damage or warping.

Replace if required.

Fig. 12 - Steering linkage.

A Steering rods
B Ball-and-socket joints
Fig. 11 - Steering arms. C Centre steering lever

208
 Drive axles - axles 4
2 W.D. extendible axle 42

Centre steering lever

— Use a universal puller to remove centre lever A together with

bearing B.

— Still using a universal puller (see fig. 15) remove bearing C and
disk B along with O-ring A.

— Make sure the centre lever is not warped or damaged, otherwi- Fig. 13 - Centre steering lever.
se replace. A Centre steering lever
B External bearing races

— Carefully examine the bearings turning them slowly, if the bea-

ring is sound no vibrations, noise nor slight jam-ups shall be
felt.

— Fix centre lever A in a vice if required, and using a light-alloy

hammer and punch remove tapered bearing outside races B,
located in the centre hole (Fig. 14), taking care to remove first
the upper race having smaller diameter by tapping from inside
outward.
Fig. 14 - Centre steering lever bearing.
A Centre steering lever
B Upper tapered-roller bearing
— Re-install the centre lever operating in reversed removing or-
der and accordingly with the following procedure:

– Before assembly carefully lubricate the tapered-roller bearings

and related races.

– Before mounting the lower bearing in the axle fit a new disk and a
new O-ring.

– When installing the castellated nut keep to the following instruc-

tions:

– Tighten the nut fully to bed the bearings properly

– Loosen the nut and tighten again until all plays have been taken up,
then fit a new check pin.
If the hole in the pin is not in the same line as the cut in the nut, tig-
hten the nut furtherly as long as a new check pin can be inserted.

— When the reassembly is completed perform pin and bearing lu-

brication with the specified grease type just operating the lubri-
cating nipples placed on the lever.

Fig. 15 - Removing the centre steering lever Cbe-

aring.
A O.ring
B Disk
C Tapered-roller bearing

209
 4 Drive axles - axles
42 2 W.D. extendible axle

Fig. 19 - Wheel hub components.

A Ball bearing D Ball bearing
B Spacer E Oil seal
C Hub
Fig. 16 - Removing the wheel hub.
A Tractor wheel
B Safety stand
C Front axle Wheel hub
— Using a universal puller withdraw whole wheel hub B from pin,
(Fig. 18) .
— Make use of a suitable puller to remove front ball bearing A and
take spacer B, (Fig. 19).
— Remove retaining ring E by prising, then using a proper puller
remove rear ball bearing D, (Fig. 19).
— Before assembly coat bearings B and D and new retaining ring
A with the recommended grease, (Fig. 20).
— Carefully insert retaining ring A using a light-alloy hammer and
punch.
— Install wheel hub C onto pin G tapping slightly with the hammer
for proper bedding.
— Tighten castellated nut E to the prescribed torque.
— Make sure the nut cut is duly aligned with the check pin hole in
the pin, otherwise tighten the nut furtherly to make them coinci-
Fig. 17 - Removing the guard cover. ding and re-install the check pin.
A Check pin — Ensure wheel hub C end play is 0.12 to 0.48 mm with respect to
B Gasket
C Cover wheel shaft pin G.
D Hub
E Nut

Fig. 20 - Section view of the wheel hub.

A Oil seal E - Castellated nut
B Innner ball bearing F - Thrust plate
C Whel hub G - Whel shaft pin
Fig. 18 - Using a puller to remove the wheel hub. D Outer ball bearing H - Space
A Wheel hub shaft pin
B Whole wheel hub

210
 Drive axles - axles 4
2 W.D. extendible axle 42

Inspections and checks

Clean bearings and the other parts carefully, then dry using com-
pressed air.
Carefully examine the bearings turning them slowly, if the bearing
is sound no vibrations, noise nor slight jam-ups shall be felt.

Carefully examine bearing race and rolling member conditions en-

suring no scoring, marking, grinding signs due to foreign matter
abrasion are noticed, otherwise replace the bearing.

WARNING: Should a bearing be no more serviceable, both the in-

ternal and the external bearings must be replaced. Fig. 21 - Wheel hub lubricating hole.
A Clearance hole
B Wheel huba
Make sure the wheel shaft has suffered no damage and threading
is whole, replace if required.

Ascertain clearance hole A permitting the external cover to be fi-

xed is not obstructed by foreign matters, if so remove any clogging
to allow hub B to be properly lubricated.
Wash any components carefully and dry with compressed air.

Be sure no signs of oxidation are visible on the wheel shaft, if so

remove with very fine abrasive paper.

Check the shaft for either warp or damage, if so replace the shaft.
Carefully inspect the axial bearing making sure no grinding, sco-
ring or marking are evident neither on the rolling members nor on
the bearing races, otherwise replace the worn parts.

Check side axle upper and lower bushes B for wear, ascertaining
they still show evidence of the purpose-made indentations, other- Fig. 22 - Removing the steering lever.
wise replace. A External steering lever
B Gasket
C Wheel shaft

Fig. 23 - Removing the wheel pivot axial bearing.

A Wheel shaft
B Axial bearing
Fig. 24 - Wheel pivot bushes. C O.ring
A Clearance hole D Axial bearing race

211
 4 Drive axles - axles
42 2 W.D. extendible axle

Correct track rod assembly (Fig. 25).

Rotate sleeve A around its axis so that knuckle B is in the position
shown in figure, i.e. make sure the knuckle working angle is 90°,
then insert and tighten both the sleeve securing bolts.

End float adjustment (Fig. 26).

Push the axle towards the rear and, using a feeler gauge, check
that the maximum end float “G” does not exceed 0.4 mm.

— If the end float exceeds this value, proceed as follows.

— Unscrew bolts E securing pin B to the front carrier A;

— Slightly move the pin and remove some of shims D to restore

correct end float.

— Re-tighten bolts E and check end float again.

Fig. 26 - Track rods.

A Sleeve
B Steering knuckle

Fig. 25 - Adjusting the endfloat of the front axle .

A Front carrier
B Pin
C Thrust plate
D Shims
E Bolt

212
 Drive axles - axles 4
4 W.D. front axle 43

FRONT-WHEEL DRIVE

Specifications
Front drive axle ratios

reduction gear-front-wheel drive

30 km/h 21/47 = 1/2,2381
40 km/h 28/47 = 1/1,6786
bevel gears (13/13+50) = 1/4,8462
final epicyclic reducer 1/23,8618
total reduction
30 km/h 1/23,8618
40 km/h 1/17,8966
mechanical ratio
(number of front wheel turns for each rear wheel turn)
30 km/h 1,3790
40 km/h 1,3830
bevel gear teeth backlash mm 0,15 ÷ 0,20
front drive axle end play 0,1 ÷ 0,4
front drive axle swinging 10°
steering angle 50°
toe-in see specification table here below
wheel caster angle 7°
camber 1°
Check value for the adjusting the bevel gears mm 1

Fig. 1 - Measuring front wheel toe-in and front wheel geometry.

Adjusting toe-in
Adjust the front wheel tie rod so as the difference A-B shown in figure 1 is:

wheel rim keying diamete r A-B mm

2RM 4RM
up to 20” (508 mm) 2÷6 0±2
from 20” to 30” (509 ÷ 762 mm) 2÷6 0±3
over 302 2÷6 0 ± 3,5

Adjusting steering angles

Make sure the front drive wheel steering angle is as specified in the table
above.
Otherwise adjust by way of the special setscrews or spacers. Fig. 2 - Front-wheel drive steering angles.

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 4 Drive axles - axles
43 4 W.D. front axle

Inspections and checks

Carry out a thorough check and adjust the end play as follows:

— Move the axle forward tapping with a non-ferrous metal ham-

mer.

— Use thickness gauge A (see Fig. 4), to make sure that the end
play between shoulder ring B and differential housing C is wit-
hin specifications given in the related table (see page 213).
If the end play is correct loosen the four nuts securing front swi-
vel support C to drive axle A (see Fig. 5) and add or remove a
number of shims B enough to obtain the recommended end
Fig. 3 - Removing/Installing the front drive axle. play.
A Swivel supports
B Front axle
C Spacers
D Swivel support — Bleed the air from the brake system.

— Check the toe-in and adjust the differential lock operating rod if
necessary.

— Tighten the swivel support securing nuts to the specified tor-

que.

Swivel support securing nuts

front 89 Nm (9,1 Kgm)

rear 142 Nm (14,5 Kgm)
Fig. 4 - Checking the front axle end play.
A Thickness gauge
B Shoulder ring
C Differential housing

Fig. 6 - Power steering cylinder securing pin.

A Pin securing pin
Fig. 5 - Front axle end play check point. B Power steering cylinder fixing pin
A Front drive axle C Power steering hydraulic cylinder
B Shims D Dust cover
C Front swivel support E Spacers

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 Drive axles - axles 4
4 W.D. front axle 43

Fig. 7 - Longitudinal section of the front-wheel drive.

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 4 Drive axles - axles
43 4 W.D. front axle

Fig.8 - Views and sections of the front-wheel drive.

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 Drive axles - axles 4
4 W.D. front axle 43

Final epicyclic reducer

Disassembling the hub

1 - If the operation involves the bevel gear pair, removal is enabled

simply by extracting the two hub swivel pins; the hub can then be
distanced together with the halfshaft.

2 - If the operation involves the hub, proceed as follows:

— remove the protective cap located at the centre of the epicyclic
housing.
— remove the circlip from its groove.
— fit puller p/n 5.9030.618.4/10 and remove the flange (see fig 9).
— remove the circlip from the groove at the end of the halfshaft.
— screw two bolts into the holes indicated by the arrows (see fig
9) and separate the hub from the epicyclic housing.

Fig. 9 - Removing the hub flange with SAT no.

WARNING: Use a non-ferrous metal hammer and punch to tap on 5.9030.618.4/10 tool.
ferrous parts for removal if necessary.

Stripping down the epicyclic (fig. 10)

Remove the ten securing bolts from the flange of the housing, then
remove the flange and the shims beneath.
Rest epicyclic reducer A on two wooden blocks as shown in figure
and using a press and a punch operate on planetary carrier case
centre B until the planetary carrier, bearing C and seal ring D can
be removed from the bottom.

NOTE: If oil leaks are noticed from seal ring D, this ring can be re-
moved from its groove without requiring the planetary carrier case
to be dismounted.

In any case, when seal ring D is removed the damage it usually

has to undergo is to such an extent to require replacement.
Tap with a hammer and a punch on bearings C and E when ha-
ving to remove, if necessary.
Take planetaries A securing pins B; remove the planetaries and
take roller cages C.

Fig. 10 - Disassembling the epicyclic reducer.

Installation the hub A Epicyclic reduction gear
Re-install the disassembled bearing C (Fig.10), in the planetary B Planetary carrier case
carrier case paying attention to the assembly direction. C Bearing
Install planetaries B with bearings C (Fig.11) into the planetary
carrier case taking care to turn the pin dogs towards the hub cen-
tre. Make the planetary and the crown wheel teeth match avoiding
any damaging when inserting the planetary carrier into the exter-
nal case.
Install bearing C (Fig.10) if previously disassembled, use a ham-
mer and a punch to tap slightly and evenly on the outer race surfa-
ce.

Shimming epicyclic reducer bearings

Fit a number of shims between the planetary carrier flange and the
pin fixing plate, until the bearing rotate freely, even though a slight
Fig. 11 - Epicylic reduction gear planetaries.
bearing preloading can be felt, then remove one 0.05 mm shim A Pins
from the shim pack. B Planetaries
Fit a new seal ring . C Roller cage

217
 4 Drive axles - axles
43 4 W.D. front axle

The following procedure should be observed on re-

assembly:

1 - Brakes
Replace the brake control piston O-rings and insert piston in its
seat with the oil grooves turned outwards.

2 - Final epicyclic reducer

Install the final epicyclic reducer holding the axle shaft in position
as shown in figure 12 by prising on cross journal A outwards; this
to prevent the axle shaft from moving inwards.

3 - Axle shafts
When inserting the axle shaft pay attention not to damage the rol-
ler bearing or the seal ring.
The axle shaft end should be correctly introduced into the differen-
tial gear planetaries.
Make sure the axle shaft is free to rotate without any hindrance.

4 -Forks
After installing the bearings and the dust rings mount the fork by
placing one 0.5 mm shim under the lower pin, then fit the pin, use a
Fig. 12 - Prising with a lever to hold the axle shaft
in position when mounting the final epicyclic re- hammer if necessary, finally tighten the securing screws.
ducer.

Fit a pack of shims thicker than the one taken on removal under
the upper pin. Install the pin tightening the securing screws.

Adjusting wheel fork bearing preloading

In the pack of shim to be put together for adjustment it is always
advisable to group more shims in one: as an example, it is better
one 0,2 mm shim be used instead of two 0,1 mm shims.
Fit no. 5.9030.267.0 magnetic base with no. 5.9030.272.0 cente-
simal dial gauge onto the drive axle and then place the gauge fee-
ler perpendicularly to the lower pin close to centre and set to zero.
Using lever A as shown in figure 13, move the fork fully upwards
and read the clearance on gauge dial.
Loosen the two screws B and remove shims from pack C so that
any clearance may be taken up without preloading the bearings.

WARNING: The clearance amount should be reduced gradually

by repeating reading with the dial gauge each time so that the bea-
rings are not preloaded.
After all clearance has been taken up, remove a 0.10 to 0.15 mm
shim pack, so that a correct bearing preloading can be obtained.
Tighten screws B and D to the specified torque.
Fig. 13 - Checking wheel hub clearance.
A Lever
B Screws After correctly performing adjustment, ensure the shaft taper roller
C Pack of shims bearing slide in their seats freely, even though a slight preloading
D Screws
E 0.5 mm shim. is felt.

218
 Drive axles - axles 4
4 W.D. front axle 43

Side hubs

Disassemble the twin universal joints if required, keeping to the following procedure:

— Remove both snap rings A from one cross journal B. A non-ferrous metal hammer and punch may help in carrying
out this operation, (see Fig. 14).

— Fix the joint fork in a vice provided with protective jaws.

— Tap with a hammer on wheel shaft fork A (see Fig. 16), so that the bearing may be removed from its seat in fork A and
taken from the top. Separate cross joint D from the fork.

— Following the same procedure separate the cross joint from the universal joint fork as well as from the axle shaft fork.

— Recover bearing rollers A along with dust rings B.

Fig. 14 - Twin universal joint.

A Snap ring
B Twin universal joint cross journal

Fig. 15 - Axle shaft twin-type universal joint bearing. Fig. 16 - Disassembling the twin-type universal
1 Rollers joint from the axle shaft.
2 Dust rings A Wheel shaft forks
B Roller bearing
C Roller bearing
D Cross joint

219
 4 Drive axles - axles
43 4 W.D. front axle

Pins
Check differential spider pin and final epicyclic reducer planetary holder pin surfaces for damaging; otherwise both
pins are to be replaced.
Follow the same procedure for pin housings.

Axle shafts
Check for excessive wear: splines should not be nicked and permit a free gear movement.

Spider forks should not be warped and bearings shall slide freely.

Gears
Make sure all gear toothing is neither worn nor damaged, teeth should work on the whole contact face.

Bearings
Examine bearings for proper working conditions, ensure they show neither excessive radial nor end play.

Holding the bearings pressed by hand and making simultaneously turn in both directions of rotation, these should slide
freely and no sliding friction felt.

Tightening torques
Before tightening all screws should be degreased and cleaned.

Kgm Nm
Differential/bevel gear securing screws 6 ÷ 6,5 58 ÷ 64
Bevel pinion fixing nut 21 ÷ 23 206 ÷ 226
Bearing holding flange securing screws 3 29
Fork flange securing screws 7÷8 68 ÷ 78

Axle swivelling pivot securing screws

- rear pin 14,5 142
- front pin 9,1 89
Engine front support securing screws 28 274
Hydraulic cylinder fixing pin 16 157
Ball-and-socket joint castellated nuts 12 119
Transmission shaft flange securing screws * 5 49
Differential housing half securing screws 11,5 ÷ 12 113 ÷ 118
* Coat the nut with a small amount of Loctite 242.

Check periodically that the wheel bolts are correctly tightened.

— Front wheel bolts 2RM (M20x1,5) 50 kgm (490 Nm)

4RM (M18x1,5) 36,8 kgm (360 Nm)
— Front wheel bolts (M20x1,5) 50 kgm (490 Nm)

220
 Drive axles - axles 4
4 W.D. front axle 43

Installing the waterproof seal

A inner half-shaft
B outer half-shaft
C pinion
D hub
E pinion
X outline plug

Using a suitable installation tool, install the seals oriented as

shown in the figure and pressing them to the full depth of the
installation tool.
The measurements indicated here are to be used to con-
struct the oil seal installation tool.

Fig. 17 - Waterproof seals.

221
 4 Drive axles - axles
43 4 W.D. front axle

Réglage du couple conique.

1 - Monter le boîtier de différentiel en interposant entre les fla-
sques-supports de roulements une épaisseur de cales jusqu’à ob-
tenir une précontrainte des roulements de 0,04 mm.

2 - Déposer à nouveau le boîtier de différentiel et monter le pignon

en interposant un jeu de cales A de 0,50 mm et un jeu de cales B
pour permettre, après avoir serré l’écrou au couple de 21 ÷ 23
kgm (206 ÷ 226 Nm), la libre rotation des roulements dans leurs lo-
gements respectifs malgré une légère précontrainte (ne doit pas
être supérieure à 0,04 mm).

Fig. 18 – Mise en place d’épaisseur de cales pour 3 - Régler la distance E boîtier de différentiel-tête du pignon en
roulements de pignon. agissant sur le jeu de cales A.

La mesure exacte pour cette opération s’obtient en additionnant

ou en retranchant de la valeur gravée sur le profil d’une dent du pi-
gnon la valeur de 1 mm.
Remarque: après avoir réglé la distance entre le boîtier de diffé -
rentiel et la tête du pignon, il faut refaire le réglage de la précontra-
inte, pour détérminer à nouveau le jeu de cales B.

4 - Remonter le boîtier de différentiel et vérifier avec un compara-

teur le jeu d’entredent pignon-couronne: il doit être de 0,15 ÷ 0,20
mm; si ce n’est pas le cas, enlever des cales au jeu C et les ajouter
au jeu D pour approcher la couronne au pignon et vice versa pour
l’éloigner de celui-ci.
Fig. 19 – Mesure du jeu d’entredent pignon/cou-
ronne pour le réglage du couple conique.

Fig. 20 - Réglage du couple conique.

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 Drive axles - axles 4
4 W.D. front axle 43

Réglage interne du blocage de différentiel de type

mécanique (Fig. 22).
(Pour le réglage de la commande extérieure, voir chapitre “com-
mandes”).

1 - Assembler les pièces en plaçant l’épaisseur de cales A du côté

du circlip B; l’épaisseur de cales mise doit faire en sorte que le jeu
de l’entretoise C soit de 0 ± 0,05 mm.

2 - Déplacer un certain nombre de cales du jeu A dans la position

G jusqu’à obtention du déplacement du manchon D en position
d’enclenchement.

REMARQUE – Le déplacement des cales doit se faire par jeu

d’une épaisseur non supérieure à 0,20 mm. L’enclenchement du
manchon D sera correct quand le manchon recouvrira les billes F
sans forcer pour se mettre dans la position indiquée par le repère
E Fig. 22.

Montage du différentiel dans le pont

Fig. 21 - Orientation du différentiel dans le pont.
Orienter le groupe de manière que le manchon du blocage de dif-
férentiel se situe du même côté du levier interne de commande.

Le manchon devra être déplacé vers l’extérieur afin de permettre

aux patins du levier de s’engager dans la gorge.
Après le montage du différentiel dans le pont, contrôler
l’enclenchement du blocage en actionnant le levier et en tournant
manuellement le pignon d’attaque.

Fig. 23 – Contrôle de la distance tête de pignon-surface rectifiée du boî- Fig. 22 - Réglage du blocage de différentiel.
tier de différentiel.
A Jauge d’épaisseur
B Tête pignon
C Axe porte-satellites

223
 4 Drive axles - axles
43 4 W.D. front axle

Diagnostic des inconvénients

pont avant surchargé n’employer que des prévoir le lestage

Usure des croisillons à chargeurs frontaux arrière du tracteur
cardan reconnus par le
constructeur

contrôler l’usure des changer les ba-

bagues d’étanchéité gues usées

Pertes d’huile

reniflard d’huile obs- nettoyer

trué

n’utiliser la double excessive exploita- monter des pneus

usure uniforme traction que sur ter- tion du tracteur pour convenables
rain agricole transports routiers
Usure des pneus

usure non uniforme contrôler le pince- prévoir le réglage

ment des roues

contrôler l’usure si nécessaire pré-

des pneus voir la substitution

contrôler l’usure des si nécessaire pré-

Oscillation des roues articulation de direc- voir la substitution
tion

contrôler les roule- régler et les rempla-

ments coniques du cer si nécessaire
moyeu

224
 Vehicle 5
Brakes 54

Brakes
General information
The service brakes are located between gearbox and final epicyclic
reducers and assure a precise and safe braking action. In addition,
the four-wheel drive tractor models are also equipped with integral
braking system providing braking on all tractor wheels.
The braking system is sintered-lining, oil-immersed disk type. The
right-hand brake control is completely independent from the
left-hand brake control; this allows the tractor turning radius to be
conveniently reduced (this operation is only possible when wor-
king on farm land and never during transport operations on public
roads).
Fig. 1 - Front service brakes.
The braking system is provided with the “SEPARATE BRAKES”
valve which enables the front wheel braking to be excluded.

Each brake pedal controls a hydraulic pump which delivers oil under
pressure to a disk thrust plate, which causes the brake disk to lock.
Operating both brake pedals simulteneously by coupling them
with the special joining latch, opens an oil duct connecting both
hydraulic circuits to balance the baking pressure on the wheels.
Brake maintenance is limited to an easy adjustment and a system
air bleeding if necessary.

The parking brake has mechanical control and acts on transmis-

sion downstream of gearbox.
Pulling the control lever upwards makes the brake disks pack to-
gether thus locking the shaft being constantly meshed with the
wheels.
Maintenance is very easy and consists of replacing the friction
pads when worn or adjusting the control lever travel.

Fig. 2 - Parking brake parts.

Specifications

service brakes front rear

2WD 4WD
Manufacturer SDFG
Type oil-immersed disks
number of disks each brake 2 (each side) 1 (each side) 1 (each side)
brake disk outside diameter mm 223,4 223,4 280
original brake disk thickness mm 4,80 4,80 7
brake disk minimum thickness allowable mm 4,40 4,40 6
brake pedal free travel mm 40
braking piston max. Play mm 1,15
thydraulic pump type Benditalia Ø 1’’
parking brake
brake type oil-immersed disks
number of braking pads double braking surface n° 2
single braking surface n° 2
original braking pad thickness double mm 5
single mm 3,5
braking pad minimum thickness allowable double mm 4,3
single mm 3,2
brake disk number 3
parking brake control lever travel mm 100

225
 5 Vehicle
54 Brakes

A - Oil tank
B - Oil delivery pipes
C - Oil pumps
D - Pumps connection pipe
E - Brake pedal coupling latch
F - Block for types without front brakes
G - SEPARATE BRAKES valve
H - Brake pedals
I - Parking brake lever
L - Toothed quadrant
M - Control rod

Fig. 3 - Brake control assembly parts.

Hydraulic pump

Disassebly and checking procedure

Referring to fig 4:
— Remove guard boot A, take snap ring B and withdraw rod C
along with the support disk.

Referring to fig 6:
— Fix the pump in a vice provided with protective jaws and pu-
shing pistons into the pump partly, as shown in figure 6, loosen
the piston retaining screws and then remove the pistons toget-
Fig. 4 - Brake pump control unit. her with the spring down below.

226
 Vehicle 5
Brakes 54

A - Pump G - Snap ring P - Piston Z - Fork

B - Delivery pipe H - Spacer Q - Seal ring X - Stop screw
union I - Seal ring R - Rod Y - Gasket
C - Delivery pipe L- Intermediate piston S - Support disk K - Pump union pipe
D - Clamp M - Spring T - Snap ring
E - Pipe fitting N - Seal ring U - Guard boot
F- Spring O - Washer V - Nut

Fig. 5 - Brake pump assembly parts.

— Examine the cylinder interior and the pistons for either scoring
or rust. Replace if necessary.

— Check cylinder and pistons for wear. If excessive plays are no-
ticed replace either the whole piston or the whole cylinder as-
sembly.

— Inspect sealing rings and dust guard boot, replace any worn
parts.

— Inspect all pump internal compartments, apertures and passa-

ges and make sure all is properly clean and free from foreign
matters.

— Ensure the springs are neither yielded nor warped. Replace if

necessary.

Fig. 6 - Piston retaining screw.

227
 5 Vehicle
54 Brakes

1 - Spring 12 - Guard boot

2 - Pump 13 - Rod
3 - Intermediate piston 14 - Nut
4 - Spring 15 - Fork
5 - Pipe fitting 16 - Snap ring
6 - Gasket 17 - Gasket
7 - Seal ring 18 - Stop screw
8 - Washer 19 - Seal ring
9 - Piston 20 - Seal ring
10 - Seal ring 21 - Spacer
11 - Support disk 22 - Snap ring

Fig. 7 - section of the brake pump.

Assembly of brake master cylinder (see fig 5).

Screw the front piston L and the rear piston P together, then check
that there is clearance between the two.
Insert the pistons into the cylinder, checking that the recess affor-
ded by the outer piston P is aligned correctly with the seat of the li-
miter screw X.

Verify correct operation of the cylinder, making certain that the pi-
stons complete their full travel freely.

Fig. 8 - Installing the front brake disk pressure pi-

ston seal ring.

Fig. 10 - Brake assembly.

A - Brake disks
B - Intermediate disk
Fig. 9 - Brake assembly flange. C - Brake control piston
A - Brake assembly flange

228
 Vehicle 5
Brakes 54

Checking the front brake disks on 2WD and 4WD

front axles and the rear brake disks.
Check the ground surfaces contacting the brake disks for excessi-
ve scoring.
If excess wear is found replace the worn-out parts.

Check disk conditions and tickness, compare with specifications

table.

Examine the brake disk broaching for wear or damage.

If excessive oil consumption is noticed, check the piston rings as

follows: Fig. 11 - Brake housing.
A - Locating dowels.
Connect no. 5.9030.520.4 hydraulic pump to the oil delivery circu- B - Brake housing
it; if the hydraulic circuit is not fully oil-tight under a 1,5 bar pressu-
re, the rings must be replaced. (To check the effectiveness of the
seals more accurately, blow compressed air around the perimeter
of the seal; if air bubbles appear, the seal is imperfect).

Check each brake.

For 4WD front brakes and rear brakes only

Mark piston and brake housing case with a reference near to a lo-
cating pin so as to make reassembly easier.

Coat the brake housing case seal ring contacting surfaces of pi- Fig. 12 - Greasing the seal contact surface of the
ston A with recommended grease, see figure 11. brake piston.
A - Piston
Carefully mount piston into the brake housing case.

Fit the brake housings and halfshaft trumpet housings, repeating

the removal operations in reverse order and observing the follo-
wing directions.

Coat the brake housing case inner surface as well as both

epicyclic gear crown wheel surfaces with recommended sealant.

Tighten the securing nuts of the brake housings and trumpet hou-
sings to the prescribed torque (see values below).

- brake housing bolts: 3,3 ÷ 4,1 (32 ÷ 42)

- trumpet housing bolts: 8,6 ÷ 9,6 (84 ÷ 94) Fig. 13 - Rear brake assembly.

Adjusting service brake pedals

Operate right-hand pump fork A (figure 14) to adjust brake pedal
position, until the most suited position for the operator is attained,
and in such a way that the pedal may complete its whole travel fre-
ely when braking.

Operate left-hand pump forkB (figure 14) to adjust the related bra-
ke pedal so that the coupling latch holes are in the same line.

Fig. 14 - Adjusting the brake pedals.

229
 4 Vehicle
54 Brakes

Fig. 14 - Rear brakes for 2WD front axle.

Fig. 15 - Parking brake inspection window

Correct installation of inspection cover for parking brake discs

Before fitting the cover, apply the sealant PIANERMETIC 510 to the surfaces in contact with the gearbox (marked A in
the figure), then tighten the three screws marked B in the figure to a torque of 5.8 kgm (55 Nm).
Check that with the control lever positioned at angle of approx. 40° relative to the horizontal, the brake play is that indica-
ted in the figure. If the play exceeds this value, replace disc C with the single braking surface with a discs with a double
braking surface (to recover 1mm of play). Alternatively insert a shim (code 009.9648.0) between the disc C and the re-
action plate (to recover 2mm of play).

230
 Vehicle 5
Brakes 54

Fig. 17 - Section view of 4WD front brakes.

Fig. 18 - Section view of rear brakes.

231
 5 Vehicle
54 Brakes

The parking brake, completely independent from the service bra-

kes, is applied by pulling the special hand lever upwards.

Once the parking brake is applied the related pilot lamp on the da-
shboard lights up.

Checking parking brake pads

Examine the brake pads for wear. If brake pad thickness is out of
specifications these shall be replaced.

Brake pads can be dismounted after removing the lower brake

pad lockpin, this permits access through the cover placed under
the gearbox to be gained.

Before installing new brake pads, check lockpin seal ring condi-
tions, replace if necessary.

Parking brake control lever overall travel

This travel should be 100 mm, otherwise operate the special adju-
sting screw until the specified dimension is obtained.
Fig. 19 - Parking brakechecking and adjusting di-
mension.

Fig. 20 - Parking brake. Measuring the brake disk thickness.

232
 Vehicle 5
Brakes 54

Fig. 21 - Parking brake assembly; (A- Brakes disk).

Bleeding air from the brake hydraulic system

Operate as follows:

— unhook pedals by removing the coupling latch: afterwards pla-

ce the “SEPARATE BRAKES” valve control in OFF position;
— operate the right-hand brake pedal several times;
— by holding the pedal in fully depressed position, slightly un-
screw and tighten soon after the relevant air bleeding valve on
the rear right-hand brake.

This operation should be repeated until such time as the oil flows
out of the bleeding valve without air bubbles. Fig. 22 - Bleeding the air from the rear service
brake hydraulic system.
Repeat the same procedure on the front right-hand brake by ac-
ting on the related air bleeding valve.

Follow the same procedure on the front and rear left-hand brakes
making use of the related air bleeding valves.

We recommend that only oil AKROS MATIC (with inter-

national specifications ATF DEXRON II) used in the bra-
king system.
Fig. 23 - Bleeding the air from the front service
brake hydraulic system.

233
 5 Vehicle
54 Brakes

“Separate Brakes” valve

The “SEPARATE BRAKES” valve permits the front wheel si-
de-slip to be removed when performing independent braking.
(This prevents cultivation damage as the front wheel is under no
braking action).

The valve operation can be stopped by operating the special con-

trol tap A.

When both brake pedals are operated at the same time (coupled
pedals), the braking of the four wheels will be always obtained.

IMPORTANT: The “idrostop” sensor must be installed in the

SEPARATE BRAKES valve housing, smearing Loctite 542 on the
screw thread.

A = LH brake pedal
B = RH brake pedal
Fig. 19 - Different braking action diagram.
C = Both when coupled

Hydraulic
connections
PR - Rear RH brake R - RH brake pedal pump
L - LH brake pedal pump AR - RH front brake
AL - Front LH brake PL - Rear LH brake
H - STOP pressure switch

Fig. 20 - “SEPARATE BRAKES” valve.

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Brakes 54

Fig. 26 - Hydraulic circuit diagram for SEPARATE BRAKES system

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 5 Vehicle
54 Brakes

Fig. 22 - Brake hydraulic system schematic diagram with tap in position “ON”.
A - oil pressure
B - discharge oil
Hydraulic connections R - RH brake pedal pump
PR - Rear RH brake AR - RH front brake
L - LH brake pedal pump AL - Front LH brake
PL - Rear LH brake H - STOP pressure switch

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Brakes 54

Fig. 23 - Brake hydraulic system schematic diagram with tap in position “OFF”
A - oil pressure
B - discharge oil
Hydraulic connections R - RH brake pedal pump
PR - Rear RH brake AR - RH front brake
L - LH brake pedal pump AL - Rear LH brake
PL - Front LH brake H - STOP pressure switch

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 5 Vehicle
54 Brakes

Diagnosing malfunctions

make sure no air is bleed the air

inside system

poor braking check for correct adjust

adjustment

check brake disks replace

for wear

bleed the air

make sure the re-
commended oil
type is used
replace
uneven braking

check for correct adjust

adjustment

make sure the re- replace

commended oil
type is used

noisy braking

check brakes disk replace

for wear

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 Vehicle 5
Hydraulic power-lift 59

Hydraulic lift with “load sensing”

The automatic draft control device, connected directly to the top link, guarantees rapid lift operation and is highly sensi-
tive to even minimal variations in the load on the implement.

The hydraulic lift is equipped with an internal cylinder positioned horizontally.

The hydraulic lift is equipped with an open-centre control valve.

The oil in the suction line is drawn from the gearbox by a high-capacity pump (the same pump supplies the auxiliary con-
trol valves) ‘and filtered through a filter with an interchangeable.
The oil under passes through the auxiliary control valves before arriving at the lift.

Fig. 1 - Lift lever shaft

Technical characteristics

manufacturer SAME DEUTZ-FAHR GROUP

lift type with open-centre control valve
safety valve setting bar 190 +010
minimum operating pressure bar 8
minimum permissible piston diameter mm 89,900
maximum permissible cylinder diameter mm 90,050
lifting capacity with load concentrated on lower link ball
ends at height of rear wheel centres kg 1600
tightening torque for cylinder retaining bolts kgm 15 - 16,5
Nm 150 - 165

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Installing the lift and front cover plate of

the gearbox

Install the two lift mounting studs (A in figu-

re) and the two cover plate retaining screws
(B in figure), applying Loctite 242 to the thre-
ads in both cases.

Fig. 2 - Fixing the front lift and the front cover to the gearbox

Fig. 3 - Lift unit components.

Lift mechanism
Inspect the splines for grooves or excessive wear; replace the le-
vers if necessary.
Inspect the splines of the lift shaft for excessive wear and check
that the machined surfaces in contact with the supports are not da-
maged; carefully clean the lubrication slots for the shaft supports.
At each dismantling, remove the seals and gaskets. Check that
there are no oil leaks from the lift cylinder.

Checking the safety valves

Check that the safety valve incorporated in the auxiliary control
valves is set to 190 bar.
Remember that to ensure the correct operation of the lift, the ope-
rating pressure in the lift circuit must not exceed 150 bar.
Fig. 4 - Hydraulic control valve.

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Hydraulic power-lift 59

Checking the protrusion of the non-return valve control pin B

Move the ball A so that rests on the valve body D, and move the valve body D so that it rests on the control valve hou-
sing, then insert pin B up against ball A (while making sure that the ball A does not move).

Check that the pin B protrudes 15.8 ÷ 0.05 mm as indicated in the figure.

Check that the moving parts slide freely

For the control vale to function properly, the following parts must slide freely:
- G - control valve spool
- K - pilot valve
- L - enabling valve

Checks to be carried out after re-assembly of the control valve.

- Check that the control valve spool slides freely.
After assembly of the control vale housing with the connection housing, check that the spool Gslides freely in its bore.
- Check coverage of lifting and lowering ports.
Push the spool G in the direction of arrow E until the point where lifting commences. From this point, move the
spool back in the direction of arrow F until lowering commences.
Check that the spool travel between the lifting and lowering positions is 0.6 to 0.8 mm.

- Check for leaks

Check that no part of the control valve leaks (plugs, check valve, etc.) at a pressure of 150 bar.

Apply Loctite 542 to all the control valve plugs before fitting.
The spring calibration values must match those specified in the tables.
For bench testing of the control valve use oil of the recommended type and a pump with a capacity of 10 to 15 l/min.
Warning: the presence of emulsified oil may prevent correct operation of the control valve.

P
15.8±0.05

L B
A
K D

F
G

Fig. 5 - Hydraulic control valve.

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59 Hydraulic power-lift - first version

1 - MAX. controlled draft

2 - Green sector - CONTROL
3 - MIN. controlled draft
4 - Lowering
5 - Red sector float
6 - Mixed control
7 - Yellow sector position
8 - Raising

Fig. 6 - Lift control adjustment diagram.

F - Position control lever (yellow knob)
G - Draft control lever (green knob)

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 Vehicle 5
Hydraulic power-lift 59

Adjusting the lift (Fig. 6)

Warning: before adjustment, attach a weight of approx. 200 kg to the 3-point hitch.

Adjust the forks of the external tie-rods of the lift control linkage so that the yellow lever and the green lever are free to
move the entire length of the control slot.

Adjusting the lift travel - YELLOW LEVER -

Start the engine, and move the yellow lever to the maximum lift position and move the green lever to position 12 in its
control slot.

Adjust screw E (fig. 6), so that it is up against its stop when the reference marks on the right-hand side of the lift housing
and the lift arm coincide.

If necessary, also adjust fork B of tie-rod A.

Adjusting the GREEN LEVER

Move the yellow lever to the position CONTR of its control slot, and check that when the green lever is moved from posi-
tion 12 towards 0, the lifting action commences when the lever is in correspondence with position 4.

If not, adjust fork D of tie-rod C.

Checking operation of the safety stop.

Move the green lever to the maximum lift position (position 0). The lift arms will be raised, rotating through a further an-
gle of approx. 4° (corresponding to a movement of the notch on the lift arm of 6 mm).

Checking balance.

With the yellow lever in the CONTR position, move the green lever from position 12 to 4 to find the point of balance (be-
fore the lifting action begins); check that when the counterweight applied to the lift arms is pulled upwards, the lift raises
the arms, and that when the counterweight is pushed downwards, the lift lowers the arms.

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59 Hydraulic power-lift

Yellow = Oil delivery to the hydraulic control valve

Blue = Oil flow from the control valve to the lowering valve
Green = Oil for piloting the valves
Red = Pressurised oil to the lift piston

1 - Valvematic
2 - Anti-shock valve
3 - Down valve
4 - Control valve
5 - Pilot valve
6 - Enabling valve
7 - Inlet valve
P - Pump
T - Return

Fig. 8 - Lift hydraulic circuit.

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Hydraulic power-lift 59

Yellow = Discharged oil

Red = Pressurized oil
Blue = Oil from hydraulic pump
Green = Oil trapped at relative pression

1 - Directional control valve

2 - Enabling valve
3 - Enabling pilot valve
4 - Unloading valve
5 - Down actuator piston
6 - Valvematic
7 - Inlet valve
8 - Anti shock valve

Fig. 9 - Hydraulic lift circuit - NEUTRAL

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Yellow = Discharged oil

Red = Pressurized oil
Blue = Oil from hydraulic pump
Green = Oil trapped at relative pression

1 - Directional control valve

2 - Enabling valve
3 - Enabling pilot valve
4 - Unloading valve
5 - Down actuator piston
6 - Valvematic
7 - Inlet valve
8 - Anti shock valve

Fig. 10 - Hydraulic lift circuit - RAISING

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Hydraulic power-lift 59

Yellow = Discharged oil

Red = Pressurized oil
Blue = Oil from hydraulic pump
Green = Oil trapped at relative pression

1 - Directional control valve

2 - Enabling valve
3 - Enabling pilot valve
4 - Unloading valve
5 - Down actuator piston
6 - Valvematic
7 - Inlet valve
8 - Anti shock valve

Fig. 11 - Hydraulic lift circuit - LOWERING

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59 Hydraulic power-lift

Fig. 12 - Control linkage for draft control.

Fig. 13 - Lift hydraulic control valve. Fig. 14 - Section views of the lift

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Hydraulic power-lift 59

Fig. 15 - Pins of the draft control and position control levers

Fig. 16 - Control linkage for draft control and stop screw for the position control lever

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59 Hydraulic power-lift

Fig. 17 - Top view of the lift.

Fig. 18 - Rear view of the lift.

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Hydraulic power-lift 59

Fig. 19 - Section views of the lift hydraulic control valve

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59 Hydraulic power-lift

Sensing arm assembly

· Install on screw A:
· ring B,
· spacer C,
· spring D,
· ring E,
· screw in nut F to take up all play.
– Screw in nut F a further quarter turn to preload the spring.
– Slide this assembly into spring holder G.
– Fit eye H and tighten nut F against it to a torque of 100 ÷105 Nm (~10 Kgm), taking care that nut F does not turn on
screw A.
– Screw plug I into spring holder G to prevent axial movement of the previously assembled pack.
– Apply a small quantity of LOCTITE 242 before fitting plug I.
– Apply a small quantity of LOCTITE 242 before fitting nut F and eye H.
– Grease spring D before fitting

I B C D F H
A E

Fig. 20 - Sensing arm assembly diagram

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Hydraulic power-lift 59

Power-lift distributor valve spring setting specifications

oil flow control valve spring

no. of springs used n. 1
wire diameter mm 1,4
external diameter mm 7,8
released spring mm 54
loaded spring (N 40,4) - kg 4,115 mm 47,5
(N 66) - kg 6,727 mm 43,37

pilot valve spring

no. of springs used n. 1
wire diameter mm 0,9
external diameter mm 7,8
released spring mm 25,5
loaded spring (N 21) - kg 2,133 mm 15,2
(N 28,5) - kg 2,899 mm 11,5

hydraulic distributor spring

no. of springs used n. 1
wire diameter mm 1,2
external diameter mm 10,4
released spring mm 110
loaded spring (N 43) - kg 4,4 mm 65
(N 39) - kg 4 mm 60

nonreturn valve spring

no. of springs used n. 2
wire diameter mm 1,1
external diameter mm 8,8
released spring mm 25
loaded spring (N 29) - kg 2,96 mm 17
(N 43) - kg 4,43 mm 13

valvematicspring
no. of springs used Nº 1
wire diameter mm 1,2
external diameter mm 9,5
released spring mm 57,3
loaded spring (N 41,3) - kg 4,2 mm 35
(N 54,3) - kg 5,5 mm 25,8

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59 Electronic power-lift

ELECTRONIC LIFT
The electronic lift is controlled by an electronic control unit and a control panel.

The electronic control unit processes the signals from the input devices and generates the output signals for the elec-
tro-hydraulic control of the lift control valve.

The system provides Draft and Position control functions.

IMPORTANT
The "ALL ROUND TESTER" provides the interface for electronic control unit self-diagnostic and programming
operations. All the display messages are given in the chapter "LIFT TESTER Control unit version 1.24A" of the
Appendix (see table of contents).

Fig. 1 - Configuration of the electronic lift system

1 - Control Unit
2 - Electro-hydraulically operated control valve (2 proportional solenoid valves)
3 - Hydraulic pump
4 - Draft sensor
5 - Position sensor
6 - Maximum lift height control knob
7 - Lowering speed control knob
8 - Draft/wheelslip intermix control knob
9 - Depth control knob
10 - Up/Down control
11 - Lock and alarm warning light
12 - Manual UP control (on the fender)
13 - Manual DOWN control (on the fender)

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Electronic power-lift 59

Control panel
The control panel comprises a series of potentiometers, lights and switches which serve to set the system operating
mode, raise or lower the lift and to provide information about system status.

The control panel is separate from the electronic control unit, to which it is connected by way of a multi-pin connector.

Fig. 2 - Control panel

1 - Lowering speed control knob
2 - Maximum lift height control knob
3 - Draft/wheelslip intermix control knob
4 - Up/Down control switch with integral Lock and Alarm warning light
5 - Depth control knob

Control level or depth control knob (5)

Used to set the reference value for the control function.
Informs the electronic control unit of the required level of working depth or draft control for respectively the position and
draft control functions. This knob is fitted with a mechanical lock to prevent excessive force being applied at the limits of
potentiometer travel.
· Turning the knob to the left increases the working depth. The first sector on the left permanent Float control.

Mix position/draft control (3)

Used to select the control mode.
· When turned fully to the left, pure draft control is selected.
· When turned fully to the right, pure draft control is selected.
· In the intermediate sector, sets the minimum depth for draft control: the function is disengaged by turning the knob
to the right, the depth is decreased by turning the knob to the left.

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 5 Vehicle
59 Electronic power-lift

Lowering speed control knob (1)

Used to vary the at which the linkage is lowered.
Sets the maximum aperture of the proportional solenoid valve that controls the lowering speed.
Turning the knob to the left reduces the lowering speed.

Maximum lift height control knob (2)

Used to set the maximum height to which the linkage is raised when the driver operates the lift control.
Turning the knob to the left reduces the maximum lift height.

Up/Down control switch (4)

Rocker switch used to raise or lower the linkage, incorporating a safety lockout/release.

Up control
Pressing this button for at least 0.2 seconds raises the lift to the maximum lift height.

Control/Float mode
If the Down button is pressed for less than 0.2 seconds, Control mode is activated.
If the button is held pressed for longer, Float mode is activated. In the latter case, the implement will be lowered at the
rate set by the lowering speed control knob and the lowering solenoid valve will be operated for as long as the button is
held pressed.
The moment the button is released, the system will exit Float mode and automatically resume Control mode.

Lock/release
Activates/deactivates total lock out of the control panel. When the lock is activated, the warning light illuminates.
On starting, the system is always locked; to release the lock, hold the Up control button pressed for 3 seconds until the
light goes out. The light will flash rapidly while the button is pressed.
To activate the lock, hold the Up control button pressed for 3 seconds after which the light will illuminate; again, the light
will flash rapidly while the button is being pressed.
On activating the lock, the linkage is immediately raised to the height determined by the maximum lift height control
knob. Any subsequent alteration to the position of the lift controls (including the maximum lift height control knob) will
have no effect on the position of the linkage until the lock is released.

Lift status indicator light

This light provides information about the operating status of the lift.
If the light is permanently illuminated, this indicates that the system is locked.
If the light is off, this indicates that the system is operating normally. If the light is flashing, this indicates an alarm condi-
tion.

WARNING: only use the Up control button located on the solenoid valve of the lift control valve in cases of extreme ne-
cessity and when the engine is running at idle speed. Release the button before the linkage reaches the maximum he-
ight, as the automatic stop determined by the both position sensor and the safety switch is excluded during this opera-
tion.

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Electronic power-lift 59

Remote pushbuttons for lift operation from ground

Two remote pushbuttons are located on the rear fender.

To enable these pushbuttons it is first necessary to release the lift control system.

Operation of the manual controls overrides any current lift functions and places the control unit in STOP condition, awai-
ting new control signals.

Fig. 3 - Lift control pushbuttons 1 - Up 2 - Down

Fig. 4 - Ground-operated lift controls.

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59 Electronic power-lift

Lift operation
On starting the engine, the lift is in Lock condition; to release the lift, press the UP switch for at least 5 seconds.
The lift control system enters STOP status in which condition the lift may be raised to the maximum lift height by pres-
sing the switch for at least 0.5 seconds but no more than 3 seconds.
To activate the lift control system, press the DOWN switch for less than 0.3 seconds; if the switch is held pressed for lon-
ger, FLOAT mode is activated and CONTROL mode will only be resumed when the switch is released.
The functions of the three potentiometers are as follows:
1 - MAXIMUM LIFT HEIGHT (used to set the maximum height to which the linkage can be raised)
2 - LOWERING SPEED (used to set the rate at which the implement is lowered).
3 - CONTROL (used to select the control type: when turned fully to the left POSITION control is selected, when turned
fully right DRAFT control is selected). When turned to the intermediate sector, mixed draft and position control is selec-
ted.

LIFT ALARMS
CODE MESSAGE ON TESTER Alarm description

11 “EVUP DISCONN” UP SOLENOID DISCONNECTED

12 “EVUP C.C. “ UP SOLENOID SHORT CIRCUIT

13 “EVDW DISCONN“ DOWN SOLENOID DISCONNECTED

14 “EVDW C.C. ” DOWN SOLENOID SHORT CIRCUIT

15 EPROM CECK- BLOCCO TOTALE DEL SISTEMA SOLLEVATORE-

21 “POS. SENS. C.C.” POSITION SENSOR SHORT CIRCUIT

22 “POS. SENS. DIS” POSITION SENSOR DISCONNECTED

23 “GEN. FAIL. CPU” GENERAL FAILURE OF CPU.

24 -

25 -

31 -

41 “DRAFT SENS NC” DRAFT SENSOR DISCONNECTED

42 “DRAFT SENS C.C.” DRAFT SENSOR SHORT CIRCUIT

45 “EEPROM CECK“ EEPROM ERROR

Example display of code 23:

all times in seconds

on
2 0.3 0.3 0.3 1,2 0.2 0.2 0.2 0.2 0.2 2
off

The criteria for encoding are as follows:

— light off for 2 seconds
— number of 0.3 second flashes corresponding to the tens digit
— light off continuously for 1.2 seconds
— number of 0.2 second flashes corresponding to the units digit
— repetition of the cycle until the alarm ceases

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 Vehicle 5
Electronic power-lift 59

Electronic circuit diagram of the

PIN OUT
ECU

1 – Vdc
2 –UP solenoid valve
3 - DOWN solenoid valve
4 – GND

REAR LIFT ECU

5 – Sensor Vdc
6 – Position
7 – Draft
8 – Lowering speed
9 – Maximum height
10 – Mix 1 2 3 4 12 6 7 8 9 10 11 5
11 – Main control

Mix
Max H.
GND

ISO 9141
12 – ISO 9141

+Vcc Sensors
Vcc

L. Speed
Draft
Position

Main Control
Electrovalve DOWN
Electrovalve UP

1K2

Lock/Alarm

Extern up
Extern down
A UP solenoid valve
B DOWN solenoid valve
C Tester IN/OUT
D Position sensor
E Draft sensor
Down Up
F Lowering speed
G Maximum height
H DRAFT/POSITION mix control
I Main control
L DOWN/UP control 1 2 1 2 1 3 2 1 3 2 1 2 3 1 2 3 1 2 3 1 2 3
V V
+ -

EVup EVdown Tester Position Draft Lowering Maximum Mix Main Down/Up
In/Out Sensor Sensor Speed Height Draft/Pos Control Control lever

A B C D E F G H I L

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 5 Vehicle
59 Electronic power-lift

Calibration of the AUTOMATIC

1 - Unlock the lift.
2 - Move the lift arms to the required height using the ground-operated UP/DOWN controls.
3 - Press the PTO AUTO switch.
4 - Press the PTO engagement switch for approx. 10 seconds.

The selected height is set as the maximum height limit for PTO operation.

Emergency manual lift control

In the event of a malfunction of the electronic system, the lift can still be controlled by way of the mechanical pu-
shbuttons located on the solenoid valves of the lift control valve (see figure below). However this operation should
only be carried in an emergency and with the engine running at idle speed.
Release the pushbutton before the lift arms reach their maximum height, as the automatic stop determined by the
position sensor is disabled during this manoeuvre.

Fig. 6 - Emergency manual lift control pushbuttons.

HYDRAULIC CONTROL VALVE A - Up Fig. 7 - Diagram of the hydraulic control valve.
(located on lift casing) B - Down Hydraulic control valve of the electronic lift
This control valve is of the open centre type and has two solenoid valves for raising and lowering the lift
arms.
The two solenoid valves are controlled directly by the ECU.
Do not connect the solenoid valves directly to an electrical power source, as they would be irreparably damaged.

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Electronic power-lift 59

LIST OF ELECTRONIC LIFT TESTS

Connect the ALL-ROUND TESTER to the diagnostics socket and select option (2) [REAR LIFT CONTROL].
Press (0) twice and enter the password [BAC0] in order to modify the parameters.
Press [E] twice to display the first screen page.
The first screen indicates the selected tractor type (10N or 10S).
If the selected tractor type does not correspond to the machine being tested, change the type by pressing the number
alongside the required model and follow the on-screen instructions to store the new type in memory.
Release 1.23A does not display the tractor type selection screen and the parameters are those relative to the 10S type.

Enter the MENU screen and press (0) to enter the modification menu.

2 - Modification menu.

1 - Monitor
2 - Parameters
3 - Tests
4 - Max/min height calibr.
5 - Alarms
6 - Calibr. PWMmin

- MONITOR -
Displays data related to the control algorithm and the PWM controls (sensor and potentiometer status).

- Parameters 10S - Programming parameters of the control solenoid valves (Ev).

- Tests - allows you to test ground-operated pushbuttons and display sensor values.

- MAXIMUM/MINIMUM LIFT HEIGHT CALIBRATION

Allows you to calibrate the maximum lift height and the lifting speed.

DEFAULT VALUES 10S:

1 - max. Height 880
2 - Lifting speed. 500

To calibrate the maximum height, put the lift control in STOP condition (seeLIFT OPERATION) and select "CALIBRATION" from the
main menu. Then select option 1 from the "CALIBRATION" menu, turn the MAXIMUM LIFT HEIGHT knob to the maximum position
and, using the ground-operated UP/DOWN pushbuttons, position the lift arms at the required maximum height.
Press "E" and "C" to save and confirm the new maximum height value. Exit the "CALIBRATION" menu and continue the tests.

3
(V=0.84 dm )
6
Rear lift

210 Bar

Fig. 8 - Functional diagram of the lift control valve. 5 4

1- UP valve
2- DOWN valve
3- Enabling valve B
2
4- Antishock valve
5- Check valve
6- Lifting cylinder 1

P
3

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59 Electronic power-lift

Fig. 9 - Control valve hydraulic circuit - NEUTRAL

1 - UP solenoid valve
2 - DOWN solenoid valve
3 - Enabling valve
4 - Check valve
P - Oil flow

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 Vehicle 5
Electronic power-lift 59

Fig. 10 - Control valve hydraulic circuit - LIFTING

1 - UP solenoid valve
2 - DOWN solenoid valve
3 - Enabling valve
4 - Check valve
P - Oil flow

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 5 Vehicle
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Fig. 11 - Control valve hydraulic circuit - LOWERING

1 - UP solenoid valve
2 - DOWN solenoid valve
3 - Enabling valve
4 - Check valve
P - Oil flow

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Electronic power-lift 59

Fig. 12 - Hydraulic control valve for electronic lift.

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Fig. 13 - Position sensor calibration of the electronic lift.

POSITION SENSOR CALIBRATION

If a new position sensor is fitted, it will have to be adjusted.
Proceed as follows:
1 - Move the lift arms to the minimum height position, connect the "ALL AROUND TESTER" and access the maximum
height calibration screen; screw the sensor in or out until a number between 4 and 10 is displayed.
2 - Tighten down the sensor
3 - Proceed with the calibration of the maximum height.

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Electronic power-lift 59

Fig. 14 - Pin for draft control of the electronic lift

1 - Pressure test fitting for lift cylinder pressure
2 - Lift control valve
3 - Anti-shock valve

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59 Electronic power-lift

Fig. 15 - Rear view of the electronic lift.

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 Vehicle 5
Electronic power-lift 59

A
(ALIMENTAZIONE DA REGOLATORE DI FLUSSO)

27 L/min MAX.

(ALIMENTAZIONE DA POMPA

O DA FRENATURA IDRAULICA)
27 L/min

26°30'

B
73°30'

26°30'
8.43
Corsa sensore
Quota sensore montato: 117.5
Quota sensore libero: 119

10

Fig. 16 - External hydraulic circuit of the lift.

A - Lift control valve

269
270
5
59

PA
T. E LE S A

Fig. 17 - Top view of the electronic lift.

Vehicle

(discesa)
Electronic power-lift

(Salita)

Asse tubo alim. da regolatore

di flusso x sollev. meccanico
 Vehicle 5
Electronic power-lift 59

Precautions for electronic equipment

The tractor is equipped with a number of sensitive electrical devices and electronic components.
In particular, electronic components do not tolerate polarity inversion, over-current, connection errors, etc..
The electronic components are provided with internal and external protections, but the following precautions are still ne-
cessary:

— Switch off the control panel before carrying out any work on electrical components.
— Do not use a screwdriver of light bulb to test for electrical current; only use the appropriate diagnostic equipment (tester).
— Do not apply excessive force when connecting and disconnecting electrical connectors; do not prise connectors
apart using a screwdriver, and always respect the polarity of the connection.
— In the event of a fault in a circuit controlled by an electronic control unit, do not immediately replace the control unit,
but first check that the sensors and actuators are functioning correctly.
— When replacing a defective electronic control unit, only unscrew the retaining screws; avoid interfering with other
screws as these could be calibration screws.
— Inspect contacts on sensors and connectors for corrosion.
— Do not use arc welding in the vicinity of electrical circuits.
— Avoid short-circuits and polarity inversion.
— When working on components controlled by microprocessors, always disconnect the power supply by turning the
ignition key to the STOP position before disconnecting the component.
— If the tractor is to be resprayed and passed through a paint baking oven, remove all electronic components.
— Do not insert the probes of the tester into multi-pole sockets on connectors or other devices (this deforms the con-
tacts and thus leads to poor connections).
— Do not test for the presence of electrical current by causing a spark, i.e. by short-circuiting components across wires
or to earth.
— Do not reverse the polarity or swap over wires in multi-pole connectors.

CHECKING THE ELECTRONIC SYSTEM

· Elements to check:
— Sensors
— Electronic control units
— Actuators

1) Checking the system power supply:

— current present at input to the connector plugged into the device;
— current present at output from connector
— earth connection
— voltage correct.
2) Check downstream components: sensors.
3) Check upstream components.

CHECKING MECHANICAL COMPONENTS

Check the splines on the external and internal lift arms for damage or excessive wear; replace the levers if necessary.

Check the bushes of the lift arm shaft for scoring or excessive wear.
Check the bushes and the pins connecting the lift arms to the hydraulic cylinder are not worn and are firmly inserted in
the seats on the levers.

Check the diameters of the rod and bushes in the cylinders and compare with the maximum wear limits in the table.

Check that the splines on the lifting shaft are not excessively worn and that the machines surfaces in contact with the
support bushes are not damaged.

NOTE: whenever the lifting cylinders are dismantled, new seals must be fitted.

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Front hydraulic lift

On request the tractor can be equipped with the front hydraulic lifting system.
It is operated by means of two hydraulic cylinders actuated by the related control lever placed at the right-hand side of
the operator driving position.
The lever controls a single-acting distributor valve linked to the rear tractor power-lift case.

Inspections
Ensure that the cylinder pin bushings are not worn and be sure these are firmly secured in their seats.
NOTE: Replace gaskets after each hydraulic lifting cylinder disassembly.

Specifications
power-lift type with two hydraulic cylinders and
removable arms
hydraulic cylinder type single-acting
oil supply from the rear auxiliary
hydraulic distributor
peak operating pressure bar 180
cylinder stem diameter mm 50
lifting stroke mm 170
lifting capacity Kg 1500

A - Front lift cylinders (2)

B - Hydraulic accumulator
Volume 0.700 litres
Nitrogen precharge 130 bar
maximum operating pressure 250 bar

C - Antishock valve

D - Lowering speed regulator valve

E - Lockout cock (prevents oil from

discharging from the cylinders when
transporting raised implements on the road).

Fig. 1 - Lift operation.

272
 Vehicle 5
Front hydraulic power-lift 59

Hydraulic accumulator and antishock valve for front lift

The front lift is equipped with a hydraulic accumulator with an antishock valve. This improves hydraulic system perfor-
mance and reduces strain on the front axle.

Fig. 2 - Front linkage components.

The grease seal ring must be fitted as shown in the figure and must enter the housing bushing by 2 mm

Fig. 3 - Front linkage components with relative valves and accumulator.

273
 5 Vehicle
59 Front hydraulic power-lift

A - To lift cylinders
B - Rate of drop valve
C - Anti-shock valve
D - Accumulator
E - Lowering speed control valve
F - Directional control valve

Fig. 4 - Oil pressure accumulator and anti-shock valve. (The directional valve to which is connecting, is convertable into sin-
gle-acting. For the operations to see auxiliary systems chapter).

274
 Vehicle 5
Front power take-off 59

Front power take-off

General information
The power take-off clutch is a multidisk, oil-bath and elec-
tro-hydraulic control type.
The front power take-off is directly linked to the crankshaft by me-
ans of a flexing coupling; while the shaft-end is equipped by an
universal joint.
The oil used for P.T.O. operation is contained in the P.T.O. casing.
A specific gear pump installed on the P.T.O. shaft sucks the oil,
which flows first through a filter for being subsequently routed un-
der pressure to the clutch assembly through an electro-hydraulic
distributor. Fig. 1 - Front P.T.O. shaft terminal.
The oil is strained through a second (15 micron) filter placed on the
pressurized circuit located between oil pump and hydraulic distri-
butor.

A maximum 57 kgm (560 Nm) torque can be transitted to the hit-

ched implement in this way, i.e. 80 CV max. (or 58 kW).
To avoid these standards may be exceeded it is recommended
that a special joint having proper specifications be installed betwe-
en implement and P.T.O.

The P.T.O. shaft rear teminal has clockwise direction of rotation

(with respect to the driving position).

Fig. 2 - Front P.T.O. clutch assembly.

.

Specifications
clutch
manufacturer SAME DEUTZ-FAHR GROUP
clutch disk no 4
clutch disk diameter mm 124,5
clutch disk set thickness - max. wear mm 20,80
- standard wear mm 21,80 - 22,20
counterdisk number 4 + 1(spacer)
disk lubricating pressure bar 1,5
peak calibrating pressure (to press the disks together):
- of brake disk bar 4
- of clutch disk bar 13
piston axial thrust kg 1523
brake disk braking torque (peak pressure) kgm 1
hydraulic pump gear type
oil flow rate (at engine peak speed) (dm/min) litre/min
3 12
oil filter cod. 9012.424.2
filtering capacity micron 90
filtering surface cm 2
222
hydraulic distributor stroke mm 1,5
rrear P.T.O. shaft terminal 1.3/8" - 6 splines
direction of rotation with regard to driving position
oil reservoir capacity litre (dm)3
2,5
oil type AKROS MULTI 10W30 (APl-GL4)

275
 5 Vehicle
59 Front power take-off

engagement stage

A - Checking the clutch assembly engagement pressure (10 ÷ 13 bar).

Fig. 3 - Front P.T.O. clutch hydraulic circuit (engagement stage).

276
 Vehicle 5
Front power take-off 59

disengagement stage

A - Checking clutch assembly engagement pressure (4 ÷ 6 bar).

Fig. 4 - Front P.T.O. clutch hydraulic circuit (disengagement stage).

277
 5 Vehicle
59 Front power take-off

Apply some LOCTITE 510 (red) on the surface betuen cover and box

Fig. 5 - Longitudinal section of the front P.T.O. assembly.

A - Solenoid valve B - Clutch pressure control valve
C - brake apply press. control valve D - Clutch engagement pressure accumulator
E - Strainer F - Oil level indicator plug

Fig. 6 - Front P.T.O. shaft flexing coupling.

278
 Vehicle 5
Front power take-off 59

Apply some LOCTITE 212 (sky-blue) on the screw threads.

Fig. 7 - Cross-section of the front P.T.O. assembly.

A - Brake disc B - Clutch discs C - Oil pump
D - Input shaft E - Strainer F - Oil drain plug
G - P.T.O. shaft

Fig. 8 - Top view of front P.TO.

Correct fitment of front P.T.O. shaft bearing
Locate the bearing 2.2421.012.0 with the shoulder directed toward the gear as indicated in fig 8.

279
 9 Vehicle
59 Front power take-off

Installing “RING-FEEDER” rings

Install all the parts following the order shown in figure.

Thoroughly tighten the pulley hub on engine crankshaft to 38 ± 2

kgm (380 ± 20 Nm).

Fit an intermediate flexible coupling with a torsional rigidity of

25,145 kgm/rad; the maximum applicable inertia must not exceed
0.5 kgm .
2

Fig. 9 - “RING-FEEDER” rings installed.

Fig. 10 - Front P.T.O. assembly parts

280
 Vehicle 5
Front power take-off 59

Checking clutch
Make sure that the clutch disk friction linings are neither worn nor torn, if so replace the disks.
The control piston should be replaced if signs of scoring are noticed.
If the splined sliding surface of the clutch disk hub is sunk in its upper part, the hub should be replaced.
Check the efficiency of the piston return spring.
The spring specifications should correspond to those indicated in the specific table. Replace if necessary.
The clutch and brake piston sealing rings as well as the brake disk itself should be replaced if excessively worn.
If either the rotary seals or the relevant seats are worn, these should be replaced.
Every time the assembly is taken to pieces, carefully clean the oil passages in the clutch casing; use compressed air if
required.

Check the clearance of the clutch friction discs

With new discs in place, check that distance A (Fig 11) is between 0,5 and 2 mm.
If the clearance is greater than the maximum value indicated, add 1 x shim p/n 2.1599.499.0 at the position arrowed.

Fig. 11 - Checking disk clearance of front power-take-off.

Checking clutch assembly engagement pressure

Fit no. 5.9030.517.4 equipment to the oil supply pipe using no.
5.9030.632.0/10 union as shown in figure 3 at pages 254-255 and
then connect no. 5.9030.514.0 oil pressure gauge.
With the P.T.O. engaged
Let the oil circulate within the clutch casing and then be sure the
following conditions are established: with engine running at peak
idling speed the pressure reading should be 13 ± 1 bar; with engi-
ne running at the lowest idling speed the pressure reading should
be 10 ± 1 bar.
N.B. - Make sure the P.T.O. shaft terminal is turning.
With the P.T.O. disengaged
Let the oil circulate within the distributor casing and then be sure
the following conditions are established: with engine running at
peak idling speed the pressure reading should be 6 ± 0.5 bar; with
engine running at the lowest idling speed the pressure reading
should be 4 ± 0.5 bar.
Fig. 12 - Electro-hydraulic control valve.
N.B: Make sure the P.T.O. shaft terminal is being braked.

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 5 Vehicle
59 Front power take-off

Diagnosing malfunctions
Verify activation of replace the soleno- recheck pressure
the solenoid valve id valve if neces-
sary

replace the springs replace the defecti-

of inefficient valves ve parts
check piston for
free stroke
inspect O-rings on replace the soleno-
piston and manifold id valves if neces-
sary
clutch slipping
verify movement of remove any roug-
piston hness preventing
smooth action

inspect clutch discs replace discs

for wear

Check the solenoid replace the soleno-

operated control id valve if neces-
valve sary

P.T.O. brake does not Check engage- inspect O-rings and

apply ment pressure replace if neces-
sary

piston jammed replace

out-of-setting valve
springs

Spring specifications

piston return spring cod. 2.4019.373.1

wire diameter mm 6,5
external diameter mm 79,5
released spring mm 61,5
loaded spring - kg 75,7 (Nm 742) mm 30
- kg 79,7 (Nm 782) mm 28

hydraulic system valve springs cod. 2.4019.179.1

quantità numero 2
wire diameter mm 1.2
external diameter mm 8.8
released spring mm 63
loaded spring - kg 3.6 (Nm 35) mm 44,6
- kg 4.6 (Nm 45) mm 39.5

282
 Controls 6
Hydrostatic steering 63

Hydrostatic steering
code 290.6310.4/10 Danfoss type for 4WD
code 010.8555.4 danfoss type for 4WD with double steering cylinder and oversized pump capacity of 14cc
code 009.3141.4/10 Danfoss type for 2WD

General information
There in no direct mechanical connection between the wheels and the steering wheel and therefore no vibration can re-
ach the driver.
Turning the steering wheel operates a rotary distributor connected to an oil flow control shutter permitting the pressure
oil to be directed to the hydraulic cylinder in the amount necessary to provide the desired steering action.
The steering system is an open-centre reactive type: the user can directly feel the steering response on the steering
wheel and perform a prompt correction of the driving direction.
In addition, the remarkable wheel caster angle will help increase the wheel self-centering effect as the wheels will auto-
matically get in a straight line when the steering wheel is released.

The hydraulic circuit is fully independent. The oil drawn from the gearbox flows first through a high-delivery filter before
being routed under pressure to the distributor by a pump constantly in mesh driven by the engine and fitted on gearbox
left-hand side.
Two powerful cylinders, connected to the front wheel hubs, ensure the thrust necessary to steering under any working
conditions.
Oil returning from the power steering unit is directed to the unit piloting the electrohydraulic controls and sole function to
lubricate the gearbox.
Moreover this system offers the advantage that the tractor can be driven also in the event of either a pump failure or an
engine stop. A valve within the distributor will allow the oil to be drawn from the discharge circuit through the oil control
shutter, whenever a pressure drop occurs in the pump delivery circuit.

hydraulic directional control valve

type of valve ospc 80 or open-centre reactive type for 2WD and 4WD
ospc 125 or open-centre reactive type for 4WD with oversized
oil pump and double steering cylinder
relief valve setting bar 150 for 4 WD
bar 100 for 2 WD
clearance between spool and sleeve mm 0,03
turns of steering wheel before road wheels respond
- engine running 0° - 2°
- engine at standstill 0° - 6°

steering cylinders
working stroke of piston rod mm 171
rod diameter 2WD mm 42
4WD mm 50
pushing force 2WD kn 13,6
4WD kn 19
steering wheel turns to full lock nº 2.17

tightening torques
valve cover securing screws kgm 3 Nm 29
cylinder securing bolt kgm 16 Nm 155

283
 6 Controls
63 Hydrostatic steering

Inspections and checks

Steering pump
Clean all component parts of the pump thoroughly, using petrol.

Check that the gears are not unduly worn, otherwise replace.

Directional control valve

Clean all parts of the valve thoroughly.
Check, utilizing a comparator for internal dimensions, that the cle-
arance between spool and sleeve (A - B - Fig 1) is no greater that
0.03 mm: otherwise replace.
The two components are not available separately as spare parts.

Check the setting of the pressure relief valve

Couple pressure gauge 5.9030.513.0 by means of adaptor
Fig. 1 - Fit diameter between internal and exter- 5.9030.579.0 to the fitting of the left hand steering cylinder (as in-
nal elements of the control valve. dicated in fig 2).

Start the engine and allow to idle for a few minutes; then, with the
steering on full right hand lock, turn the wheel further until the hand
of the gauge stabilizes at around the maximum pressure. If this is
different to the maximum operating pressure (150 bar for 4WT and
100 bar for 2WT), adjust the setscrew (A - fig 10, page 290) of the
valve until the requisite value is re-established in the circuit.

Repeat the same sequence of operations with the pressure gauge

and adaptor fitted to the right hand steering cylinder, this time on
the left hand lock.

Fig. 2 - Testing pressure in the hydraulic steering

circuit.
A - fitting
B - cylinder Bleeding the hydraulic circuit
Start the engine and allow to idle at minimum rpm.

Loosen the two fittings at the cylinder and turn the steering wheel
each way until oil emerges devoid of air bubbles.

Assembly of orbital pump unit

Locate the rotor A in the stator B as illustrated, making certain that
the pin C is perpendicular to the plane x - x of the valve body as in-
dicated in fig 3.
Fig. 3 - Correct assembly of orbital pump unit

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 Controls 6
Hydrostatic steering 63

Teering wheel shaft

Verify the integrity of the steering column, and in particular, make
certain that the surfaces of the bearings are not scored, also that
the splines are neither damaged nor showing signs of excessive
wear.
Do not grease or oil the bearing inside the sleeve.

Check that the steering column rotates freely, without sticking, but
also without excessive play.
Before refitting the rubber boot A (Fig 4), smear the steering co-
lumn B with the grease at the position indicated in fig 4.
Having tightened all components, check that the steering wheel
Fig. 4 - Section through steering wheel shaft
continues to operate correctly even when at its two height adju- A - Rubber boot
stment limit positions (fully raised and fully lowered). B - Steering column

Steering cylinders

Clamp the cylinder in a vice and withdraw the piston G (fig. 7);
If necessary, remove the circlip F (fig. 8) from its groove with the
aid of a suitable tool to allow withdrawal of the ball end G (fig. 8).

Fig. 5 - Steering column.

A - Bearing
B - Sleeve

A - Shock valves
B - Anticavitation valves
C - Pressure relief valve (150 bar)
D - Emergency steering
check valve
E - By-pass valve (redirects
return flow to inlet)
F - Orbital pump unit
G - Directional control valve

Fig. 6 - Components of directional control valve

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63 Hydrostatic steering

Fig. 7 - Single acting cylinder. I - Snap ring

A - Snap ring L - Head
B - Ball M - Gasket
C - Cylinder N - Dust seal
D - Self-locking nut O - Spring
E - Guide ring P - Ring nut
F - Seal
G - Piston
H - Shaft
Servicing
Verify the integrity of the O-ring and wiper seals. Replace any
components showing signs of wear or damage.

Inspect the sliding surfaces both of the rod and of the cylinder for
signs of scoring, heavy wear or any kind of damage; if any of these
are discernible, replace the affected component.

Check for correct operation of the ball end, ensuring that it betrays
no signs of heavy wear, scoring or oxidation, the presence of
which dictates replacement.
Lubricate the wiper seals and ball end with care.

Reassemble the cylinder, repeating the dismantling operations in

reverse sequence.
Fig. 8 - Ball joint
F - Circlip
G - Ball joint

Fig. 9- Section through single acting cylinder.

A - Wiper D - Head G - Self-locking nut L - Piston
B - Ring nut E - Cylinder H - Ball end M - O-ring
C - Gasket F - O-ring I - Circlip N - Shaft

286
 Controls 6
Hydrostatic steering 63

Instructions for the hydro-

static steering distributor
assembly

1 - Insert the spring set (blue) as shown 2 -Insert first the two external spring bla-
in figure. des into the rotary distributor and subse-
quently the two internal ones.

3 - Press the spring blades to align in 4 - Reassemble the rotary distributor. 5 - Act on springs in such a way they are
centre position. prevented from projecting outwards with
respect to the rotary distributor outside
surface.

6 -Fit the spacer onte the distributor. 7 - Insert the drive pin into the cylinder 8 - Install the axial bearing following the
assembly order shown in next figure.

9 - Axial bearing installation. 10 - Use no. 5.9030.480.0 tool to fit the 11 - Insert the O-ring after fitting the tool
seal ring. sleeve into the distributor case.

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 6 Controls
63 Hydrostatic steering

12 - O-ring as installed on the plug. 13 - Insert the O-ring into the sleeve and 14 - Pull out the tool.
press until it is fully inserted.

15 - Insert the distributor from the bot- 16 - Press the distributor until the plug is 17 - Turn the distributor case upside
tom trying to make installation easier al- pushed out of the opposite side. down holding the rotary distributor in
ternately rotating in both directions. place and iserting the shunt valve as in -
dicated by the arrow in figure.

18 - Screw down the valve grub screw in 19 - Insert the balls as shown by the ar- 20 - Insert the two pins in the same posi -
its seat. row. tions as previously shown.

21 - Fit the seal ring in the related seat. 22 - Fit the spacer in such a way the ho- 23 - Insert the drive shaft in the distribu -
les in it are in the same line as the corre- tor so that the notching may engage into
sponding grooves. the pin in a position being parallel to the
distributor face.

288
 Controls 6
Hydrostatic steering 63

24 - Place the fork as shown in figure so 25 - After inserting the two O-rings pro - 26 - The rotor should be placed to the sta -
as the drive shaft may be held in posi- perly lubricated into the oil flow control tor and then swiveled with regard to the
tion. shutter fit the stator positioning as drive shaft as shown in figure.
shown in figure.

27 - Place the spacer ring, (only for tho- 28 - Install the pin screw in the special 29 - Fit the cover.
se models which the spacer is fitted). hole (the ball valve hole).

30 - Fix the cover with the securing 31 - Fit the seal ring. 32 - Insert the seal ring into its seat.
screws by tightening to the recommen-
ded torque.

33 - Install the pressure relief valve. 34 - Insert the spring. 35 - Fit the pressure relief valve cap
screw.

289
 6 Controls
63 Hydrostatic steering

A - pressure relief valve F - return flow

B - check valve L - to left hand cylinder
C - from pump R - to right hand cylinder
D - anticavitation valve P - pump
E - emergency steering check valve T - discharger

Fig. 10 - Distributor cross-section.

290
 Controls 6
Hydrostatic steering 63

1 - Oil to the main pump

2 - Oil to the flow control shutter
3 - Oil to the steering cylinder
4 - Oil trapped in closed circuit
5 - Oil in the discharging line
6 - Oil in the aspirating line
7 - Right-hand rotation
8 - Left-hand rotation
9 - Neutral position

Fig. 11 - Reactive-type, open-centre hydraulic distributor schematic diagram.

291
 6 Controls
63 Hydrostatic steering

Greasing the steering shaft

On assembly, grease the areas shown on the left with Molikote

GN-PLUS

Fig. 12 - Greasing the steering shaft.

Fig. 13 - Components of steering controls and hydrostatic power steering support

292
 Controls 6
Hydrostatic steering 63

8 Bar

L R

OSPC 80 OR

100 Bar 2 WD
0.009.3141.4/11

150 Bar 4 WD
0.290.6310.4/10

T P

Fig. 14 - Hydrostatic steering operation diagram.

293
 6 Controls
63 Hydrostatic steering

Diagnosing malfunctions

Check oil level in Restore level

tank

Check for air Bleed the system

in system
Unable to steer tractor
Check safety valve Check for shorn di- Replace pin
setting stributor securing
pin

Reset or replace if
necessary

Bleed the system

Hard steering Check safety valve
setting Check for air in the
system Check for leakage Replace worn seal
from the distributor rings
and the piston seal
rings in the hydrau-
lic cylinder

Change oil and re-

place filter
Distributor and oil flow Check oil filter for
control shutter worn dirt
Check that the oil is Change oil and re-
of prescribed type place filter

Clean distributor
and replace oil
Blocked distributor Check for dirty oil

Check that oil is not Stop tractor and let

excessively hot oil cool

Bleed the system

Check for oil leaka- Replace seal ring

Wheels oscillation Check for air in ge in the hydraulic
system cylinder

Check valve setting Adjust

294
 Controls 6
Mechanical controls 64

Mechanical controls
Given the constructional simplicity of these controls, we present a series of figures illustrating the individual compo-
nents of the controls.
Only some of these controls require adjustment; for instructions for these adjustments, refer to the chapter dealing with
corresponding unit.

Fig. 1 - Gearbox inversor control

Fig. 2 - Gear-change control
Fig. 3 - Gearbox reduction unit control
Fig. 4 - Synchronised P.T.O. control
Fig. 5 - Hand throttle control
Fig. 6 - Accelerator pedal control
Fig. 7 - Lift controls
Fig. 8 - Ground-operated lift controls
Fig. 9 - Auxiliary control valve controls

N.B.: For P.T.O. controls see instructions on page 178.

WARNING: It is important that those tie-rods fitted with adjustable forks are adjusted so that their respective control le-
vers can be moved through their entire range from min. to max. without obstruction.

Fig. 1 - Gearbox inversor control

295
 6 Controls
64 Mechanical controls

Fig. 2 - Gear-change control.

Fig. 3 - Gearbox reduction unit control.

296
 Controls 6
Mechanical controls 64

Fig. 4 - Synchronised P.T.O. control.

Lever play adjustment: insert a washer 2.1311.010.2 and , if necessary, other washers 2.1580.004.0 in the space A to
obtain a play of 0.5-1 mm.

Fig. 5 - Hand throttle control.

Control adjustment: tighten nut A to a torque of 7 kgm (70 Nm), screw in screw B to obtain lever movement with a load of 70N
Turn the control lever backward and forward 2-3 times through approx. 25° and re-check the load on the lever; adjust if
necessary.

297
 6 Controls
64 Mechanical controls

Fig. 6 - Accelerator pedal control (for instructions on

adjustment see page 58).

Control adjustment: screw in the screw with spring (Bel-

leville) to obtain lever movement with a load of 35N.
Turn the control lever backward and forward 2-3 times
through approx. 22° and re-check the load on the lever,
and reset the load to 45N.

Fig. 7 - Lift controls.

298
 Controls 6
Mechanical controls 64

Fig. 9 - Auxiliary control valve controls.

Fig. 8 - Ground-operated lift controls.

299
 6 Controls
68 Electro-hydraulic controls

Electro-hydraulic controls

Front P.T.O. clutch engagement control

The front P.T.O. can only be engaged when the engine is running. Pressing the pushbutton engages the front P.T.O..
The integral light illuminates to indicate that the P.T.O. is engaged.

Rear P.T.O. clutch engagement control

Activation and deactivation of the P.T.O. clutch are piloted by a dedicated control unit.
The activate/deactivate control function is se-lected by pressing the button, which returns to the off position when relea-
sed.
An integral light shows when the function is activated, and serves also to indicate the type of fault that may affect the
electrohydraulic control.
When the engine is started, the warning light blinks to indicate that the control system is activated.
The P.T.O. is engaged by pressing and holding the button for at least 2 se-conds.
If the button is held for more than 10 seconds, or if there is a fault with the electrohydraulic control, the P.T.O. will be de-
activated automatically.
The control unit also disengages the P.T.O. every time the engine is swit-ched off.
The rear P.T.O. can be engaged by pressing the ground-operated pushbutton located on the rear right-hand fender.

Differential lock engagement control

Pressing the pushbutton engages the front and rear differential locks. The integral light illuminates to indicate that the
locks are engaged. Pressing the pushbutton again disengages the locks.

Front-wheel drive engagement control

Pushbutton with integral indicator light.
Press to engage front-wheel drive; press again to disengage.

N.B. Engagement of the above devices is also signalled by indicator lights on the console.

Gearbox
The Agroshift transmission offers the possibility to select each speed in or or (using the gear and range le-
ver) without having to depress the clutch pedal simply by pressing the electro-hydraulic control switch.
This is achieved by way of three multi-plate clutches.

Front and rear lift

The front lift is operated by way of the control lever of the auxiliary service control valves located on the right of the dri-
ving seat, after first opening the shut-off cock in the oil delivery line to the front lift.
The mechanical rear lift is operated by controls located to the right of the driving seat.

For tractors equipped with electronic lifts, see p. 258 for a description of the controls.

300
 Controls 6
Electro-hydraulic controls 68

R
F
210 Bar
Rear lift

3
4RM 2RM (V=0.84 dm )

T
8 Bar

L R

Q
T
A - Main oil filter on supply circuit OSPC 80 OR
T T
B - Hydraulic pump for auxiliary service Lift Lower
control valve and power lift
C - Hydraulic pump for hydrostatic
steering and electro-hydraulic controls E 6 Bar

Neutral
E - Hydrostatic steering control valve
F - Steering cylinders
G - Oil cooler
100 Bar 2 WD
H - Pressure control valves 0.009.3141.4/11
P T
I - Gearbox lubrication
L - Hydraulic power unit 150 Bar 4 WD
M - Differential locks 0.290.6310.4/10
N - 4WD engagement
O - Rear P.T.O. clutch T P
P - Auxiliary service control valve
Q - Front lift hydraulic control valve
R - Lifting cylinder

O B A B A T
P.T.O.
M Main shaft
Diff.look N P
32 cc

I
Dis.
Inn.

Front Rear 4 Wd
Inn.
Dis.

1
1
E H.P.C.
Sec. shaft

0
ø 1.1
P

2
190 Bar

1
A A A

0
G T

P T P T P T
2.3719.730.0

11 bar
L

16 bar 5 bar

11 cm 3 14 cm 3
19 cm 3
27 L/min. 35 L/min.
47 L/min.
N.giri/min.pompe:2522
B Rh Lf
Rapp. 1/1.0732 (44/41)
C

150 Micr.
x

Fig. 1 - Hydraulic circuit diagram (with electronic lift - STANDARD version).

301
 6 Controls
68 Electro-hydraulic controls

3
6 (V=0.84 dm )

Rear lift
U
R
L R
210 Bar
2.3729.320.0 A
OSPC 80 OR 4 5

700 cc
70 Bar
E 2
V1
1
100 Bar 2 WD
0.009.3141.4/11

150 Bar 4 WD P Q
3
0.290.6310.4/10 V2

T P
S
2 2

1 1 3 3

O Rear free return

B A B A B A
T
P.T.O.
M 190 bar
Main shaft X P-Ecc.
Diff.look N
32 cc
I
A - Main oil filter on supply circuit
Dis.
Inn.

Front Rear 4 Wd
B - Hydraulic pump for auxiliary service
control valve and power lift
Inn.
Dis.

C - Hydraulic pump for hydrostatic steering N

Trailer brake
and electro-hydraulic controls
Sec. shaft
D - AGROSHIFT ø 1.1
E - Hydrostatic steering control valve
F - Steering cylinders P-Reg.
G- Delivery line filter L A A A
H - Pressure control valves
I - Gearbox lubrication P T P T P T
L - Hydraulic power unit T 2.3719.740.0/10 P
M - Differential locks Y Tractor brake
N - 4WD engagement 11 bar G
O - Rear P.T.O. clutch
P - 6-way auxiliary service control valve
Q - Front lift hydraulic control valve 16 bar 5 bar
P 2.3719.810.0/10 (Italia) Freno inser.=13 bar,disinser.=5 bar
R - Lifting cylinder H 2.3719.550.0/20 (Francia) =3 bar
S - Shut-off valve for front lift
T - Control valve for hydraulic trailer braking
U - Front lift cylinders
V1 - Anti-shock valve for front lift P T P T
11 cm 3 11 cm 3
V2 - Lowering speed control valve for front lift 27 L/min. 27 L/min.
Z - Hydraulic unloader (oil level pump) ø1 A A N.giri/min.pompe:2522
Rh Lf
B Rapp. 1/1.0732 (44/41)
H M L
C
Z
25 Micr.
x

25 Micr.
A

Fig. 2 - Hydraulic circuit diagram (version with full complement of optional equipment).

302
 Controls 6
Electro-hydraulic controls 68

A - Check valve
B - Check valve
C - Gearbox lubrication pressure control valve (5 bar)
D - Sequence valve (16 bar)
P - Pump
T - Oil return
L1- Gearbox lubrication
L2- PTO lubrication
1 - Rear PTO
2 - Differential lock
3 - 4WD

Fig. 3 - Hydraulic circuit on right-hand side of gearbox.

303
 6 Controls
68 Electro-hydraulic controls

The hydraulic injector A inserted in the transfer pipe B equalises the oil levels in the front and rear gearboxes.

The injector allows oil in the front gearbox to flow easily into the rear gearbox.

TECHNICAL CHARACTERISTICS
Flow used 1,8 l/min
Pressure of jet 16 bar
Flow transferred 25 l/min

A - Hydraulic injector
B - Transfer pipe
C - Front gearbox
D - Rear gearbox
E - Venturi pipe

Fig. 4 - Details of front and rear gearboxes.

304
 Controls 6
Electro-hydraulic controls 68

A - Circuit transmission lubrification\PTO

B - Flow control valve

Fig. 5 - Machine with electrohydraulic controls operating differential lock, four wheel drive and power take-off, equipped with
AGROSHIFT.

305
 6 Controls
68 Electro-hydraulic controls

A - Circuit transmission lubrification\PTO

B - Flow control valve

Fig. 6 - Machine with electrohydraulic controls operating differential lock, four wheel drive and power take-off, not equipped with
AGROSHIFT.

306
 Controls 6
Electro-hydraulic controls 68

Specifications
Solenoid operated valve controlling four wheel drive engagement, differential lock, equipped with AGROSHIFT and the rear P.T.O.
clutch.
Code 2.3719.670.0 max. delivery rate l/min 12 max. pressure bar 210.

Before tightening the lock nut, smear the thread with LOCTlTE 242 (blue).

Fig. 7 - Solenoid valve

307
 6 Controls
68 Electro-hydraulic controls

Specifications
Solenoid operated valve controlling the front P.T.O. clutch

Code 007.5339.0/10 max. Delivery l/min 12 max. pressure bar 210.

Before tightening the lock nut, smear the thread with LOCTlTE 242 (blue).

Fig. 8 - Solenoid valve

308
 Controls 6
Electro-hydraulic controls 68

Fig. 9 - AGROSHIFT solenoid valves - LOW clutch engagement

309
 6 Controls
68 Electro-hydraulic controls

Fig. 10 - AGROSHIFT solenoid valves - MEDIUM clutch engagement

310
 Controls 6
Electro-hydraulic controls 68

Fig. 11 - AGROSHIFT solenoid valves - HIGH clutch engagement.

311
 6 Controls
68 Electro-hydraulic controls

Adjustment of front and rear differential lock control

Turn fork A and lock nut B to preload spring C, so as to obtain a distance X allowing contact with piston E (with spring D
attached) when the piston is positioned flush with surface F (on version with electrohydraulic controls) or protrudes 18.5
mm (on version with mechanical controls).
Also check that the shoes of the fork do not rub against the sides of the engagement sleeve.
For adjustment of engagement sleeve, see chapter on front-wheel drive.
To make sure that the shifting of the piston of the rear differential look is of 12 mms.

Fig. 12 - Front and rear differential lock control.

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 Body 7
Driving position 71

Platform

Fig. 1 - Instrument panel. Fig. 2 - Roll bar.

Fig. 3 - Structure of the platform.

313
 7 Body
71 Driving position

Cab
general specifications

The cab responds to international standards in terms both of safety and of internal noise levels. The enclosure is
equipped with ventilation, heating and air conditioning systems.
Versions available are:
— Cab with ventilation and heating
— Cab with ventilation, heating and air conditioning

Fig. 4 - Structure of cab. Fig. 5 - Front window glass and seals.

Fig. 6 - Front windows glass and seals. Fig. 7 - Cab doors

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 Body 7
Driving position 71

Fig. 8 - Rear window. Fig. 9 - Internal claddings

Fig. 10 - Cab roof. Fig. 11 - Screenwash pump and liquid container.

315
 7 Body
71 Driving position

Fig. 12 - Cab air filter unit

1 - Air filter
2 - Protective grille

Cab air filter

Periodically (as dictated by operating conditions): clean the filter.
To gain access to the filter, lower the protective grille,release the two filter clamp knobs, and remove
The filter is cleaned as follows:
— blast with compressed air (6 bar max) in the direction opposite to that of normal filtration, until all accumulated dust
has been dislodged;
— wash for about 15 minutes in a solution of detergent and water at 40 °C;
— rinse clean in running water;
— leave to dry naturally at ambient temperature.
Important: the filter must be replaced if damaged, or renewed routinely after cleaning 6 times.

Screen wash
Periodically (as dictated by operating conditions):
check the level of screenwash liquid in the plastic container located at the rear of the machine.
In the event of the jet being rendered defective by an obstruction, this will be remedied generally by freeing the nozzle
outlet with a pin.
If necessary, reposition the nozzle so that the jet strikes the screen at the top of the sweep made by the wiper blade.
It is good policy during winter months to add antifreeze solution to the screenwash liquid, or methyl alcohol.
Warning: it is important that all glass in the cab is kept thoroughly clean.
The rear view mirrors must always be kept clean and properly positioned.

Screen wipers (front and rear)

The wiper blade has a bayonet fitting.
The blade is removed by lifting the catch of the central mounting.

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 Body 7
Driving position 71

Fig. 13 - Front screen wiper. Fig. 14 - Rear screen wiper.

REMOVING THE DRIVING PLATFORM COMPLETE WITH CAB

NOTE: even though not strictly necessary, we advise that you remove the rear wheels to facilitate access to parts re-
quiring disconnection.

PROCEED AS FOLLOWS:

— Using a hydraulic jack, raise the rear of the tractor and place stands under the rear trumpet housings, then remove
the rear wheels;
— Remove the top engine hood;
— Remove the front panel, disconnecting the leads of the front lights and then disconnect the positive (+) and nega-
tive(-) battery leads;
— Disconnect the leads from the starter motor and the engine oil pressure switch;
— Disconnect the bulkhead connector of the dashboard warning lights;
— Disconnect the leads on the right-hand side of the gearbox connected to the solenoid valves of the electro-hydraulic
services and the AGROSHIFT unit;
— Disconnect the lead connected to the actuator of the electronic accelerator (only on tractors equipped with electronic
governors);
— Disconnect the two tie-rods of the THROTTLE and ENGINE STOP from the governor;
— Disconnect the lead connected to wheel speed sensor positioned on the left-hand side of the front gearbox;
— Disconnect the three leads connected to the PTO selection sensors (540-775-1000 rpm);
— Disconnect the lead to the cab heating element from the heater alternator;
— Disconnect the oil pipe from the clutch control actuator;
— Disconnect the brake pipes from the “separate brakes” valves;
— Disconnect the lift control rods and remove them from the tractor;
— Disconnect the hydrostatic steering oil delivery and return pipes underneath the platform and on the right-hand side
of the gearbox;
— Disconnect the three 3 control levers GEARCHANGE-INVERSOR-RANGE GEARS from underneath the platform,
removing the retaining screws of each lever;

317
 7 Body
71 Driving position

— Remove the two securing straps of the exhaust silencer and remove the silencer itself;
— Detach the two pipe clamps positioned in the channel passing over the engine and disconnect the oil return pipe
from the cooler and the oil pipe of front lift;
— Disconnect the two hydrostatic steering delivery-return pipes from the hydrostatic steering oil cooler;
— Disconnect the lead and remove the brake and clutch oil reservoir securing strap;
— Disconnect the handbrake control and the synchro PTO control rod on the left-hand side under the driving platform;
— Loosen the 4 screws securing the platform to the silent-blocks;
— Disconnect the air conditioning system pipes at the quick-fit couplings and then loosen the respective retaining nuts
of the pipes connected to the cab so that they may be detached from their support brackets;
Connect the cab to a suitable hoist and raise it, taking care that it disengages form the tractor, then remove it from the
tractor;

Fig. 15 - Disconnecting the parts connecting Fig. 16 - Lifting the cab off the tractor using a hoisting.
the cab to the tractor.

Remove cab.

WARNING: during the cab hoisting operation, check care-

fully that all the parts have been disconnected and that the
cab disengages from the tractor.

IMPORTANT: If the fuel tank is also to be removed, discon-

nect the flexible pipe from the rigid injector leak-off pipe.

Refitting the cab or driving platform.

Refitting: the reverse of removal.

BREAKAGE OF THE TOP ENGINE HOOD RELEASE CA-

BLE

To open the hood, insert a screwdriver between the hood

and the grille to operate the hood catch.
Push the screwdriver to the left (relative to the driving posi-
tion) to release the hood.

Fig. 17 - Position the cab on suitable supports and

proceed with the operations on the tractor.

318
 Body 7
Driving position 71

Fig. 18 - Hood catch release control. Fig. 19 - Condenser and filter/dryer unit.

Fig. 20 - Air conditioning system pipes from compressor Fig. 21 - Air conditioning system compressor
to condenser and from the condenser to the filter/dryer.

319
 7 Body
71 Driving position

84

Fig. 22 - High visibility cab air filter Fig. 23 - Coverings and outlets for air circulation in high
visibility cab

Fig. 24 - High visibility cab roof.

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Air conditioning 86

Ventilation
The ventilation unit is housed in the cab ceiling.
To switch it on and adjust it, turn the electrical fan switch to the desired speed.
The cab becomes slightly pressurized when the ventilation system is in operation, so that fresh air can enter only by way
of the filter installed in the rear section of the cab roof.
The fan switch can be operated only after the ignition key is inserted.

The air flow can be regulated and directed by suitably positioning the air diffusers.
Air can be taken in fresh from outside or recirculated from within the cab by way of the relative side inlets.
· Recirculation inlets fully closed: air is taken in entirely from outside the cab through the rear grille and filte-
red through a paper element positioned behind the grille.
· Either fully or partially open air recirculating grille: now the air is recirculated inside the cab.

N.B. - It is very important that the air diffusers never be completely closed so as to allow for a steady air flow.
To obtain a greater pressurization inside the cab, it is necessary to take the air from the outside, therefore the inside air
recirculating grille should be fully closed.

Climate control system

A - Condenser

B - Temperature sensor

C - Control switches

D - 2400 Watt electric heating element

(resistance across terminals 0.655 ohm)

E - Defroster

F - Ventilation unit

Heating System
The heater is switched on and adjusted by rotating the control knob at the roof console, then switching on the blower
and setting the selector at the preferred speed.
To warm the cab up quickly, the knob should be rotated fully clockwise and the blower set to speed III.
The screen is demisted or defrosted by air directed through a slot vent.
For defrost or fast demist, all other vents should be closed off.

IMPORTANT: ventilation is provided by a single blower unit serving both the heating system and the air-conditioning
system.
After reaching the desired temperature adjust the system to suit your needs.

N.B. - For ideal system operation, the engine must run at 1600 r.p.m.
WARNING:Before starting the engine, make sure the system is off (by turning off the ventilation fan) so as not to overlo-
ad the battery.

After using the system at full power for a long period of time, never turn it off suddenly but let it first idle for about 20 se-
conds.

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86 Air conditioning

System configuration
The heating system consist of two units:
1 - Electric heater (3 Fig. 1) and blower unit (4 Fig. 1) installed behind roof console.
2 - Power supplyng set, consisting of an auxiliary alternator (1Fig. 1) located front of the engine and driven by a belt di -
rectly linked to the engine pulley.

If the air does not come out from the diffusers right away as soon as the system is started, turn off immediately and iden-
tify the fault.

N.B. Never turn on the heating system when working in dusty environments.

In the event of the system failing to operate, check the fuse in the roof terminal box.

Fig. 1 - Configuration of ventilation and heating unit.

1 - Alternator
2 - Compressor
3 - 3 speed fan
4 - Electric resistence
5 - Evaporator
6 - Ventilator
7 - Dehydrating filter
8 - Condenser
9 - Air filter
10 - Recirculation inlets
11 - Pivotable air diffusers

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Air conditioning 86

Temperature sensor

Ventilation switch

Temperature control potentiometer

Heating control unit

Fig. 2 - Ventilation - heating system.

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86 Air conditioning

Temperature control knob

Blower motor

Heating relay

Fig. 3 - Components of the ventilation - heating system.

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 Systems 8
Air conditioning 86

Air conditioning unit for cabs

The air conditioning system will operate only with engine running and the 3-speed electric fan unit switched on.

Technical specifications

type of refrigerant R 134 a

inlet circuit pressure (*): high bar 2,5
- normal bar 0,8 ÷ 2,5
- low bar 0,8
delivery circuit pressure bar see page 350
quantity of refrigerant in circuit g 1400
quantity of oil cc 200
type of oil Suniso SP20
minimum pressure switch settingbar 2
maximum pressure switch setting bar 27
electric fan pressure switch setting close at 15 bar - open at 11 bar
tightening torque for pipeline fittings kgm (Nm) 6 (58)

(*) Pressure is influenced by ambient temperature; in normal operating conditions, with a temperature of 27 °C, pressu-
re in the delivery circuit will be 12 bar.

Pressure in the same system will register at around 16 bar with an ambient temperature of 38 °C.

1 - Electromagnetic coupling
2 - Compressor
3 - Condenser
4 - Fan
5 - Filter
6 - Sight glass
7 - Minimum pressure switch
8 - Electric fan control
pressure switch
9 - Maximum pressure switch
10 - Expansion valve
11 - Evaporator
12 - Bulb
13 - Potentiometer

Fig. 4 - Diagram showing operation of air conditioning system.

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86 Air conditioning

Operation and maintenance of the air-conditioning system

Air-conditioning process

The cooler is provided with a three-speed fan which aspirates the air from the cab interior thereafter forcing it across the
radiant block, thus making it cool down.

The heat exchange occurring between the gaseous coolant and the air lapping the walls of the cooler radiant block re-
sults in air cooling.

The conditioned air undergoes a humidification process, as the low temperature inside the cooler causes a great deal of
condensate to deposit on the external walls of the cooler. This condensate is subsequently conveyed under liquid state
outside the cab through a special drainage system.

The coolant at the cooler exit is still under gaseous state and has a temperature of 5 to 10°C, in spite of the thermal ex-
change that has taken place, and then it is aspirated by the compressor again.

How to operate the system

Before starting the air-conditioning system set the electric fan onto the desired speed. If the electric fan is switched off,
the conditioning system will not start.

The air-conditioning system is turned on by progressively rotating the control potentiometer clockwise, which is located
in the front top section of the cab compartment. Rotate it anticlockwise to turn the system off.

Warning: Before starting the engine, always make sure the air-conditioning system is switched off so that the battery
will not be overloaded.

When the air-conditioning system is operating, the pivotable air diffusers should never be completely closed.
To obtain a quick cab environment cooling the following is recommended:

— Fully open the air recirculation grating and the pivotable air diffusers;

— Turn first the fan control and then the potentiometer control all the way out;

— Open the doors a few seconds so as to let the hot air out of the cab compartment if the tractor has stood under
the sun radiation for a long period;

— Adjust the system according to personal preference when the desired temperature has been attained.

Checking the air-conditioning system charge

System fully charged Sight glass clear

(refrigerant entirely in liquid state)
System fully discharged
(refrigerant entirely in gaseous state)

Sight glass cloudy

System not fully charged (Bubbles or foam visible)
Refrigerant in part gaseous and part liquid state

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 Systems 8
Air conditioning 86

The system is activated by way of the 3 speed

Switching on the air conditioning electric fan switch.

Once the potentiometer is moved beyond

the initial contact, a voltage of 12 V is gene-
rated between terminal B (red wire) and the
brown wire terminal of the potentiometer.

Engagement and disengagement is piloted

Electromagnetic coupling by the temperature control potentiometer,
and by the pressure switch located at the
demoisturizing filter which cuts in respecti-
vely at: 2 bar and 27 bar.

Pressure switch (positioned on demoisturi-

zing filter). Comprises 3 switches:
Pressure switches — 1 controlling minimum pressure
— 1 controlling maximum pressure
— 1 controlling the electric fan of the con-
Expansion valve denser. The electric fan unit is interloc-
ked to the pressure switch, which is set:
- to close the circuit at 15 bar
Temperature sensor - to open the circuit at 11 bar

Electric fan unit

By-pass the pressure switch (place jumpers across the two terminals of the pressure switch and the 2 leads of the fan
unit).

If the fan operates: the pressure switch is defective

If the fan does not operate: a) check the fuse;

b) check the relay.

Tracing faults in the electric fan unit

Fault Causes Action

Fan does not start Defective pressure switch Replace pressure switch

Defective relay Replace relay

Defective electrical or mechanical Replace fan unit

motorino difettosa

Relay (see electrical diagram)

Place a jumper across terminals 30 and 87a; if the fan comes into operation, the relay needs to be replaced.

Water dripping from the points at which condensate drain lines are connected to the condi-
tioning unit
The problem can be overcome by loosening the clip that fastens the drain line to the cab upright and pulling the tube
downwards, so that the water can run away freely.

327
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86 Air conditioning

Fig. 5 - Compressor, air conditioning system.

Fig. 6 - Demoisturizing filter, air conditioning system.

328
 Systems 8
Air conditioning 86

Checking system
Check belt tension: under finger pressure applied to the mid point between the two pulleys, belt should not deflect more
than 8 to 10 mm maximally.

Always keep condenser fins duly clean.

Cleaning should be carried out by a water or air jet (be careful not to bend the fins, use the special combing tool to straig-
hten them again).

Ascertain the compressor is firmly secured to tractor and the pulleys are properly aligned.

Warning: When removing the strainer or the air-conditioning unit it is required to plug the inlet and the outlet pipes at
once, this is to prevent both dust and moisture from entering.

Even a few minutes’ exposure to the environmental humidity makes it necessary to replace the filter.

System safety elements

Minimum pressure switch (7 Fig. 4).
Switches the system off when a failure causes the pressure to drop below 2 bar within the high pressure circuit.

Maximum pressure switch (9 Fig. 4).

Switches the system off when pressure exceeds 27 bar inside the circuit as a result of an excessive setting or a failure
(high pressure area).

Condenser fan control pressure switch (8 Fig. 4)

Switches the condenser fan on when coolant attains the same pressure of the switch setting pressure.

Note: The above three safety devices are grouped inside the thermostatic bulb located on the dehydrator filter. (figura
6 page 328).

Temperature regulation

Temperature regulation is obtained through the potentiometer, which automatically regulates the temperature of the air
flow from the radiator according to the environmental temperature, through a combined action with the fan.

A pressure switch located on the electric circuit opens and closes the electric circuit of the compressor electromagnetic
coupling as a consequence of the potentiometer operation. When the circuit is open the pulley will be idling, on the other
hand, when the circuit is closed, this will operate integrally with the compressor shaft.

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86 Air conditioning

Charging the system

with recharging station p/n 5.9030.508.6

1 - High pressure gauge

2 - Low pressure gauge
3 - Low pressure valve
4 - Vacuum pump valve
5 - Metering pipeline valve
6 - Recharge pipeline valve
7 - Metering pipeline
8 - Vacuum pump pipeline
9 - Low pressure circuit recharge pipeline
(blue)
10 - High pressure circuit recharge pipeline
(red)
11 - Vacuum pump
12 - Electric switch
13 - Metering gauge
14 - Air bleed valves
15 - Metering unit
16 - Electrical power supply
17 - Compressor
18 - Refrigerant bottle
19 - Electric leak detector
20 - Electric heater element for refrigerant

Fig. 7 - Charging station for air conditioning circuit.

Filling the metering unit

Connect the refrigerant bottle to the metering unit by means of the high or low pressure hose (9 - 10 Fig. 7).
Make certain that the valve (5 Fig. 7) is securely shut, then open the valve of the bottle.
As the refrigerant flows into the metering unit, open and shut the air bleed valve (14, Fig. 7) intermittently.
Read the value given by the hand of the metering unit pressure gauge (13, Fig. 7) and position the value against the indicator.
Once 1400 grams of refrigerant have been transferred into the metering unit, close the valve of the bottle and detach the hose.

Refilling the system with oil

Connect the high pressure hose (9, Fig. 7) of the recharge station by way of the smaller diameter valve A (Fig. 8) positioned
on the pipeline connecting with fitting D (Fig. 5) at the compressor (mounted in the engine compartment), and the low
pressure hose (10, Fig. 7) of the station by way of the larger diameter valve B (Fig. 8) positioned on the pipeline connec-
ted with fitting S (Fig. 5) at the compressor; then activate the pump for 30 minutes approx to establish a vacuum in the
circuit.
The valves (3 - 4 - 5 - 6, Fig. 7) must remain open during this operation.

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 Systems 8
Air conditioning 86

Filling the system with oil

Detach the low pressure hose from the recharge station and immerse the end in a graduated vessel containing 200 g
approx of SUNISO SP 20 or equivalent oil. Allow 250 grams of the oil to be drawn into the circuit.
Reconnect the hose to the station.

Filling the system with R134a refrigerant

When the low pressure gauge (2, Fig. 7) registers a minimum value (760 mm Hg) that remains stable for between 5 and
10 minutes, close the valve (5 Fig. 7).
Open the filler valve (5, Fig. 7) and wait until the specified quantity (1800 g) of refrigerant has entered the system.
In the event that the flow of refrigerant contained in the metering unit should be interrupted, warm the unit by means of
the electric heater (20, Fig. 7), rechecking the pressure on the relative gauge.

Should this not be sufficient, start the engine and throttle up to 1200 rev/min approx. Switch on the air conditioning
system, and the R 134a refrigerant will be drawn directly into the circuit by the compressor.

Close the filler valve (5, Fig. 7), and check with the leak detector that there is no escape of fluid from the fittings of the cir-
cuit. Should any leaks be detected, these must be eliminated, and the refrigerant reintroduced.

Caution: In the event of oil leaks being detected, the circuit must be emptied completely and the entire recharge proce-
dure recommenced.

Fig. 8 - Valves for connection of the tractor to the air conditioning recharge and service station.
A - “HIGH PRESSURE” valve
B - “LOW PRESSURE” valve

Final checks
Once all the refrigerant has been put into the air conditioning circuit, check (with the engine running and the system in
operation) that the high pressure gauge shows a value of between 15 and 20 bar, and the low pressure gauge a value
between 1.5 and 2.5 bar.

331
 8 Systems
86 Air conditioning

Verifying operation of the system after recharging

The system can be regarded as performing to its full capabilites when the delivery pressure gauge shows the following
values:
Ambient temperature °C Delivery circuit pressure

27 12 bar
32 14 bar
35 15 bar
38 17 bar
40 18 bar
43 20 bar

The temperature values indicated are those likely to be encountered in the course of a typical twelve month period.

Having established that the system is operating correctly, detach the high and lower pressure hoses of the station from
the tractor and check again with the leak detector that there is no escape of fluid from any part of the system.

CAUTION: use only R 134a refrigerant as indicated on the Connecting the tractor to the air conditioning system recharge
data plate attached to the compressor of the air conditioning and service station.
system.

Directions for tightening air conditioning system pipeline fittings.

All fittings have an internal seal. Screw the two parts of the fitting together by hand until the nut is finger tight, then hol-
ding the one part steady with a fixed wrench, apply a torque wrench to the nut and tighten to the value indicated in the ta-
ble.

Type Thread Tightening torque

6 5/8” - 18 UNF 13,6 ÷ 20,3 Nm (1,4 ÷ 2,1 kgm)
7 3/4” - 16 UNF 33,5 ÷ 40,0 Nm (3,3 ÷ 4,0 kgm)
8 7/8” - 14 UNF 35,5 ÷ 42,0 Nm (3,6 ÷ 4,3 kgm)
9 1 1/16” - 14 UNF 40,3 ÷ 47,3 Nm (4,1 ÷ 4,8 kgm)

332
 Systems 8
Air conditioning 86

Fig. 9 - Control switches

1 - Heating control.
2 - Air conditioning control.
3 - Ventilation control.

Fig. 10 - Receiver-drier located in cab roof. Fig. 11 - Ventilation - conditioning - heating.

1 - Level sight glass.

333
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86 Air conditioning

Dettaglio A
Detail

+ -
CAVO BLU' CAVO NERO
BLUE CABLE BLACK CABLE

3/4"-16UNF-2A A

5/8"18 UNF-2A

Fig. 12 - Components of the ventilation - conditioning - heating system. Fig. 13 - Air handling unit for high visibility cab

334
 Systems 8
Air conditioning 86

Fig. 14 - Condenser and fan unit for high visibility cab

335
 8 Systems
86 Air conditioning

Fig. 15 - Ventilation-heating unit for high visibility cab

336
 Systems 8
Air conditioning 86

Fig. 16 - Ventilation-heating unit components for high visibility cab

337
 8 Systems
86 Air conditioning

Fig. 17 - Climatisation system components for high visibility cab

338
 Systems 8
Diagnosing malfunctions 86

Diagnosing malfunctions

LOW PRESSURE CIRCUIT

excessive pressure compressor not overcharged circuit release system

in the high pressure operatin smoothly pressure through
circuit the compressor ne-
edle valves
Excessive pressure
too a low pressure pressures inside expansion valve replace the valve
in the high pressure both high and low jammed up
circuit pressure circuits
tend to balance

excessive pressure bubbles are visible air in the circuit dehydrate the cir-
in the high pressure through the filter in- cuit
circuit spection glass
Normal pressure
normal pressure in poor system effi- Out-of-setting com- replace the valves
the high pressure ciency pressor needle val-
circuit ves

after some working humidity inside the replace the filter and
time circuit bleed the air. Re-
charge the circuit

normal pressure in expansion valve replace the expan-

the high pressure jammed up sion valve
Excessively low pres- circuit
sure
blocked circuit change the part and
replace the filter

low pressure in the discharged system recharge system

high pressure cir-
cuit

burnt fuse replace the fuse

System fails to operate

disconnected wires connect the wires

inspect with a le- stop the leakage

Poor system efficiency coolant leaks ak-finder and recharge the
system

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 8 Systems
82 Hydraulic system

Hydraulic system

KEY TO FIGURE 1:

1 - Delivery line pressure test point

2 - Hydrostatic steering - maximum hydrostatic steering pressure (see instructions on page 284)
3 - 4WD steering cylinder pressure test point
4 - 2WD steering cylinder pressure test point
5 - Gearbox oil cooler
6 - Electro-hydraulic control unit (see instructions on page 190)
7 - Hydraulic power unit pressure test point (see instructions on page138-190)
8 - Lubrication oil pressure test point
9 - Agroshift
10 - Hydraulic unloader for equalising oil level in gearboxes
11 - Gearbox lubrication
12 - Rear P.T.O. (see instructions on page 190)
13 - Diff. lock hydraulic actuators
14 - 4WD engagement hydraulic actuator
15 - Trailer braking hydraulic control valve
16 - Pressure test point for trailer braking hydraulic control valve
17 - 8-way auxiliary control valve (see instructions on pages 348)
18 - Pressure relief valve oil pressure test point
19 - Kick-out oil pressure test point (see instructions on page 348)
20 - Hydraulic ways oil pressure test point
21 - Connected implement
22 - Rear lift
23 - Front lift antishock valve and accumulator (see instructions on page 272)
24 - Implement coupled to rear lift
25 - Lifting cylinder
26 - Rear lift antishock valve
27 - Front lift (see instruction on page 272)
28 - Lifting cylinder pressure test point
29 - Front lift antishock valve
30 - Shut-off valve for oil supply to front lift
31 - Free oil return line on rear of tractor (for hydraulic motors)
32 - Front P.T.O. control valve (see instructions on page 276)

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 Systems 8
Hydraulic system 82

ATTREZZO COLLEGATO
24

Pressione dii esercizio 23

3 4
(V=0.84 dm )
3
25
Sollevatore anteriore Rear lift
con attrezzo collegato
28
Pressione di esercizio 210 Bar

150 bar 8 Bar A

100 bar
26
L R 27
70 Bar

700 cc
SOLLEVATORE
ANTERIORE 22
B
OSPC 80 OR SOLLEVATORE
POSTERIORE
2 A

GUIDA
IDROSTATICA
29 P

100 Bar 2 WD
30
150 Bar 4 WD 6/20 L/min. 18 190 bar
ATTREZZO COLLEGATO
150 bar
T P
190 bar 20 19
5 21
Rear free return
B A B A B A

31 190 bar
T

Diff.look
12
Main shaft 16 P-Ecc.
32 cc
Dis.
Inn.

4 Wd PTO
Front Rear
11
17
Inn.
Dis.

N
DISTRIBUTORE IDRAULICO
Trailer brake
Sec. shaft
ø 1.1
13 14 16 bar

A A A
1 15 P-Reg.

DISTRIBUTORE IDRAULICO
P T P T P T PER LA FRENATURA DEL RIMORCHIO
6 Y Tractor brake
CENTRALINA COMANDI ELETROIDRAULICI
11 bar

7 16 bar 5 bar
P Freno inser.=13 bar,disinser.=5 bar

16 bar 5 bar 8
P T 9 P T
19 cm
3
11 cm 3 13 bar 4 bar
AGROSHIFT 47 L/min. 27 L/min.

A A N.giri/min.pompe:2522
ø1 Rh Lf
H M L
Rapp. 1/1.0732 (44/41)
32
VALVOLA DI COMANDO
10 25 Micr. PTO anteriore
x

25 Micr.

V max V max V max

11.6 cm 3 14.7 cm 3 13.9 cm 3

F.to A2

Fig. 1 - Points provided for measurement of oil pressures in the tractor’s hydraulic system (see references on page 340).

341
 8 Systems
82 Hydraulic system

Oil filters
The oil filters are mounted to the rigth hand side of the transmission at the rear end, and are easily replaced.
Filters must be replaced whenever the blockage indicator lights up at the instrument panel.
The filter blockage pressure switch is set at 0.5 bar, and must be replaced with another of identical specifications if faulty.
Ensure that the replacement is stamped with the correct 0.5 bar setting.
Whenever the transmission is stripped down for servicing or overhaul, clean the mesh strainer fitted to the bottom of the hou-
sing.

CAUTION - Operate the lift system and auxiliary spool valves only when the blockage indicator is no longer alight.

IMPORTANT - If during normal operation of the machine the clogging filter indicator should light up, remplace the filter.

Hydraulic pumps
The hydraulic pumps require no servicing or adjustment even after a long period of operation, although the splines of the
pump shaft must be inspected with care: there must be no signs of wear or damage.

Checking the relief valves of the hydraulic lift system

Using tool 5.9030.520.4, check that the circuit pressure relief valve incorporated into the auxiliary spool valves is set at 190 Fig. 3 - Pump assembly cover. Fig. 4 - Pump case.
bar and the system pressure shock valve at 210 bar. A - Cover B - Pump case.
Remember that for the lift to function correctly, operating pressure in the circuit should not exceed 150 bar. B - Pump case
C - Base
The operating pressure can be measured by coupling a gauge to the oil pressure line between the directional control valve
and the lift; for machines with assistor cylinders, the gauge can be coupled to the pressure line connecting with the assistors.
Stripping the hydraulic pump
Removal

The pump is secured to the tractor by 2 of the 4 bolts holding the pump assembly together. These two bolts are diagonally op -
posite.
Having removed the pump from the vehicle, the components are freed by unscrewing the two remaining bolts which keep the
cover A (see fig 3) clamped to the frame C and the pump body B; this done, remove the washers and then the cover.
Using a proper pointed tool remove gasket E (Fig. 6 pag. 343), mark with a reference the position of the bearings with respect
to the pump case and then take the bearings from their seats by pushing from inside outwards and being careful the connec-
ting pin neither be lost nor damaged.
A - Snap-ring H - Bearing
B - Seal ring I - Bushes Block the pump case in a vice as shown in figure and then remove snap ring F.
C - Cover L - Driver gear
D - Gasket M - Pump case Remove the seal ring.
E - Gasket N - Gasket
F - Gasket O - Driver gear
G - Feather key P - Cover

Fig. 5 - Pump disassembly.

B - Pump case
C - Base
D - Bearings
G - Gears
I - Screw

Fig. 2 - Component parts of the hydraulic pump assembly

342
 Systems 8
Hydraulic system 82

WARNING - If pump bearings, pinions or casing are found to be

damaged or worn, these parts cannot be repaired because of their
construction tolerances.

When performing checks, because of an oil leakage or an exces- D - Bearing

sive and irregular delivery pressure, only the gaskets indicated in E - Gasket
the spare parts lists can be replaced.

After checking the pump for wear due to abrasion from impurities
and for any other visible damage, when reassembling use, in any
case, a new set of gaskets.
It is also indispensable to mark each single part to reinstall cor-
rectly.

Inspections and checks

After removing all gaskets, both on the covers and in the pump ca- Fig. 6 - Internal pump case parts.
sing, carefully clean all parts using a proper solvent.
Carefully dry all parts with compressed air; this is to avoid that any
solvent residuals may damage the gaskets on reassembly.
Visually check the pump case internally and ascertain it is not da-
maged.
Check both pinions and bearings for wear, abrasion due to foreign
matters or cavitation.

NOTE: Should any damage, wear or in any case a component re-

placement be required, with the exception of the gaskets, the enti-
re pump must be replaced.

WARNING: Do not press onto the stop ring to prevent any damage.
+ 0, 05
Use a dial gauge to make sure the stop ring height be 21
, - 0,15 mm, C - Housing
otherwise replace taking care the new stop ring installed be mea- D - Bearing
G - Gear
sured accordingly. H - Bush
If reading is above specification fit the new ring in reversed posi-
tion. Fig. 7 - Pump gears.

A - Stop ring
B - Gasket
C - Bearings

C - Base
F - Snap ring

Fig. 9 - Inside seals. Fig. 8 - Snap ring removal.

343
 8 Systems
82 Hydraulic system

1064-48

A - Seal ring
Fig. 10 - Seal ring. Fig. 11 - Piloted check valve components

Assembly
Before assembly all parts shall be oiled.
Correctly position the gaskets in their seats paying particular attention stop ring A and gasket B be correctly fitted into bea-
rings C (see fig. 9). Coat the cover inner side with a slight grease layer then apply to pump case and tightening the secu-
ring screws to the recommended torque.

WARNING:The securing screws should be tightened gradually making also sure that rotors are not hampered in their
movements.

Tightening torques
Pump cover securing screws:
- M8 2 kgm (20 Nm)
- M10 5 kgm (49 Nm)
Restore the recommended oil level and then bleed the air from the hydraulic circuit.

Fig. 12 - Connection of check valve to hydraulic control valve.

NOTE: To ensure correct operation of the check valve, it must be connected to the element of the control valve
fitted with DETENT (as shown in the figure ).

344
 Systems 8
Auxiliary systems 88

Auxiliary hydraulic spool valves

Auxiliary spool valves are used to control hydraulically operated external implements.
The controls consist in 2 levers for a 4-way valve, or 3 levers for a 6-way valve.
The levers are located on the driver’s right hand side.

Auxiliary hydraulic spool valves:

Version 1: 4 way, 2 way double acting - 2 way double acting convertible to single acting, with spool detent

Version 2: 6 way, 2 way double acting convertible to single acting, with kickout - 2 way double acting convertible to sin-
gle acting, with spool detent (with perfect sealing valve) - 2 way double acting with float position - throttle valve (FLOW
DIVIDER) with tap in cab - quick coupling for free discharge.

NB:with the auxiliary spool valve in use (unless a Flow Divider is incorporated), the operation of the hydraulic lift system
remains inhibited (except in FLOAT position).

Important: the lever should be recentred to the neutral position as soon as the external actuator has reached its stroke
limit, to ensure that the hydraulic circuit does not remain pressurized any longer than strictly necessary; prolonged pres-
sure will result ultimately in the hydraulic system being subjected to hazardous levels of stress.
Auxiliary spool valves levers must always be in the neutral position when external services are not in use.

Fig. 1 - 4-way auxiliary control valves.

A - Quick coupling for free discharge

345
 8 Systems
88 Auxiliary systems

Fig. 2 - 4-way auxiliary control valves.

A - Quick coupling for free discharge
B - Pressure relief valve.

346
 Systems 8
Auxiliary systems 88

NOTE : The 6-way auxiliary spool valve incorporates a FLOW DIVIDER which ensures that oil can be delivered at a
constant flow rate of between 3 and 42 l/min to the 2-way kickout section (first valve alongside the flow divider).
The tap has set in the cab, to left hand of the place of guide.

NB: Even when the flow divider is shut off by turning the knob fully in the direction marked (-), a residual flow of oil will
continue to reach the valve at a steady rate of 3 l/min.

4
Float
A A A
5 5

5 5

5 5

B B B

T C

P
N

B B
KICK-OUT DETENT. FLOAT

B A B A B A
T
190 bar
P-Ecc.

P N

P-Reg.

Fig. 3 - 6-way hydraulic control valve.

A - Pressure relief valve
B - Screws to convert from double-acting to single-acting control valve
C - Perfect seal valve
P - Hydraulic pump
N - To rear lift
T - Return

347
 8 Systems
88 Auxiliary systems

Checking the pressure relief valve setting

The setting of the pressure relief valve must always be 190 bar,
and can be checked by fitting gauge p/n 5.9030.513.0 to either of
the valve work ports and operating the relative lever. If the gauge
reading is not correct, adjust the pressure relief valve see pages
346 - 347

NOTE: Remember that the purpose of the relief valve is to mainta-

in pressure in the hydraulic lift circuit within a given safety limit, in
this instance 190 bar.

Fig. 4 - Checking the operating pressure of auxi-

liary spool valves.
A - Quick coupler
B - Implement oil line Checking the operating pressure (see fig 4).
C - Tee To verify the operating pressure of an implement connnected to
the work ports of the auxiliary spool valves, proceed as follows:

— Connect a Tee between quick coupler A and the implement

pressure line B.
— Connect pressure gauge p/n 5.9030.513.0 to the Tee.
— Start the engine, apply the parking brake in the interests of sa-
fety, and operate the spool valve connected to the implement.
— The gauge will show the operating pressure currently registe-
ring in the circuit.

The operating pressure depends on the weight of the hitched im-

plement, and should not normally exceed 150 bar.
Fig. 5 - A conversion screw allowing conversion
from double to single acting operation; B conver-
sion screw lock washer.

Conversion of auxiliary spool valves from double

acting to single acting operation (see fig 5)
Where particular requirements dictate, a double acting spool val-
ve can be converted to operate in single acting mode.

To effect the conversion from double to single acting, hold the fit-
ting secure and loosen the screw A by between 4 and 5 turns.
NOTE: Once slack, the screw is best rotated by hand to avoid
applying excessive force and unseating the lock washer B; if this
were to happen, the washer would find its way into the hydraulic
circuit and disallow normal operation of the lift system.

The conversion from single to double acting operation is effected

by tightening the screw A fully.

Checking the surface of the valve spools

Check that the machined surface of the spool is free of scoring or
any other kind of wear.

Fig.6 - Longitudinal section through 4/6-way spo-

ol valve.

348
 Systems 8
Auxiliary systems 89

Trailer hydraulic braking system

The tractor can be equipped with a trailer hydraulic braking system on request.
For trailers with “safety brake” (ITALY version), the system is equipped with a specific distributor.

The oil used is drawn from the tractor’s main hydraulic system by a special distributor.

This distributor is activated by a valve which is hydraulically connected to the tractor hydrostatic braking system control.

Trailer hydraulic braking distributor unit

Specifications (see Fig. 2, page 352)

P supply
N services connections
B trailer brake connection
T oil discharge
Y trailer braking system connection
E parking brake signaling pressure switch

Supply l/min 20 ÷ 80
Constant pressure in B bar 12,5 ± 2
(only for distributor ITALY version)
Maximum pressure in B bar 135 ± 5
(only for distributor ITALY version)
Maximum operating pressure in N bar 200
(distributor ITALY version)
Working temperature °C -20 + 100
Supply in P with hydraulic mineral oil
Pilot Y (supplied from below) with hydraulic mineral oil

349
 8 Systems
89 Auxiliary systems

Fig. 1 - Oil lines connected to directional control valve of hydraulic trailer braking system. A - bistable valve (fitted only in conjunction
with ITALY version of the control valve) allows trailer brake to be applied even when tractor brakes are operated independently.

350
 Systems 8
Auxiliary systems 89

Use of the tractor with CUNA 341/01 hydraulic trailer braking

The trailer hitched to a tractor equipped with this type of trailer braking requires a constant pressure of 12.5 ± 2.5 barin
order to release the parking brake ( spring operated).

Therefore, before hitching or unhitching the trailer, this pressure must be eliminated at the coupler by switching off the
engine, or better still, by applying the tractor handbrake.

The female quick-action couplers are specially-designed to remain connected if the internal pressure exceeds
1.5 bar.

Unless the driver waits the few seconds required to eliminate the pressure, the coupling or uncoupling operation will be
extremely difficult if not impossible.

The correct type of female coupler inserts are marked FASTER VFBO/1815F and can also be identified by the release
ring, which is 44 mm in diameter and 38 mm long.

When uncoupling is performed to hastily, the pressure in the trailer's hydraulic system will lock the coupling, and in addi-
tion to compromising the efficiency of the emergency brake, it will prevent re-coupling.

In this event:

— Uncouple the push-pull coupler which passes through the reservoir mounted on the trailer, by pulling on the pipe
connecting the trailer to the tractor.

— Discharge the pressure.

— Re-couple

Special recommendations

In order to change from parking brake applied from the trailer (tractor handbrake in lowered position) to efficient service
braking, the tractor needs to send large quantities of oil to the cylinders.
Some time is therefore required before trailer braking reaches full efficiency and therefore, should it be necessary to
use the service brake urgently, after having released the parking brake, accelerate the engine to maximum
speed before releasing the tractor handbrake.

In general, remember that if the engine revs are high, braking will be more responsive.

Users who have trailers with "France" type non-type approved hydraulic braking may adapt the SAFIM brake valve to
this type of operation by unscrewing the hex socket screw on the pilot side cover by three turns (6 mm Allen wrench).
In this way, the 12.5 bar pressure is eliminated, the red light remains on, only going out on braking.

It is dangerous to leave the valve by-pass lever in the braking position; trailers which do not conform to the Cuna 341/01
standard are not equipped any protection against this.

The lever on the valve serves to completely by-pass the valve when trailers are not to be hitched to the tractor for long
periods (on trailers which conform to the Cuna 341/01 standard, even if the lever is left in the OFF position, the trailer
parking brake is not released).

351
 8 Systems
89 Auxiliary systems

Starting

1 - Trailer parking brake control knob

(present only on mechanically operated valves)
A - Rotation for engagement
B - Rotation for disengagement

Fig. 2 - Control valve for hydraulic trailer braking.

No special precautions are required, simply start the engine and allow time(10-15 seconds) for the hydraulic pipes to fill
with oil before operating the brake pedal.

Checking operation

The red indicator light illuminates when the pressure at the trailer brake coupling is less than 10 bar; the light therefore
gives an indication of whether the system is functioning correctly.
During normal operation, providing the handbrake is released and the brake pedal is not depressed, the red light should
be off.
When the handbrake is applied, the light will stay on even if the brake pedal is pressed.
The light also comes on if the engine stalls under load, as there will be no pressure at the trailer brake coupling.
In normal operation with the handbrake released, on pressing the brake pedal it is possible to hear the pump as it incre-
ases the pressure.
To test the pressures, apply a pressure gauge with a minimum full-scale value of 160 bar to the trailer brake coupling.

352
 Systems 8
Auxiliary systems 89

Fig. 3 - Operation of the hydraulic control valve

1 - Brake ON/OFF control
2 - Lift
3 - Trailer brake
4 - Trailer brake lever

353
 8 Systems
89 Auxiliary systems

The pressure readings to be taken are:

— Engine running with handbrake released: 12.5 ± 2.5 bar (10 to15 bar)
— With handbrake applied: 0 bar
— With handbrake released and brake pedal depressed, the pressure will rise from 12.5 to 130 ± 10 bar (120 to
140 bar).

N.B.: the valve is factory-set by Safim.

( ) values in brackets refer to pressure limits specified by the Cuna standard.

Malfunctions

Insufficient pressure Check the position of the valve by-pass lever, which should be ali-
gned with the axis of the valve.

Release the handbrake lever.

For valves with mechanical par- Check that the lever on the valve returns to the limit stop when the
king brake control handbrake is lowered.

Check that the microswitch is functioning correctly (operated

when the handbrake is lowered).

Check the power fuse and the power supply in general.

For electrically controlled valves
Check the connections to the coil on the two opposite poles.

If the coil is energised, by loosening the retaining nut it is possible

to feel the pull of the magnet; the coil will be very hot.

The valve pressure rises very Clean the holes of the main piston; to access the piston, remove
slowly the plug on the opposite side to the pilot side (27 mm wrench).
Withdraw the piston and blow clean.
Close the hex socket adapter screw (France type).

Clean the holes (by washing and blowing) the rapid discharge pi-
ston, which can be accessed by first removing the solenoid valve
The parking brake is slow to and the adapter.
release Warning: the valve has been tested and calibrated correctly
prior to delivery.
Before attempting to adjust the springs and the shims, to solve
pressure problems, clean all the holes of the piston and solenoid
valve with petrol and compressed air.

The pressure settings are regulated by way of shims, which can

be accessed by removing the pilot valve and withdrawing the 25
Low and high pressure settings mm diameter piston.
The internal spring regulates the pressure of 12.5 ± 2.5 bar, while
the outer spring regulates the pressure of 130 ± 10 bar.

354
 Systems 8
Auxiliary systems 89

Fig. 4 - View of the hydraulic control valve.

1 - Lever position with handbrake fully applied

2 - Start of trailer braking
3 - Lever position with handbrake released

355
 8 Systems
89 Auxiliary systems

Installing the hydraulic braking valve for trailers equipped with “safety brake” (ITALY version)
For correct valve and related controls installation, it is necessary to proceed as follows:

— Secure the distributor to the tractor and connect the various oil tubes;

— Bring the tractor parking brake lever to position A (4th notch of the toothed sector) and carry out the parking bra-
ke adjustment so that, in this position, the tractor is braked. Then bring the parking brake lever to position B
(stop notch).

— Keeping the parking brake lever in position B, hook the hose fork to lever Y, pushing it against stop screw X.
Then connect the hose to lock plate C by means of the special adjusting nuts.
Under these conditions, acting on the parking brake hand lever of the tractor synchronizes the tractor and trailer
stationary braking.

— Connect the wiring of the pressure switch, that is screwed on the distributor, to the specific warning light instal-
led on the instrument panel of the dashboard.
Then, when engaging the parking brake, the tractor warning light and the trailer warning light will light up at the
same time.

CAUTION:
When the trailer is hitched to the tractor the knob on the control valve must always be turned counter-clockwise to posi-
tion "1". When a trailer is not hitched or during trailer hitching/unhitching operations, the lever on the control valve must
always be in the position "0".

On the hydraulic distributor is placed a sensor (E Fig, 5). This sensor active the warning light on the dashboard, when
the trailer brakes is operated.

Fig. 5 - Diagram illustrating adjustment of brake control valve for trailer equipped with safety brake (ITALY version)

356
 Systems 8
Auxiliary systems 89

Fig. 6 - Components of the hydraulic control valve - FRANCE version.

357
 8 Systems
89 Auxiliary systems

Fig. 7 - Components of the hydraulic control valve - FRANCE version

358
 Systems 8
Electrical system 84

ELECTRICAL SYSTEM FOR DORADO 55 - 65 (up serial number 1112) - 75 - 85

CONTENTS

THE STRUCTURE OF THE UNIT ................................................................................................. 361

HOW TO CONSULT THE UNIT..................................................................................................... 362
INTRODUCTION ....................................................................................................................... 363
1.1 List of wiring looms ........................................................................................................... 363
1.2 Definition of components and symbols ............................................................................. 364
1.3 General rules .................................................................................................................... 364
1.3.1 Modification of the tractor’s electrical/electronic circuits ......................................... 364
1.3.2 Main wiring faults.................................................................................................... 364
1.3.3 Removal, refitting and drying of connectors and wiring.......................................... 365
1.4 Diagnostic instruments ..................................................................................................... 366
1.5 Wire colour codes ............................................................................................................. 366
2. INDICES .................................................................................................................................... 367
2.1 Component description index ........................................................................................... 367
2.2 Component code index ..................................................................................................... 373
2.3 Connector index................................................................................................................ 379
3. COMPONENTS ......................................................................................................................... 389
3.1 Connector layouts............................................................................................................. 389
3.2 Component technical data ................................................................................................ 391
3.3 Pinouts and descriptions of electronic control units.......................................................... 398
3.3.1 HML control unit ..................................................................................................... 398
3.3.2 Power lift control unit .............................................................................................. 399
3.3.3 Preheating control unit............................................................................................ 400
3.3.4 Analogue instrument panel..................................................................................... 401
3.3.5 Digital instrument panel .......................................................................................... 403
3.3.6 Engine control unit.................................................................................................. 405
4. SYSTEMS.................................................................................................................................. 407
4.1 Earthing points.................................................................................................................. 409
4.2 Starting and preheating (version with mechanical governor)............................................ 411
4.3 Lights - steering column switch unit (version with mechanical governor - platform) ......... 412
4.4 Lights - steering column switch unit (version with mechanical governor - standard cab) . 413
4.5 Lights - steering column switch unit (version with mechanical governor - high-visibility cab).
414
4.6 Accessories - Diagnostics (version with mechanical governor - platform)........................ 415
4.7 Accessories - Diagnostics (version with mechanical governor - standard cab) ................ 416
4.8 Accessories - Diagnostics (version with mechanical governor - high-visibility cab) ......... 417
4.9 Wipers (version with mechanical governor - standard cab) .............................................. 418
4.10 Wipers (version with mechanical governor - high visibility cab)........................................ 419
4.11 Front instrument panel (version with mechanical governor) ............................................. 420
4.12 Radio (version with standard cab) .................................................................................... 421
4.13 Radio (version with high-visibility cab) .............................................................................. 421
4.14 Heater (version with mechanical governor - standard cab) .............................................. 422
4.15 Heater (version with mechanical governor -high-visibility roof) ........................................ 423
4.16 Heating and air conditioning
(version with mechanical governor - standard cab) .......................................................... 424
4.17 Heating and air conditioning
(version with mechanical governor - high-visibility roof) ................................................... 425
4.18 Braking system - trailer braking (version with mechanical governor) ............................... 426
4.19 HML transmission (version with mechanical governor) .................................................... 427
4.20 Electronic lift (version with mechanical governor)............................................................. 428
4.21 Rear and front PTOs (version with mechanical governor)................................................ 429
4.22 Starting and preheating (version with electronic governor) .............................................. 430

359
 8 Systems
84 Electrical system

4.23 Electrical engine control (version with electronic governor) .............................................. 431
4.24 Lights - steering column switch unit (version with electronic governor - platform) ........... 432
4.25 Lights - steering column switch unit (version with electronic governor - standard cab) ... 433
4.26 Lights - steering column switch unit (version with electronic governor - high-visibility cab)...
434
4.27 Accessories - diagnostics (version with electronic governor - platform) ........................... 435
4.28 Accessories - diagnostics (version with electronic governor - standard cab).................... 436
4.29 Accessories - diagnostics (version with electronic governor - high-visibility cab) ............. 437
4.30 Wipers (version with electronic governor - standard cab) ................................................. 438
4.31 Wipers (version with electronic governor - high-visibility roof) .......................................... 439
4.32 Front instrument panel (version with electronic governor) ................................................ 440
4.33 Heater (version with electronic governor - standard cab) ................................................. 441
4.34 Heater (version with electronic governor - high-visibility roof)........................................... 442
4.35 Heating and air conditioning
(version with electronic governor - standard cab) ............................................................. 443
4.36 Heating and air conditioning
(version with electronic governor - high-visibility cab)...................................................... 444
4.37 Braking system - trailer braking (version with electronic governor)................................... 445
4.38 HML transmission (version with electronic governor) ....................................................... 446
4.39 Electronic lift (version with electronic governor)................................................................ 447
4.40 Rear and front PTO (version with electronic governor)..................................................... 448
LAYOUTS, ELECTRICAL WIRING DIAGRAMS, CONNECTOR POSITIONS
Engine wiring .................................................................................................................................. 449
Central wiring (Version with mechanical governor) ........................................................................ 457
Front light wiring (Version with cab)................................................................................................ 459
Central wiring (Version with electronic governor) ........................................................................... 473
Agroshift wiring (Version with mechanical governor)...................................................................... 489
Agroshift lever wiring ...................................................................................................................... 493
Electronic lift wiring ......................................................................................................................... 497
Standard cab
Roof wiring...................................................................................................................................... 503
Worklights wiring............................................................................................................................. 511
Screenwash pumps wiring.............................................................................................................. 517
Windscreen wiper wiring................................................................................................................. 518
Speaker wiring ................................................................................................................................ 519
Heater power supply wiring ............................................................................................................ 525
Heater wiring................................................................................................................................... 531
Air conditioning wiring..................................................................................................................... 537
Air conditioning fan wiring............................................................................................................... 543
High-visibility roof
Roof wiring...................................................................................................................................... 547
Worklights wiring............................................................................................................................. 553
Screenwash pump wiring................................................................................................................ 557
Windscreen wiper wiring................................................................................................................. 558
Speaker and radio wiring ................................................................................................................ 561
Heater power supply wiring ............................................................................................................ 567
Heater wiring................................................................................................................................... 573
Air conditioning wiring..................................................................................................................... 579
Air conditioning fan wiring............................................................................................................... 585

360
 Systems 8
electrical system 84

7+(6758&785(2)7+(81,7

For easier consultation, this unit has been divided into the following chapters:

,QWURGXFWLRQ

Contains a brief description of the terminology used, the procedures to follow for troubleshooting
and repairs, and the instruments required for troubleshooting.

,QGLFHV

Contains the indices arranged by connector name, by component code and by component
description.

&RPSRQHQWV

Contains the layouts of the connectors used in the electrical system, descriptions of the
components installed on the tractor, the technical data necessary for functional testing and the
pinouts of the electronic control units.

6\VWHPV

Contains the electrical diagrams of the tractor’s systems.

/D\RXWVHOHFWULFDOZLULQJGLDJUDPVFRQQHFWRUSRVLWLRQV

Contains the layouts, the wiring diagrams and the positioning of connectors on the tractor.

361
 8 Systems
84 electrical system

HOW TO CONSULT THE UNIT How to consult the table

The quickest way to determine the cause of a malfunction of a

A B component (e.g. the starter motor) is to check all the components
in the system in which the component is incorporated.
2
The example given on this page assumes a malfunction of the
starter motor, which fails to start the engine.
9
Interruttore comando
2.7659.108.0 42 X10 2 40 1 -Look in paragraph «2.1. Component description index»

0.011.6955.4
PTO posteriore
12
(figure A) for the starter motor and identify the system
X10
in which it is incorporated.
The system is indicated in the column «System (para
4.xx)» and in this case is “2” (figure A).
Motorino d’avviamento 2.9619.360.0 X37 2 22
2 - 2 -Consult paragraph «4.2 Starting» (figure B), in which all
the components in the system are indicated in the elec-
E trical diagram; these components are accompanied by
C numbers that correspond to the key on the same page.
3 - 3 -Check all the components in the system, starting, for
example, with the switch “12”.
4 -Look in paragraph «2.1. Component description index»
X10
(figure A) for “Rear PTO control switch” and check in
the column «Technical description (para 3.2.xx)» if
42 X10 there is a technical description of the component (in
this case it is given at n° 42 of the paragraph «3.2
Component technical data») (figure C).
12 Interruttore comando PTO posteriore Make a note also of the name of the connector to which the
component is connected (in this case “X10”).

Only if the position of the component is not known

D 0.011.6855.4 5 - Look in paragraph «2.3 Connector index» (figure D) for
the name of the connector to which the component is con-
nected (in this case “X10”) and note down the wiring loom
X10 6 0.011.6955.4 Interruttore comando
F in which it is incorporated (in this case “0.011.6955.4” or
2.7659.108.0 “0.011.6958.4”) and the type of connector (in this case
PTO posteriore
“6”).
X10
6 - 6 -Look for the wiring loom in chapter «Layouts, electri-
cal wiring diagrams, connector positions» using the
main index .
G 7 - 7 -Look for the name of the connector in the photos at-
tached to the electrical diagrams and determine its posi-
tion on the tractor from the drawing (figure E).
6
NOTE.
The electrical diagrams (figure F) contain the names
of the connectors and the descriptions used in all the
tables in chapter 2.
8 - 8 -Using the data contained in the paragraph «3.2 Com-
ponent technical data» (figure C) at position n° 42, check
the operation of the switch.
If the pinout of the connector is not known, look in paragraph
«3.1 Connector layouts» (figure G) for the number found
in the column “Type” of paragraph «2.3 Connector index».

0.011.6855.4

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1. INTRODUCTION
This section of the workshop manual is intended as a practical guide to troubleshooting the
tractor’s electrical and electronic systems.
The following pages provide the technician with all the necessary information about the
tractor’s systems and components.
Due to the possible time difference between the introduction of technical modifications (in line
with our policy of continuous product improvement) and the corresponding amendment of our
printed documentation, we are obliged to state that the data contained in this document are
subject to modification and as such are not binding.

1.1 LIST OF WIRING LOOMS

DESCRIPTION NOTES CODE

Cab accessories wiring Standard roof 0.009.7851.4/40

Mechanical
Agroshift wiring governor 0.009.7627.3/10

Heater power supply wiring Standard roof 0.009.7852.3/40

Heater power supply wiring High-visibility roof 0.011.3761.3/30

Speaker wiring Standard roof 0.011.0729.4/10

Speaker and radio wiring High-visibility roof 0.011.3596.3/30

Air conditioning wiring Standard roof 010.2130.1

Air conditioning wiring High-visibility roof 010.2562.1

Front light wiring Only with cab 0.010.5582.3/01

Agroshift lever wiring 0.009.7855.3/10

Mechanical
Central wiring governor 0.011.6955.4/11

Electronic governor
Central wiring 0.011.6958.4/22

Worklights line wiring High-visibility roof 0.011.3595.3/10

Engine wiring 0.009.7624.4/50

Electronic lift wiring 0.011.6943.4/10

Roof wiring Standard roof 0.009.7850.4/50

Roof wiring High-visibility roof 0.011.3606.4/51

Screenwash pump wiring High-visibility roof 0.011.3743.3

Screenwash pumps wiring Standard roof 0.009.7854.3/10

Heater wiring Standard roof 010.2123.2

Heater wiring High-visibility roof 010.2558.1

Windscreen wiper wiring Standard roof 0.010.4516.3/01

Windscreen wiper wiring High-visibility roof 0.011.3597.3/03

Air conditioning fan wiring Standard roof 0.009.7853.3/21

Air conditioning fan wiring High-visibility roof 0.011.3610.3/20

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1.2 DEFINITION OF COMPONENTS AND SYMBOLS

To prevent any misunderstanding or ambiguity, listed below are definitions for some of the key
terms used in this unit.
TERM DESCRIPTION
Element used to connect two components (e.g. wiring-switch,
Connector
wiring-wiring)
Temperature Electrical component that converts the temperature of a medium
sensor (air, water, oil, etc.) into a voltage or resistance
Pressure Electrical component that converts the pressure of a medium (air,
sensor water, etc.) into a voltage or resistance
Position Electrical component that converts the angular or linear position of
sensor an object into a voltage
Pressure Switch that changes state (opens or closes a contact) according to
switch the operating pressure in the circuit in which it is installed
Switch that changes state (opens or closes a contact) according to
Thermostat
the temperature of the medium in which it is immersed.

Switch Mechanical component that opens or closes one or more electrical

contacts.
Solenoid valve Valve operated by applying electrical current to a coil (or solenoid)

Chapter “3.2 Component descriptions” contains the wiring diagrams for some switches and
pushbuttons.
The following symbols are used for clarity:
SYMBOL DESCRIPTION

Contact between pins CLOSED (stable switch position)

Contact between pins CLOSED (non-stable switch position)

LED warning light

Warning light

1.3 GENERAL RULES

The inspection, maintenance, troubleshooting and repair operations are essential to ensure
that the tractor continues to operate correctly over time and to prevent malfunctions and
breakdowns.
The scope of this paragraph is to describe repair procedures and to help improve the quality
of repairs.

1.3.1MODIFICATION OF THE TRACTOR’S ELECTRICAL/ELECTRONIC CIRCUITS

The manufacturer prohibits any modification or alteration of the electrical wiring for the
connection of any non-approved electrical equipment or components.
In particular, if it is discovered that the electrical system or a component has been modified
without authorisation, the Manufacturer will accept no liability for any damage to the vehicle
and the vehicle warranty will be invalidated.
1.3.2MAIN WIRING FAULTS
a. Poor contact between connectors
The main causes of poor contact between connectors are incorrect insertion of the male
into the female connector, deformation of one or both connectors, and corrosion or
oxidisation of the pin contact surfaces.

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b. Welding or crimping of defective pins

The pins of the male and female connectors make good contact in the crimped or welded
area, but the wires are subjected to excessive tension, leading to breakage of the
insulation or the wire itself and a poor connection.
c. Disconnecting wiring
If components are disconnected by pulling on the wires, or if components are removed
with the wires still connected, or if the wiring is subject to a heavy impact this could
damage the connections at the pins, breaking strands of wire.
d. Penetration of water in connectors
The connectors are designed to prevent penetration of liquids (water, oil etc.); however,
it is possible that when the tractor is cleaned using high-pressure water or steam, water
could penetrate or condense in the connectors.
As the connectors are designed to prevent liquid penetration, any water that does get in
will not be able to drain out, and thus may cause shortcircuits across the pins.
For this reason it is good practice to dry the connectors with a low pressure jet of
compressed air after washing the tractor.
e. Oil or dirt on connectors
Oil or grease on the connectors or pins can create a poor contact (oil and grease are non-
conductors). Clean the connectors thoroughly using a dry cloth or a low pressure jet of
compressed air and use specific products (deoxidising sprays, etc.) to degrease the
contacts.

★ Take care not to bend the pins when cleaning them.

★ Use dehydrated but not lubricated compressed air.

1.3.3REMOVAL, REFITTING AND DRYING OF CONNECTORS AND WIRING

a. Disconnection of connectors
When disconnecting wiring, pull on the connectors rather than on the wires themselves.
For connectors that are held in position with screws or levers, fully loosen the screws,
then pull on the connector. For connectors that are clipped together, fully depress the
clip then pull the connector apart. After disconnecting connectors, cover them in a
waterproof material to prevent dirt or moisture getting into the contacts.

b. Connecting the connectors

Check the condition of the connectors:
• Make sure the pin contact surfaces are free of water, dirt or oil.
• Check that the connectors are not deformed and that the pins are not corroded.
• Check that the connector casings are not damaged or split.
★ If a connector is contaminated with oil or grease, or if moisture has penetrated the
casing, clean it as described in paragraph 1.3.2.
★ If a connector is damaged, deformed or broken, replace it with a new one.
When connecting connectors, make sure they are properly aligned before applying any
force.
For connectors with clips, insert the two halves until they clip together.
c. Cleaning and drying wiring
When wiring is dirty or contaminated with oil or grease, clean it with a dry cloth, or, if
necessary, with water or steam.
If the wiring has to be cleaned with water, avoid directing the water or steam jet on the
connectors; if water penetrates the connector, proceed as described in paragraph 1.3.2.
★ Check that the connector is not short circuited by humidity by testing the continuity
across the pins.

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★ After checking the connector is good condition, degrease the contacts using a
deoxidising product.
d. Renewal of damaged electrical components.
• When replacing electrical components (fuses, relays, etc.), use only original parts
supplied by the manufacturer.
• When replacing fuses, check that the new fuse conforms to DIN 72581 standards
and in particular:
- fuse F1 (100A) DIN 72581/2
- bayonet fuse (F2, F3, etc.) DIN 72581/3C
The fitting of replacement fuses that do not comply with these standards will
invalidate the warranty with immediate effect and release the manufacturer from
any liability.
• When replacing relays, make sure that the new relay conforms to the standards
marked on the original relay.

1.4 DIAGNOSTIC INSTRUMENTS

For the correct diagnosis of any faults in tne tractor’s electrical system, the following
instruments are required:
1 - Digital multimeter with the following minimum characteristics:
AC VOLT 0-600
DC VOLT 0-600
OHM 0-32M
AC AMP 0-10
DC AMP 0-10
2 - All Round Tester

1.5 WIRE COLOUR CODES

COLOUR CODES COLOUR CODES

A Light blue M Brown
B White N Black
C Orange R Red
G Yellow S Pink
H Grey V Green
L Dark blue Z Purple

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2. INDICES

2.1 COMPONENT DESCRIPTION INDEX

Tech. Mechanical Electronic

Component descr. governor governor
Component description code (Chap. Connector system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
Cigar lighter 2.7099.770.0 X2 6-7-8 27-28-29
Alternator ISKRA 65A 2.9439.420.0 X65 2 22
Alternator ISKRA 85A 2.9439.450.0/10 X65 2 22
Heating alternator 2.9439.440.0/10 B- 14-15-16-17 33-34-35-36
ISKRA 70A
RH speaker X133 12-13
LH speaker X132 12-13
Actuator 007.0992.4/60 8 A 23
Radio X86-X131 12-13
Horn 2.8419.003.0 X61 3-4-5 24-25-26
Glowplug 2.7659.103.0/10 X57 2 22
Alarms control unit 0.010.1027.4 X41 2-11-18
Preheating control unit 0.008.0618.4/20 X43 2
22-23-27-28-
Engine control unit 0.012.3913.4 X53 29-32-37-38-
39-40
Rear lift control
unit 0.011.2992.4/20 X71 6-7-8-20 27-28-29-39

Hazard lights control unit 2.8639.007.0 X40 3-4-5 24-25-26

HML control unit 0.010.8869.4/20 X72 19
Heater settings control unit 0.007.6766.4 X136 14-15-16-17 33-34-35-36

Fan speed selector switch 009.4743.1 X139 14-16 33-35

Fan speed selector switch 010.2528.1 X154 15-17 34-36
Air conditioning compressor 009.7660.4 X59 16-17 35-36
Compressor for
driver’s seat air suspension X12 6-7-8 27-28-29

Diagnostics connector X30-X42 6-7-8-20 27-28-29-39

2-3-4-5-11-
Analogue instrument panel 2.8339.210.0/10 X3
18-19-21
22-23-24-25-
Digital instrument panel 2.8339.211.0/20 X3 26-32-37-38-
40
24-25-26-27-
Lights selector switch 0.009.6491.4 46 X36 3-4-5-6-7-8
28-29
Diff lock control solenoid valve
2.3719.670.0 11 X16 19 38
(DF)
4WD control
solenoid valve 2.3719.670.0 12 X15 19 38

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Tech. Mechanical Electronic

Component description Component descr. Connector governor governor
code (Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
High range control solenoid valve
(HI) 2.3729.240.0/10 14 H 19 38

Low range control solenoid valve 2.3729.240.0/10 15 L 19 38

(LO)
Preheating control solenoid valve 2.9219.130.0 X58 2 22
Rear
PTO control solenoid valve (PTO) 2.3719.670.0 13 X17 21 40

Lift lowering solenoid valve 2.3729.460.0 DW SV 20 39

Front PTO solenoid valve 2.3729.400.0 X63 21 40
Lift raising solenoid valve 2.3729.460.0 UP SV 20 39
Front right headlamp 2.8019.970.0 X13 3 24
Front left headlamp 2.8019.960.0 X27 3 24
Front right worklight 2.8029.730.0 X124 4-5 25-26

Front left worklight

2.8029.730.0 X121 4-5 25-26

Rear right worklight

2.8029.730.0 X123 4-5 25-26

Rear left worklight

2.8029.730.0 X122 4-5 25-26

Number plate light 2.8029.240.0/10 X28 3-4-5 24-25-26

Front right lights 2.8029.760.0/30 X64 3-4-5 24-25-26
Front left lights 2.8029.770.0/30 X62 3-4-5 24-25-26
Front right sidelight and direction
indicator 0441.1920 X13 4-5 25-26

Front left sidelight and direction

indicator 0441.1921 X27 4-5 25-26

Rear right light 2.8019.190.0 X14 3-4-5-18 24-25-26-37

Left rear light 2.8019.180.0 X29 3-4-5-18 24-25-26-37
Rear worklight 2.8029.300.0 X22 3 24
(platform version)
Roof wiring fuse X104 5-8-10 26-29-31
(40 Amp)
22-23-24-25-
2-3-4-5-6-7-
8-9-10-11- 26-27-28-29-
Starter switch 2.7659.127.0 35 X32 30-31-32-33-
14-15-16-17- 34-35-36-37-
18-19-20-21
38-39-40
Air conditioning
010.2560.1 X158 17 36
control switch

Diff lock control switch 2.7659.163.0 39 X9 19 38

4WD control switch 007.5945.0/20 41 X8 19 38

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Electrical system 84

Tech. Mechanical Electronic

Component descr. Connector governor governor
Component description (Chap. system system
code
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
Rotating beacon control switch 2.7659.126.0 X81 7 28
Rotating beacon control switch 2.7659.159.0 38 X96 8 29
Front worklights switch
2.7659.154.0 37 X100 5 26

Front worklights switch 2.7659.078.0 X85 4 25

Rear worklights switch 2.7659.079.0 X78 4 25

Rear worklights switch

2.7659.155.0 36 X99 5 26

2.7659.091.0 X80 9 30
Front screen washer switch

2.7659.223.0 31 X80 10 31
Front screen washer switch
Front PTO control switch
2.7659.108.0/10 43 X35 21 40

Rear PTO control switch

2.7659.108.0/10 42 X10 2-21

PTO AUTO switch 2.7659.215.0/10 47 X112 40

Winscreen wiper
2.7659.092.0 32 X84 9 30
control switch
Winscreen wiper
control switch 2.7659.224.0 45 X98 10 31

Rear wiper control switch

2.7659.146.0 33 X79 9 30

Rear wiper control switch 2.7659.192.0 44 X97 10 31

Start enable switch 2.7659.097.0 X31 2 22

Handbrake switch 2.7659.129.0 23 X24 18 37
Hazard warning lights switch 2.7659.110.0 34 X33 3-4-5 24-25-26
Rear worklights switch
(Not utilised) X34

Brake pedal switch 2.7659.097.0 X5 18 37

Flashing light X127 7-8 28-29
Windscreen wiper motor 0441.3192 X130 9-10 30-31
Rear screen wiper motor 2.9019.100.0/20 X125 9 30
Rear screen wiper motor 2.9019.180.0 X125 10 31
BOSCH starter motor
2.9619.300.0/10 X37-X38 2 22
(Dorado 55/65)
BOSCH starter motor
2.9616.290.0/10 X37-X38 2 22
(Dorado 75/85)
ISKRA starter motor
(Dorado 65) 2.9619.360.0 X37-X38 2 22

ISKRA starter motor

(Dorado 75/85) 2.9619.380.0 X37-X38 2 22

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Tech. Mechanical Electronic

Component description Component descr. Connector governor governor
code (Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
MARELLI starter motor
(Dorado 65) 2.9619.370.0 X37-X38 2 22

MARELLI starter motor 2.9619.340.0 X37-X38 2 22

(Dorado 75/85)
Clock 2.9389.002.0 X83 7-8 28-29
Interior roof light 2.8339.032.0 X74 7-8 28-29
Front screen washer pump 0.9241.566.1 X129 9-10 30-31
Rear screen washer pump 0.9241.566.1 X135 9-10 30-31
Max. lift height adjustment
potentiometer 0.011.2990.0 4 H1 20 39

Lift position adjustment

potentiometer 0.011.2990.0 5 P1 20 39

Heater adjustment potentiometer

98707.67.3 X138-X145 14-15-16-17 33-34-35-36

Draft/wheelslip adjustment
potentiometer 0.011.2990.0 6 M1 20 39

Lift lowering speed adjustment

potentiometer 0.011.2990.0 7 V 20 39

Outlet socket (in cab) 2.6039.017.0 X11 6-7-8 27-28-29

Trailer socket
(For lights and X26 3-4-5-18 24-25-26-37
auxiliary power)
Air conditioning pressure switch 010.2262.0 X116 17 36
Air conditioning pressure switch 010.2140.0 X118-X120 16 35
T ra il e r br a k ing l ow pr e ss ur e
switch 2.7099.430.0 X25 18 37

Hydraulic oil low pressure switch

2.7099.660.0/10 18 X20 11 32

Pressure switch - hydraulic oil

filter clogging X19 11 32

Engine oil pressure switch 2.7099.680.0 19 X55 11 32

Engine governor reset button 2.7659.139.0 24 X45 23

Rear lift "lower" control

pushbutton 2.7659.182.0 28 DW 20 39

HML control pushbutton 2.7659.085.0 X73 19 38

Rear PTO control pushbutton
2.7659.142.0/01 48 X10 40

Rear PTO
control pushbutton (on fender) 2.7659.177.0/10 27 X49 40

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Electrical system 84

Tech. Mechanical Electronic

Component description Component descr. Connector governor governor
code (Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
Rear lift "raise"
control pushbutton 2.7659.182.0 29 UP 20 39

Rear lift control pushbutton 0.011.7720.0/10 40 C-I 20 39

Tyre size selection pushbutton 2.7659.140.0 25 X52 23

Engine governor display
pushbutton 2.7659.173.0 26 X44 23

Memory pushbutton 2.7659.203 30 X47 23

4-5-7-8-9- 25-26-28-29-
Relay - cab roof wiring X103 10-14-15-16- 30-31-33-34-
17 35-36
Relay -1st heater fan and air
conditioning on X156 17 36

Relay - 3rd heater

fan vspeed X157 15-17 34-36

Relay - air conditioning X143 16 35

Relay - alternator excitation
X142 14-15-16-17 33-34-35-36

Relay - maximum fan speed

X146 15-17 34-36

Relay - heat exchanger fan

X115 16-17 35-36

Relay - supplementary heat

exchanger fan X114 17 36

Relay RL1 RL1 2 22

Relay RL2 RL2 2 22
23-24-25-26-
27-28-29-30-
Relay RL3 RL3 31-32-33-34-
35-36-37-38-
40
Relay RL4 RL4 22
Heater unit resistance X106 14-15-16-17 33-34-35-36
Resistor - right 010.2555.0 X149 15-17 34-36
heater fan
Resistor - heater fan 010.2122.0 X140 14-16 33-35
Resistor - left
heater fan 010.2555.0 X148 15-17 34-36

Air cleaner clogged sensor 2.7099.320.0 17 X60 11 32

Fuel level sensor 2.7059.998.0 16 X23 11 32
Brake fluid level sensor X66 18 37
Throttle lever position sensor
2.7099.740.0 20 X46 23

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84 Electrical system

Tech. Mechanical Electronic

Component description Component descr. Connector governor governor
code (Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
Accelerator pedal position
sensor 008.8199.3 10 X48 23

Rear lift position 0.009.2194.4 1 P2 20 39

sensor
Lift draft sensor 0.011.2164.0/10 3 S1 20 39
Heating air temperature sensor
010.2124.1 X137 14-15-16-17 33-34-35-36

Coolant temperature
sensor 2.7099.830.0 22 X54 11 32

Engine speed sensor 2.7099.790.0 21 X51 23

Cooling fan speed sensor
0.010.1214.4 2 X67 11 23

Transmission speed sensor 008.1646.0 9 X50 23

PTO engagement sensor 2.7659.097.0 S 21 40
1000 rpm PTO engagement sensor 2.7659.131.0 1 21 40
540 rpm PTO engagement sensor 2.7659.131.0 5 21 40
750 (ECO) PTO engagement
2.7659.131.0 E 21 40
sensor
Intermittent windscreen wiper
interval timer 2.8639.008.0 X82 9-10 30-31

Antifrost thermostat 009.4744.0 X144 16 35

Air conditioning 010.2522.0 X159 17 36
thermostat
Right heater fan 011.8858.4 X153 17 36
Right heater fan 011.2047.4 X153 15 34
Heater fan 010.2121.1 X141 14-16 33-35
Air conditioning heat exchanger
fan 010.2545.2 X117a 17 36

Air conditioning heat exchanger

fan 010.0618.4 X119 16 35

Left heater fan 011.8858.4 X151 17 36

Left heater fan 011.2047.4 X151 15 34
Supplementary air conditioning
heat exchanger fan 010.2545.2 X117b 17 36

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Electrical system 84

2.2 COMPONENT CODE INDEX

Tech. Mechanical Electronic

descr. governor governor
Code Description (Chap. Connector system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)
Heater settings control unit
0.007.6766.4 X136 14-15-16-17 33-34-35-36

0.008.0618.4/20 Preheating control unit X43 2

Rear lift position

0.009.2194.4 sensor 1 P2 20 39

24-25-26-27-
0.009.6491.4 Lights selector switch 46 X36 3-4-5-6-7-8 28-29

0.010.1027.4 Alarms control unit X41 2-11-18

0.010.1214.4 Cooling fan speed sensor 2 X67 11 23

0.010.8869.4/20 HML control unit X72 19

0.011.2164.0/10 Lift draft sensor 3 S1 20 39

Max. lift height adjustment

0.011.2990.0 potentiometer 4 H1 20 39

Draft/wheelslip adjustment
0.011.2990.0 potentiometer 6 M1 20 39

Lift position adjustment

0.011.2990.0 potentiometer 5 P1 20 39

Lift lowering s peed adjustment

0.011.2990.0 potentiometer 7 V 20 39

0.011.2992.4/20 Rear lift control unit X71 6-7-8-20 27-28-29-39

0.011.7720.0/10 Rear lift control pushbutton 40 C-I 20 39

22-23-27-28-
0.012.3913.4 Engine control unit X53 29-32-37-38-
39-40

0.9241.566.1 Front screen washer pump X129 9-10 30-31

0.9241.566.1 Rear screen washer pump X135 9-10 30-31

007.0992.4/60 Actuator 8 A 23

007.5945.0/20 4WD control switch 41 X8 19 38

008.1646.0 Transmission speed sensor 9 X50 23

008.8199.3 Accelerator pedal 10 X48 23

position sensor

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Tech. Mechanical Electronic

descr. governor governor
Code Description Connector
(Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)

009.4743.1 Fan speed selector switch X139 14-16 33-35

009.4744.0 Antifrost thermostat X144 16 35

009.7660.4 Air conditioning compressor X59 16-17 35-36

010.0618.4 Air conditioning heat exchanger fan X119 16 35

010.2121.1 Heater fan X141 14-16 33-35

010.2122.0 Resistor - heater fan X140 14-16 33-35

010.2124.1 Heating air temperature sensor X137 14-15-16-17 33-34-35-36

010.2140.0 Air conditioning pressure switch X118-X120 16 35

010.2262.0 Air conditioning pressure switch X116 17 36

Air conditioning
010.2522.0 X159 17 36
thermostat
010.2528.1 Fan speed selector switch X154 15-17 34-36

010.2545.2 Air conditioning heat exchanger fan X117a 17 36

Supplementary air conditioning heat

010.2545.2 exchanger fan X117b 17 36

Resistor -
010.2555.0 left heater fan X148 15-17 34-36

Resistor -
010.2555.0 right heater fan X149 15-17 34-36

Air conditioning
010.2560.1 control switch X158 17 36

011.2047.4 Left heater fan X151 15 34

011.2047.4 Right heater fan X153 15 34

011.8858.4 Left heater fan X151 17 36

011.8858.4 Right heater fan X153 17 36

Front right sidelight and direction

0441.1920 indicator X13 4-5 25-26

Front left sidelight and direction

0441.1921 indicator X27 4-5 25-26

0441.3192 Windscreen wiper motor X130 9-10 30-31

4WD control
2.3719.670.0 solenoid valve 12 X15 19 38

Diff lock control solenoid valve

2.3719.670.0 (DF) 11 X16 19 38

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Tech. Mechanical Electronic

descr. governor governor
Code Description Connector
(Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)

2.3719.670.0 Rear PTO 13 X17 21 40

control solenoid valve (PTO)

2.3729.240.0/10 High range control solenoid valve 14 H 19 38

(HI)

2.3729.240.0/10 Low range control solenoid valve 15 L 19 38

(LO)

2.3729.400.0 Front PTO solenoid valve X63 21 40

2.3729.460.0 Lift lowering solenoid valve DW SV 20 39

2.3729.460.0 Lift raising solenoid valve UP SV 20 39

2.6039.017.0 Outlet socket (in cab) X11 6-7-8 27-28-29

2.7059.998.0 Fuel level sensor 16 X23 11 32

2.7099.320.0 Air cleaner clogged sensor 17 X60 11 32

Trailer braking low pressure switch

2.7099.430.0 X25 18 37

Hydraulic oil low pressure switch

2.7099.660.0/10 18 X20 11 32

2.7099.680.0 Engine oil pressure switch 19 X55 11 32

2.7099.740.0 Throttle lever position sensor 20 X46 23

2.7099.770.0 Cigar lighter X2 6-7-8 27-28-29

2.7099.790.0 Engine speed sensor 21 X51 23

Coolant temperature
2.7099.830.0 sensor 22 X54 11 32

2.7659.078.0 Front worklights control switch X85 4 25

2.7659.079.0 Rear worklights control switch X78 4 25

2.7659.085.0 HML control pushbutton X73 19 38

2.7659.091.0 X80 9 30
Front screen washer control switch

2.7659.092.0 Winscreen wiper 32 X84 9 30

control switch

2.7659.097.0 PTO engagement sensor S 21 40

2.7659.097.0 Start enable switch X31 2 22

2.7659.097.0 Brake pedal switch X5 18 37

2.7659.103.0/10 Glowplug X57 2 22

2.7659.108.0/10 Rear PTO control switch 42 X10 2-21

375
 8 System
84 Electrical system

Tech. Mechanical Electronic

descr. governor governor
Code Description Connector
(Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)

2.7659.108.0/10 Front PTO control switch 43 X35 21 40

2.7659.110.0 Hazard warning lights switch 34 X33 3-4-5 24-25-26

2.7659.126.0 Rotating beacon control switch X81 7 28

2-3-4-5-6-7- 22-23-24-25-
26-27-28-29-
2.7659.127.0 Starter switch X32 8-9-10-11- 30-31-32-33-
14-15-16-17-
18-19-20-21 34-35-36-37-
38-39-40

2.7659.129.0 Handbrake switch 23 X24 18 37

2.7659.131.0 1000 rpm PTO engagement sensor 1 21 40

2.7659.131.0 540 rpm PTO engagement sensor 5 21 40

2.7659.131.0 750 (ECO) PTO engagement sensor E 21 40

2.7659.139.0 Engine governor reset button 24 X45 23

2.7659.140.0 Tyre size selection pushbutton 25 X52 23

2.7659.142.0 Rear PTO control pushbutton 48 X10 40

Rear wiper control switch

2.7659.146.0 33 X79 9 30

2.7659.154.0 Front worklights control switch 37 X100 5 26

2.7659.155.0 Rear worklights control switch 36 X99 5 26

2.7659.159.0 Rotating beacon control switch 38 X96 8 29

2.7659.163.0 39 X9 19 38
Diff lock control switch

2.7659.173.0 Engine governor display pushbutton 26 X44 23

Rear PTO control pushbutton

2.7659.177.0/10 27 X49 40
(on fender)

Rear lift "lower" control pushbutton

2.7659.182.0 28 DW 20 39

Rear lift "raise" control pushbutton

2.7659.182.0 29 UP 20 39

Rear wiper control switch

2.7659.192.0 44 X97 10 31

2.7659.203 Memory pushbutton 30 X47 23

2.7659.215.0/10 PTO AUTO switch 47 X112 40

2.7659.223.0 31 X80 10 31
Front screen washer control switch

376
 System 8
Electrical system 84

Tech. Mechanical Electronic

descr. governor governor
Code Description Connector
(Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)

2.7659.224.0 Winscreen wiper 45 X98 10 31

control switch

2.8019.180.0 Left rear light X29 3-4-5-18 24-25-26-37

2.8019.190.0 Rear right light X14 3-4-5-18 24-25-26-37

2.8019.960.0 Front left headlamp X27 3 24

2.8019.970.0 Front right headlamp X13 3 24

2.8029.240.0/10 Number plate light X28 3-4-5 24-25-26

Rear worklight
2.8029.300.0 (platform version) X22 3 24

Front left worklight

2.8029.730.0 X121 4-5 25-26

Rear left worklight

2.8029.730.0 X122 4-5 25-26

Rear right worklight

2.8029.730.0 X123 4-5 25-26

2.8029.730.0 Front right worklight X124 4-5 25-26

2.8029.760.0/30 Front right lights X64 3-4-5 24-25-26

2.8029.770.0/30 Front left lights X62 3-4-5 24-25-26

2.8339.032.0 Interior roof light X74 7-8 28-29

2-3-4-5-11-
2.8339.210.0/10 Analogue instrument panel X3 18-19-21

22-23-24-25-
2.8339.211.0/20 Digital instrument panel X3 26-32-37-38-
40
2.8419.003.0 Horn X61 3-4-5 24-25-26

2.8639.007.0 Hazard lights control unit X40 3-4-5 24-25-26

Intermittent windscreen wiper

2.8639.008.0 interval timer X82 9-10 30-31

2.9019.100.0/20 Rear screen wiper motor X125 9 30

2.9019.180.0 Rear screen wiper motor X125 10 31

2.9219.130.0 Preheating control solenoid valve X58 2 22

2.9389.002.0 Clock X83 7-8 28-29

2.9439.420.0 Alternator ISKRA 65A X65 2 22

Heating alternator
2.9439.440.0/10 B- 14-15-16-17 33-34-35-36
ISKRA 70A

2.9439.450.0/10 Alternator ISKRA 85A X65 2 22

377
 8 System
84 Electrical system

Tech. Mechanical Electronic

descr. governor governor
Code Description Connector
(Chap. system system
3.2.x) (Chap. 4.xx) (Chap. 4.xx)

2.9616.290.0/10 BOSCH starter motor X37-X38 2 22

(Dorado 75/85)

2.9619.300.0/10 BOSCH starter motor X37-X38 2 22

(Dorado 55/65)

2.9619.340.0 MARELLI starter motor X37-X38 2 22

(Dorado 75/85)

2.9619.360.0 ISKRA starter motor X37-X38 2 22

(Dorado 65)

2.9619.370.0 MARELLI starter motor X37-X38 2 22

(Dorado 65)

2.9619.380.0 ISKRA starter motor X37-X38 2 22

(Dorado 75/85)

Heater adjustment potentiometer

98707.67.3 X138-X145 14-15-16-17 33-34-35-36

378
 System 8
Electrical system 84

2.3 CONNECTOR INDEX

Connection
Connector Type Wiring code wiring or Component description
component code

0.011.6955.4
1 2.7659.131.0 1000 rpm PTO engagement sensor
0.011.6958.4
0.011.6955.4
5 2.7659.131.0 540 rpm PTO engagement sensor
0.011.6958.4

A 2 0.011.6958.4 007.0992.4/60 Actuator

0.009.7852.3
B- 2.9439.440.0/10 Heating alternator ISKRA 70A
0.011.3761.3

0.009.7852.3
B+ 2.9439.440.0/10 Heating alternator ISKRA 70A
0.011.3761.3

C 0.011.6943.4 0.011.7720.0/10 Rear lift control pushbutton

Rear lift "lower"

DW 3 0.011.6943.4 2.7659.182.0 control pushbutton

0.011.6955.4
E 2.7659.131.0 750 (ECO) PTO engagement sensor
0.011.6958.4

DW SV 2 0.011.6943.4 2.3729.460.0 Lift lowering solenoid valve

UP SV 2 0.011.6943.4 2.3729.460.0 Lift raising solenoid valve

0.009.7627.3
H 2 2.3729.240.0/10 High range control solenoid valve (HI)
0.011.6958.4

Max. lift height adjustment potentiometer

H1 3 0.011.6943.4 0.011.2990.0

I 0.011.6943.4 0.011.7720.0/10 Rear lift control pushbutton

0.009.7627.3 Low range control solenoid valve

L 2 2.3729.240.0/10
0.011.6958.4 (LO)

0.011.6958.4 0.009.7855.3/10
M 3
0.009.7627.3 0.009.7855.3/10
Draft/wheelslip adjustment potentiometer
M1 3 0.011.6943.4 0.011.2990.0

P1 3 0.011.6943.4 0.011.2990.0 Lift position adjustment potentiometer

P2 3 0.011.6943.4 0.009.2194.4 Rear lift position sensor

0.011.6955.4
RL1 Relay RL1
0.011.6958.4

379
 8 System
84 Electrical system

Connection
Connector Type Wiring code wiring or Component description
component code

0.011.6955.4
RL2 Relay RL2
0.011.6958.4

RL3 0.011.6958.4 Relay RL3

RL4 0.011.6958.4 Relay RL4

0.011.6955.4
S 2.7659.097.0 PTO engagement sensor
0.011.6958.4
S1 3 0.011.6943.4 0.011.2164.0/10 Lift draft sensor

Rear lift "raise" control

UP 3 0.011.6943.4 2.7659.182.0 pushbutton

Lift lowering speed adjustment

V 3 0.011.6943.4 0.011.2990.0 potentiometer

0.011.6955.4/10
X1 1 0.009.7624.4
0.011.6958.4/21

0.011.6955.4
X2 2.7099.770.0 Cigar lighter
0.011.6958.4
0.011.6955.4 2.8339.210.0/10 Analogue instrument panel
X3 7
0.011.6958.4 2.8339.211.0/20 Digital instrument panel

0.011.6955.4
X4 9 0.010.5582.3
0.011.6958.4

0.011.6955.4
X5 2.7659.097.0 Brake pedal switch
0.011.6958.4

X6 8 0.011.6955.4 0.009.7627.3/10

0.011.6955.4
X7 4 0.011.6943.4/10
0.011.6958.4

0.011.6955.4
X8 6 007.5945.0/20 Four-wheel drive control switch
0.011.6958.4

0.011.6955.4
X9 6 2.7659.163.0
0.011.6958.4 Diff lock control switch

0.011.6955.4 2.7659.108.0/10 PTO control switch

X10 6
0.011.6958.4 2.7659.142.0/01 PTO control pushbutton
0.011.6955.4
X11 2.6039.017.0 Outlet socket (in cab)
0.011.6958.4

380
 System 8
Electrical system 84

Connection
Connector Type Wiring code wiring or Component description
component code

0.011.6955.4
Compressor for driver’s seat
X12 air suspension
0.011.6958.4

0.010.5582.3 0441.1920 Front right sidelight and

direction indicator
X13
0.011.6955.4
2.8019.970.0 Front right headlamp
0.011.6958.4

Front left sidelight and direction indicator

0.010.5582.3 0441.1921
X14
0.011.6955.4
2.8019.190.0 Rear right light
0.011.6958.4

0.011.6955.4 4WD control

X15 2 2.3719.670.0
0.011.6958.4 solenoid valve

0.011.6955.4
X16 2 2.3719.670.0 Diff lock control solenoid valve
(DF)
0.011.6958.4
0.011.6955.4
Rear PTO
X17 2 2.3719.670.0 control solenoid valve (PTO)
0.011.6958.4

0.011.6955.4
X18
0.011.6958.4

0.011.6955.4
X19 Pressure switch -
hydraulic oil filter clogging
0.011.6958.4
0.011.6955.4
Hydraulic oil low pressure switch
X20 2.7099.660.0/10
0.011.6958.4

0.011.6955.4
X21
0.011.6958.4

0.011.6955.4
X22 2.8029.300.0 Rear worklight
(platform version)
0.011.6958.4
0.011.6955.4
X23 4 2.7059.998.0 Fuel level sensor
0.011.6958.4

0.011.6955.4
X24 2.7659.129.0 Handbrake switch
0.011.6958.4

0.011.6955.4
X25 2 2.7099.430.0 Trailer braking low pressure switch
0.011.6958.4

381
 8 System
84 Electrical system

Connection
Connector Type Wiring code wiring or Component description
component code

0.011.6955.4 Trailer socket

X26 (For lights and auxiliary
0.011.6958.4 power)

0.011.6955.4
X27 2.8019.960.0 Front left headlamp
0.011.6958.4

0.011.6955.4
X28 2.8029.240.0/10 Number plate light
0.011.6958.4
0.011.6955.4
X29 2.8019.180.0 Left rear light
0.011.6958.4

X30 0.011.6958.4 Diagnostics connector

0.011.6955.4
X31 2.7659.097.0 Start enable switch
0.011.6958.4

0.011.6955.4
X32 2.7659.127.0 Starter switch
0.011.6958.4
0.011.6955.4
X33 6 2.7659.110.0 Hazard warning lights switch
0.011.6958.4

X34 6 0.011.6955.4 Rear worklights switch

(Not utilised)

0.011.6955.4
X35 6 2.7659.108.0/10 Front PTO control switch
0.011.6958.4

0.011.6955.4
X36 5 0.009.6491.4 Lights selector switch
0.011.6958.4

BOSCH starter motor

2.9619.300.0/10
(Dorado 55/65)

ISKRA starter motor

2.9619.360.0
(Dorado 65)

0.009.7624.4 MARELLI starter motor

2.9619.370.0
0.009.7852.3 (Dorado 65)
X37 0.011.3761.3
0.011.6955.4 ISKRA starter motor
2.9619.380.0
0.011.6958.4 (Dorado 75/85)

BOSCH starter motor

2.9616.290.0/10
(Dorado 75/85)
MARELLI starter motor
2.9619.340.0
(Dorado 75/85)

382
 System 8
Electrical system 84

Connection
Connector Type Wiring code wiring or Component description
component code

BOSCH starter motor

2.9619.300.0/10
(Dorado 55/65)
ISKRA starter motor
2.9619.360.0
(Dorado 65)

0.009.7624.4 MARELLI starter motor

2.9619.370.0
0.009.7852.3 (Dorado 65)
X38 0.011.3761.3
0.011.6955.4 ISKRA starter motor
2.9619.380.0
0.011.6958.4 (Dorado 75/85)
BOSCH starter motor
2.9616.290.0/10
(Dorado 75/85)
MARELLI starter motor
2.9619.340.0
(Dorado 75/85)

0.009.7852.3
0.011.6955.4
0.011.3761.3
X39 2
0.009.7852.3
0.011.6958.4
0.011.3761.3
0.011.6955.4
X40 2.8639.007.0 Hazard lights control unit
0.011.6958.4

X41 0.011.6955.4 0.010.1027.4 Alarms control unit

X42 3 0.011.6955.4 Diagnostics connector

X43 10 0.011.6955.4 0.008.0618.4/20 Preheating control unit

X44 6 0.011.6958.4 2.7659.173.0 Engine governor display pushbutton

X45 6 0.011.6958.4 2.7659.139.0 Engine governor reset button

X46 12 0.011.6958.4 2.7099.740.0 Throttle lever position sensor

X47 2 0.011.6958.4 2.7659.203 Memory pushbutton

X48 0.011.6958.4 008.8199.3 Accelerator pedal position sensor

Rear PTO control pushbutton

X49 3 0.011.6958.4 2.7659.177.0/10 (on fender)

X50 0.011.6958.4 008.1646.0 Transmission speed sensor

X51 11 0.011.6958.4 2.7099.790.0 Engine speed sensor

X52 0.011.6958.4 2.7659.140.0 Tyre size selection pushbutton

X53 17 0.011.6958.4 0.012.3913.4 Engine control unit

X54 0.009.7624.4 2.7099.830.0 Coolant temperature

sensor

X55 0.009.7624.4 2.7099.680.0 Engine oil pressure switch

X57 0.009.7624.4 2.7659.103.0/10 Glowplug

383
 8 System
84 Electrical system

Connection
Connector Type Wiring code wiring or Component description
component code

X58 0.009.7624.4 2.9219.130.0 Preheating control solenoid valve

X59 0.009.7624.4 009.7660.4 Air conditioning compressor

X60 0.009.7624.4 2.7099.320.0 Air cleaner clogged sensor

X61 0.009.7624.4 2.8419.003.0 Horn

X62 0.009.7624.4 2.8029.770.0/30 Front left lights

X63 2 0.009.7624.4 2.3729.400.0 Front PTO solenoid valve

X64 0.009.7624.4 2.8029.760.0/30 Front right lights

X65 0.009.7624.4 2.9439.420.0 Alternator ISKRA 65A

X65 0.009.7624.4 2.9439.450.0/10 Alternator ISKRA 85A

X66 0.009.7624.4 Brake fluid level sensor

Cooling fan speed sensor
X67 3 0.009.7624.4 0.010.1214.4

Rear lift control

X71 0.011.6943.4 0.011.2992.4/20
unit
X72 15 0.009.7627.3 0.010.8869.4/20 HML control unit

X73 0.009.7855.3 2.7659.085.0 HML control pushbutton

0.009.7850.4
X74 2.8339.032.0 Interior roof light
0.011.3606.4

0.009.7850.4 0.009.7854.3
X75
0.011.3606.4 0.011.3743.3
X76 0.009.7850.4 0.009.7853.3

X77 0.009.7850.4 0.009.7851.4

X78 0.009.7850.4 2.7659.079.0 Rear worklights switch

X79 0.009.7850.4 2.7659.146.0 Rear screen washer switch

0.009.7850.4 2.7659.091.0 Front screen washer switch

X80
0.011.3606.4 2.7659.223.0 Front screen washer switch

X81 0.009.7850.4 2.7659.126.0 Rotating beacon control switch

0.009.7850.4 Intermittent windscreen wiper interval

X82 2.8639.008.0 timer
0.011.3606.4

X83 0.009.7850.4 2.9389.002.0 Clock

0.011.3596.3

384
 System 8
Electrical system 84

Connection
Connector Type Wiring code wiring or Component description
component code

X84 0.009.7850.4 2.7659.092.0

Front screen washer switch
Rear worklights
X85 0.009.7850.4 2.7659.078.0
switch
0.009.7850.4 Radio
X86
0.011.3596.3 Radio

X87 0.009.7850.4 0.009.7852.3

X88 0.009.7850.4 0.010.4516.3

010.2123.2
X89 0.009.7850.4
010.2130.1

X90 0.009.7850.4 010.2130.1

X91 0.011.3761.3 0.011.3606.4

X92 13 0.011.3606.4 0.011.3597.3

010.2558.1
X93 0.011.3606.4
010.2562.1

010.2558.1
X94 0.011.3606.4
010.2562.1

X95 0.011.3606.4 0.011.3595.3

X96 0.011.3606.4 2.7659.159.0 Rotating beacon control switch

X97 0.011.3606.4 2.7659.192.0 Rear wiper control switch

X98 0.011.3606.4 2.7659.224.0 Winscreen wiper

control switch

X99 0.011.3606.4 2.7659.155.0

Rear worklights control switch

X100 0.011.3606.4 2.7659.154.0

Front worklights control switch

X101 0.011.3606.4 0.011.3596.3 To loudspeakers and radio wiring

To air conditioning fan wiring
X102 0.011.3606.4 0.011.3610.3

0.009.7850.4
X103 Relay - cab roof wiring
0.011.3606.4

0.009.7852.3 0.009.7850.4
X103-30
0.011.3761.3 0.011.3606.4

Roof wiring fuse

X104 0.011.3606.4 (40 Amp)

385
 8 System
84 Electrical system

Connection
Connector Type Wiring code wiring or Component description
component code

0.009.7852.3
X106 Heater unit resistance
0.011.3761.3

010.2123.2
X107 0.009.7852.3
010.2130.1

0.009.7852.3
X108 2
0.011.3761.3
0.009.7852.3
X109 2.9439.440.0/10 Heating alternator ISKRA 70A
0.011.3761.3

0.009.7852.3
X111
0.011.3761.3
X112 6 0.011.6958.4 2.7659.215.0/10 PTO AUTO switch

010.2558.1
X113 4 0.011.3761.3
010.2562.1
Relay - supplementary heat exchanger
X114 0.011.3610.3 fan

0.009.7853.3
X115 Relay - heat exchanger fan
0.011.3610.3

X116 14 0.011.3610.3 010.2262.0 Air conditioning pressure switch

X117a 16 0.011.3610.3 010.2545.2 Air conditioning heat exchanger fan

Supplementary air conditioning heat

X117b 16 0.011.3610.3 010.2545.2
exchanger fan

X118 3 0.009.7853.3 010.2140.0 Air conditioning pressure switch

X119 0.009.7853.3 010.0618.4 Air conditioning heat exchanger fan

X120 0.009.7853.3 010.2140.0 Air conditioning pressure switch

0.009.7851.4
X121 2.8029.730.0 Front left worklight
0.011.3595.3

0.009.7851.4
X122 2.8029.730.0 Rear left worklight
0.011.3595.3

0.009.7851.4
X123 2.8029.730.0 Rear right worklight
0.011.3595.3
0.009.7851.4
X124 2.8029.730.0 Front right worklight
0.011.3595.3

386
 System 8
Electrical system 84

Connection
Connector Type Wiring code wiring or Component description
component code

0.009.7851.4 2.9019.100.0/20
X125 Rear screen wiper motor
0.011.3596.3 2.9019.180.0

0.009.7851.4
X126
0.011.3596.3

0.009.7851.4
X127 Flashing light
0.011.3596.3
0.009.7854.3
X129 0.9241.566.1 Front screen washer pump
0.011.3743.3

0.010.4516.3
X130 0441.3192 Windscreen wiper motor
0.011.3597.3
0.011.0729.4
X131 Radio
0.011.3596.3

0.011.0729.4
X132 LH speaker
0.011.3596.3

0.011.0729.4
X133 RH speaker
0.011.3596.3
0.009.7854.3
X135 0.9241.566.1 Rear screen washer pump
0.011.3743.3

010.2123.2

010.2130.1
X136 0.007.6766.4 Heater settings control unit
010.2558.1

010.2562.1

010.2123.2

010.2130.1
X137 010.2124.1 Heating air temperature sensor
010.2558.1

010.2562.1

010.2123.2
X138 98707.67.3 Heater adjustment potentiometer
010.2130.1
010.2123.2
X139 009.4743.1 Fan speed selector switch
010.2130.1

010.2123.2
X140 010.2122.0 Resistor - heater fan
010.2130.1

387
 8 System
84 Electrical system

Connection
Connector Type Wiring code wiring or Component description
component code

010.2123.2
X141 010.2121.1 Heater fan
010.2130.1

010.2123.2
X142 Relay - alternator excitation
010.2130.1

X143 010.2130.1 Relay - air conditioning

X144 010.2130.1 009.4744.0 Antifrost thermostat

010.2558.1
Heater adjustment potentiometer
X145 98707.63.3
010.2562.1

010.2558.1
X146 Relay - maximum fan speed
010.2562.1
010.2558.1
X147 Relay - alternator excitation
010.2562.1

010.2558.1
X148 010.2555.0 Resistor - left heater fan
010.2562.1

010.2558.1
X149 010.2555.0 Resistor - right heater fan
010.2562.1
010.2558.1
X150
010.2562.1

010.2558.1 011.2047.4
X151 Left heater fan
010.2562.1 011.8858.4

010.2558.1
X152
010.2562.1

010.2558.1 011.2047.4
X153 Right heater fan
010.2562.1 011.8858.4

010.2558.1
X154 010.2528.1 Fan speed selector switch
010.2562.1

Relay -1st heater fan and air

X156 010.2562.1 conditioning on

010.2558.1
X157 Relay - 3rd heater fan
speed
010.2562.1
X158 010.2562.1 010.2560.1 Air conditioning control switch

X159 010.2562.1 010.2522.0 Air conditioning thermostat

388
 System 8
Electrical system 84

3. COMPONENTS
This chapter contains:
1 - Connectors table: the shapes and pinouts of the connectors
2 - Components table: technical and functional description of the components
3 - Pinouts of the electronic control units

3.1 CONNECTOR LAYOUTS

1 1 3
2 3
4 8
9 1 3 14
4 8
9 14

15 15 20 20
21 25
26 29

21 25 1 2 1 3
2
26 29

4 1 2 5
1 2 3 3 2 1

4 5 6 6 5 4
3 4
7 8 9 9 8 7

4 3 2 1

6 1 7 7 8 8 3

36 28 7
2 6 27 19
6

18 10 5 2
3 5 9 1
4 4 1

389
 8 System
84 Electrical system

9 4 1 10 10 1 11
5 2
1
4

2
5

6
6
7

7 3
3
8

4
1 8
5
4
1

2
5
2

6
7

3 1 2 3
3

7
8

17 9
8

12 13 4 1 14 2
3 6 3

3 2
2
1 4

4
1 1
2 3

15 6 7 16

A B

A B
1 12

17 2 22

45
24

68
46

390
 System 8
Electrical system 84

3.2 COMPONENT TECHNICAL DATA

N° Description Code Characteristics Notes Connector

Pin1 = earth
Pin2 = output signal
1 Rear lift positio 0.009.2194.4 Pin3 = 10Vdc power P2
n sensor 0.2Vdc output (sensor not engaged)
8.3 Vdc
(Sensor fully pressed)
Pin1 = 12Vdc power
Pin2 = earth
Pin4 = output signal
Cooling fan speed sensor With 1kOhm resistance between
2 0.010.1214.4 pins 1 and 3 and 12V X67
between pins 1 and 2
0 Vdc output
(Sensor near metal)
12 Vdc output
(Sensor far away from metal)
Pin1 = earth
Lift draft Pin2 = analogue signal
3 sensor 0.011.2164.0 Pin3 = 10V power S1
Signal with sensor disconnected
from the tractor between pins 1 and 2: ~5 V
Max. lift height adjustment Resistance between pin1 and pin 3:
4 potentiometer 0.011.2990.0 ~4.7 kOhm H1
Resistance between pin1 and pin 2:
0÷4.7 kOhm
Lift position adjustment Resistance between pin1 and pin 3:
5 potentiometer 0.011.2990.0 ~4.7 kOhm P1
Resistance between pin1 and pin 2:
0÷4.7 kOhm
Resistance between pin1 and pin 3:
6 Draft/wheelslip adjustment 0.011.2990.0 ~4.7 kOhm M1
potentiometer Resistance between pin1 and pin 2:
0÷4.7 kOhm
Max. lift height adjustment Resistance between pin1 and pin 3:
potentiometer ~4.7 kOhm
7 0.011.2990.0 Resistance between pin1 and pin 2: V
0÷4.7 kOhm
Resistance between pin1 and pin 2:
8 Actuator 007.0992.4 2.3±0.5 Ohm A

Transmission speed sensor Resistance between pin1 and pin 2:

9 008.1646.0 ~1000 Ohm at 20°C X50

Resistance between pin A and pin E:

Accelerator pedal position ~1800 Ohm
10 sensor 008.8199.3 Resistance between pin A and pin S: X48
5÷1800 kOhm
Diff lock control solenoid
valve Resistance between pin1 and pin 2:
11 2.3719.670.0 ~___ Ohm at 20°C X16
(DF)
4WD Resistance between pin1 and pin 2:
12 control solenoid valve 2.3719.670.0 ~___ Ohm at 20°C X15

Rear
13 PTO control solenoid valve 2.3719.670.0 Resistance between pin1 and pin 2: X17
(PTO) ~___ Ohm at 20°C

High range control solenoid

14 valve 2.3729.240.0 Resistance between pin1 and pin 2: H
(HI) ~8 Ohm at 20°C

391
 8 System
84 Electrical system

N° Description Code Characteristics Notes Connector

Low range control solenoid
15 valve 2.3729.240.0 Resistance between pin1 and pin 2: L
(LO) ~8 Ohm at 20°C

Resistance between pin 2 and pin 3:

___ Ohm (Tank full ___ mm)
___ Ohm (Tank half full ___ mm)
Fuel level sensor ___ Ohm (Tank empty ___ mm)
16 2.7059.998.0 Illumination reserve warning light X23
(Closes contact between pins 1 and 3):
at _____ mm from tank empty signal

Air cleaner clogging sensor

17 2.7099.320.0 Normally open contact X60

Hydraulic oil low pressure

18 switch 2.7099.660.0 Normally open contact X20

19 Engine oil pressure switch 2.7099.680.0 Normally closed contact X55

Pin1 = 5.0Vdc power
Pin2 = earth
Throttle lever position Pin4 = analogue signal
20 sensor 2.7099.740.0 0 Vdc output X46
(Hand throttle at minimum)
4.8 Vdc output
(Hand throttle at maximum)
Engine speed sensor Resistance between pin1 and pin 2:
21 (Pick-Up) 2.7099.790.0 ~900 Ohm X51

Resistance between pin1 and pin 2:

at 20°C ~7500 Ohm
22 Coolant temperature 2.7099.830.0 at 60°C ~1576 ± 8 Ohm X54
sensor at 80°C ~764 ± 6 Ohm
at 100°C ~398 ± 4 Ohm
Normally closed contact
23 Handbrake switch 2.7659.129.0 (Handbrake on) X24

Engine governor reset

24 button 2.7659.139.0 Normally open contact X45

Tyre size selection

25 pushbutton 2.7659.140.0 Normally open contact X52

Engine governor display

26 pushbutton 2.7659.173.0 Normally open contact X73

Rear PTO control

pushbutton Normally open contact (NO)
27 2.7659.177.0 resistance with contact closed 3.9 Ohm X49
(on fender)
Rear lift "lower" control
pushbutton Normally open contact (NO)
28 2.7659.182.0 resistance with contact closed 3.9 Ohm DW

Rear lift "raise" Normally open contact (NO)

29 control pushbutton 2.7659.182.0 resistance with contact closed 3.9 Ohm UP

30 Memory pushbutton 2.7659.203 Normally open contact X47

Front screen washer control
switch Normally open contact between
31 2.7659.223.0 contacts 2 and 3. X80

392
 System 8
Electrical system 84

N° Description Code Characteristics Connector

0
1
2

1 2 3 4

5 6 7 8

Winscreen wiper
32 2.7659.092.0 X84
control switch

Pin 1 2 3 4 5 6 7 8
Pos

0
1
2

1 2 3 4

5 6 7 8

33 Rear wiper control switch 2.7659.146.0 X79

Pin 1 2 3 4 5 6 7 8
Pos

0
1
30
b
49

30
15
49a

L R
Hazard warning lights
34 2.7659.110.0 X33
switch

Pin 15 49 30 L 49a R
Pos

393
 8 System
84 Electrical system

N° Description Code Characteristics Connector

0
P 1
2

15

30
50

30/1
17

19

35 Starter switch 2.7659.127.0 Pin 15 30/1 50 19 30 17

X32
Pos

7 4 5 6 3 2 1 8

36 Rear worklights control 2.7659.155.0 X99

switch
Pin 1 2 3 4 5 6 7 8
Pos

7 4 5 6 3 2 1 8

37 Front worklights control 2.7659.154.0 X100

switch
Pin 1 2 3 4 5 6 7 8
Pos

394
 System 8
Electrical system 84

N° Description Code Characteristics Connector

3 2 1 8
Rotating beacon control 7 4 5 6

38 switch 2.7659.159.0 X96

Pin 1 2 3 4 5 6 7 8
Pos

0
1
4 3

2
1
5

6 7

39 2.7659.163.0 X9
Diff lock control switch

Pin 1 2 3 4 6 7
Pos

2
0
1
1 2 3 4 5

Rear lift control

40 pushbutton 0.011.7720.0 C-I
Pin 1 2 3 4 5
Pos

395
 8 System
84 Electrical system

N° Description Code Characteristics Connector

0
1
30

b
49

30
15
49a
L R

41 4WD control switch 007.5945.0 X8

Pin 15 49 30 30b L R
Pos

0
1
30 b
49

30
15
49a

L R

42 Rear PTO control switch 2.7659.108.0 X10

Pin 15 49 30 30b L R
Pos

0
1
30
b
49

30
15
49a

L R

Front PTO control switch

43 2.7659.108.0 X35

Pin 15 49 30 30b L R
Pos

396
 System 8
Electrical system 84

N° Description Code Characteristics Connector

0
1
2

7 4 5 6 3 2 1 8

Rear wiper control switch

44 2.7659.192.0 X97
Pin 1 2 3 5 6
Pos

0
1
2

7 4 5 6 3 2 1 8

45 Winscreen wiper 2.7659.224.0 X98

control switch
Pin 1 2 3 5 6
Pos

Pin 1 2 3 4 5 6 7 8 9
Pos
Freccia sx
46 Lights selector switch 0.009.6491.4 X36
Freccia dx

Clacson

Lampeggio

Luci di
posizione
Luci
anabbagl.
Luci
abbagl.

397
 8 System
84 Electrical system

N° Description Code Characteristics Connector

0
1
30

b
49

30
15
49a
L R
PTO AUTO control
47 switch 2.7659.215.0 X112

Pin 15 49 30 30b L R
Pos

0
1
C
S

31 S1

PTO engagement
48 2.7659.142.0 X10
pushbutton

Pin S1 S 31 C
Pos

398
 System 8
Electrical system 84

3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC CONTROL UNITS

3.3.1 HML CONTROL UNIT

CONNECTOR X72

1 6

1 2 3 4 5 6

12 11 10 9 8 7

12 7

Pin Volts. Abbreviation Description

1 0V Battery negative
2 "M" warning light output
3 +12V Power (+) commmon for "H-M-L" solenoid valves
4 0V Configuration pin
5 Not utilised
6 Digital signal - range downshift pushbutton
7 Digital signal - range upshift pushbutton
8 0V Range switch common
9 Power for "L" solenoid valve
10 Power for "M" solenoid valve
11 Power for "H" solenoid valve
12 +12V Battery positive

399
 8 System
84 Electrical system

3.3.2 POWER LIFT CONTROL UNIT

CONNECTOR X71

1 6

1 2 3 4 5 6

12 11 10 9 8 7

12 7

Pin Volts. Abbreviation Description

1 +12V Battery positive
2 Power for "UP" solenoid valve
3 Power for "DOWN" solenoid valve
4 0V Battery negative
5 +10V Power (+) common for solenoid valves and sensors
6 Analogue input - lift position sensor
7 Analogue input - lift draft sensor
8 Analogue input - lift lowering speed adjustment trimmer
9 Analogue input - max. lift height adjustment trimmer
10 Analogue input - lift draft-wheelslip adjustment trimmer
11 Analogue input - lift position adjustment trimmer
12 ISO 9141 serial interface (Diagnostics connector)

400
 System 8
Electrical system 84

3.3.3 PREHEATING CONTROL UNIT

CONNECTOR X43

17 10

17 16 15 14 13 12 11 10

9 8 7 6 5 4 3 2 1

9 1

Pin Volts. Abbreviation Description

1 +12V Battery positive
2 Not utilised
3 Power for preheating warning light
4 Not utilised
5 Not utilised
6 Not utilised
7 Power for preheating relay
8 Not utilised
9 Not utilised
10 0V Battery negative
11 Not utilised
12 Not utilised
13 Not utilised
14 Not utilised
15 Not utilised
16 Digital input - "W" (Alternator rotation)
17 Not utilised

401
 8 System
84 Electrical system

3.3.4 ANALOGUE INSTRUMENT PANEL

CONNECTOR X3

36
35

27
34

26

18
33

25

17

9
32

24

16

31 REF.SAME-10S-10N ANALOGICO
23

15

7
30

22

6
14

2200RPM=567A-473W HZ 12V
W
21
29

13

REF.AST/Rev. DATE........
28

12
20

4
19

AST MADE IN SPAIN

A
11

3
10

2
1

Pin Volts. Abbreviation Description

1 Warning light - "Memorising selected gear"
2 Analogue input - "W" (Alternator rotation)
3 Not utilised
4 Input - engine temperature sensor
5 Input - fuel level sensor resistance
6 Warning light - "High beam"
7 Warning light - "Preheating"
8 "Clogged air cleaner" warning light
9 Warning light - "Low engine oil pressure"
10 Warning light - "Handbrake - Low fluid level"
11 Warning light - "Low gear" (L)
12 Warning light - "Fuel reserve"
13 Warning light - "Low trailer braking pressure"
14 Warning light - "Battery charging"
15 Warning light - "Hydraulic oil filter clogged - Low oil presure"
16 Warning light - "Front PTO engaged"
17 Warning light - "Rear PTO engaged"
18 Warning light - "Broken belt alarm"
19 Instrument panel lighting
20 Warning light - "Diff lock"
21 Warning light - "4wd engaged"
22 Warning light - "Direction indicators"
23 Warning light - "1st trailer direction indicators"
24 Warning light - "2nd trailer direction indicators"

402
 System 8
Electrical system 84

25 Warning light - "Rear PTO Groundspeed"

26 Warning light - "High gear" (H)
27 Warning light - "Medium gear" (M)
28 Warning light - "Rear PTO at 540 rpm"
29 Warning light - "Rear PTO at 1000 rpm"
30 Warning light - "Rear PTO ECO"
31 0V Common earth fore warning lights (pins 1,6,16,18,19,22,23,24)
Power common for warning lights
32 +12V (Pins 7,8,9,10,11,12,13,14,15,17,20,21,25,26,27,28,29,30)
33 Power for "External alarm" warning light
34 Not utilised
35 Not utilised
36 Not utilised

403
 8 System
84 Electrical system

3.3.5 DIGITAL INSTRUMENT PANEL

CONNECTOR X3

36
35

27
34

26

18
33

25

17

9
32

24

16

SWITCH SELEZIONE ACQUA/ARIA

31
23

15

7
30

22

6 REF.SAME-10S-10N DIGITALE
14
21
29

13

2200RPM=1760 Hz12V
28

12
20

4
19

REF.AST/Rev. DATE........
11

3
10

AST
2

MADE IN SPAIN
1

Pin Volts. Abbreviation Description

1 Warning light - "Memorising selected gear"
2 Input - engine speed signal (from engine control unit - Pin 22)
3 Digital input - transmission speed sensor
4 Input - engine temperature sensor
5 Input - fuel level sensor resistance
6 Warning light - "High beam"
7 Warning light - "Preheating"
8 Spia "Intasamento filtro aria"
9 Warning light - "Low engine oil pressure"
10 Warning light - "Handbrake - Low fluid level"
11 Warning light - "Low gear" (L)
12 Warning light - "Fuel reserve"
13 Warning light - "Low trailer braking pressure"
14 Warning light - "Battery charging"
15 Warning light - "Hydraulic oil filter clogged - Low oil presure"
16 Warning light - "Front PTO engaged"
17 Warning light - "Rear PTO engaged"
18 Warning light - "Broken belt alarm"
19 Instrument panel lighting
20 Warning light - "Diff lock"
21 Warning light - "4wd engaged"
22 Warning light - "Direction indicators"
23 Warning light - "1st trailer direction indicators"
24 Warning light - "2nd trailer direction indicators"

404
 System 8
Electrical system 84

25 Warning light - "Rear PTO Groundspeed"

26 Warning light - "High gear" (H)
27 Warning light - "Medium gear" (M)
28 Warning light - "Rear PTO at 540 rpm"
29 Warning light - "Rear PTO at 1000 rpm"
30 Warning light - "Rear PTO ECO"
31 0V Common earth fore warning lights (pins 1,6,16,18,19,22,23,24)
Power common for warning lights
32 +12V (Pins 7,8,9,10,11,12,13,14,15,17,20,21,25,26,27,28,29,30)
33 Power for "External alarm" warning light
34 Input - "Display" pushbutton
35 Input - "Reset" pushbutton
36 Input - "Select" pushbutton

405
 8 System
84 Electrical system

3.3.6 ENGINE CONTROL UNIT

CONNECTOR X53

2 22

45
24

68
46

Note: the figure shows the wiring connector

Pin Volts. Abbreviation Description

1 Not utilised
2 Not utilised
3 Input - engine temperature signal
4 Input - signal from lift position sensor
5 Input - signal from accelerator pedal sensor
6 Input - signal from hand throttle sensor
7 Not utilised
8 Not utilised
9 Input - PTO AUTO signal
10 Input - engine speed sensor (Pick-Up)
11 Input - signal from wheel sensor
12 Input - signal from cooling fan speed sensor
13 Not utilised
14 Not utilised
15 Not utilised
16 Not utilised
17 Not utilised
18 Not utilised
19 Not utilised
20 Not utilised
21 Not utilised
22 Engine speed digital output
23 Not utilised
24 0V Battery negative
25 0V Battery negative
26 Not utilised
27 TxD ISO 9141 serial interface (Diagnostics connector)

406
 System 8
Electrical system 84

28 +5V +5V reference voltage for signal on pins 5 and 6

29 RxD ISO 9141 serial interface (Diagnostics connector)
30 Not utilised
31 Not utilised
32 Not utilised
33 0V Power (–) for sensors
34 Not utilised
35 Signal - Rear PTO engagement key
36 Connected to earth
37 0V Connected to earth
38 Not utilised
39 Not utilised
40 Not utilised
41 Not utilised
42 Not utilised
43 Engine temperature signal output
44 +12V Battery positive (+15)
45 +12V Battery positive (+15)
46 Power (+) for actuator
47 Power (–) for actuator
48 Not utilised
49 Not utilised
50 Not utilised
51 Not utilised
52 +12V Power (+) common for "H", "L" and "rear PTO" solenoid valves
53 Power (–) for "H" gear engagement solenoid valve
54 Power (–) for "L" gear engagement solenoid valve
55 Power (–) for rear PTO engagement solenoid valve
56 Power (–) for glowplugs relay
57 Power (–) for preheating light
58 Power (–) preheating solenoid relay
59 Power (–) for broken belt light
60 Power (–)for "M" range light
61 Power (–) for "HOLD" light
62 Signal - range upshift pushbutton
63 Signal - range downshift pushbutton
64 Signal - handbrake on
65 Signal - preheating solenoid in operation
66 Signal - low engine oil pressure switch
67 Signal - HOLD key
68 Signal - glowplugs in operation

407
 8 System
84 Electrical system

4. SYSTEMS
Mechanical governor Electronic governor
N° System Standard Standard
Platform Platform
cab HV Cab cab HV Cab
1 Earths X X X X X X
2 Starting and preheating X X X
3 Lights - steering column switch unit X
4 Lights - steering column switch unit X
5 Lights - steering column switch unit X
6 Accessories - Diagnostics X
7 Accessories - Diagnostics X
8 Accessories - Diagnostics X
9 Wipers X
10 Wipers X
11 Front instrument panel X X X
12 Radio X X
13 Radio X X
14 Heating X
15 Heating X
16 Heating and air conditioning X
17 Heating and air conditioning X
18 Braking system - Trailer braking X X X
19 HML transmission X X X
20 Electronic lift X X X
21 Rear and front PTO X X X
22 Starting and preheating X X X
23 Electrical engine control X X X
24 Lights - steering column switch unit X
25 Lights - steering column switch unit X
26 Lights - steering column switch unit X
27 Accessories - Diagnostics X
28 Accessories - Diagnostics X
29 Accessories - Diagnostics X
30 Wipers X
31 Wipers X
32 Front instrument panel X X X
33 Heating X
34 Heating X
35 Heating and air conditioning X
36 Heating and air conditioning X
37 Braking system - Trailer braking X X X
38 HML transmission X X X
39 Electronic lift X X X
40 Rear and front PTO X X X

408
 Systems 8
electrical systems 84

4.1 EARTHING POINTS

GND5
GND4

F0028140 F0028100

GND9
GND5
GND1

GND2

F0028120

GND8
GND3

F0026980 F0028560

D0007220

409
 8 Systems
84 electrical systems

GND6

F0027370

GND7

F0027210

D0007860

410
 Systems 8
electrical systems 84

4.2 STARTING AND PREHEATING (VERSION WITH MECHANICAL GOVERNOR)

4
2 3
2 1 0
1

GND5
3 30 86 85 87 87a 87 85 86 30 15 30/1 30 50

0.011.6955.4
X41 RL2 RL1 X32

12 X10
R
7
30b
2
ON

49
4

Fmax
20A

40A
30A
F1

F6
15 1
OFF

30
6
L
3

CARICA BATTERIA 14

+12 VOLT 32
W (ROTAZIONE ALTERNATORE) 2

PRERISCALDO 7
X3
11

X43 X31 X1 X38 X37

1 3 7 16 10 4 3 2 1 5 12 11 13 4

+30
+50
GND4
M

5
+ -
10 9
0.009.7624.4

BATTERY

X58 X57 X65

D+ B+ W

8
G

6
7

1 Alarms ECU 7 Glowplug

2 Relay RL2 8 Preheating control solenoid valve
3 Relay RL1 9 Start enable switch
4 Starter switch 10 Preheating control unit
5 Starter motor 11 Instrument panel
6 Alternator 12 Rear PTO control switch

D0007020

411
 8 Systems
84 electrical systems

4.3 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH MECHANICAL GOVERNOR - PLATFORM)

7 8 10 1 Rear left light

6
OFF 2 Front left headlamp

IND. DIR. 2° RIMORCHIO

IND. DIR. 1° RIMORCHIO

ON
9 G
11 3 Number plate light

ILL. CRUSCOTTO

IND. DIREZIONE
2 1 0

ABBAGLIANTI
4 Rear right light
5 Front right headlamp

49a
+15

+30

49a

-31
0.011.6955.4

C3
C2
49

49
R

C
L
15 30/1 30 50 1 3 6 5 7 4 19 22 24 23 6 7 5 4 1 3 1 4 2 3 5 6 1 2

X32 X33 X26 X40 X22

6 Starter switch
X3
1 2 7 Hazard warning lights switch
X21 8 Instrument panel
GND5 9 Trailer socket
X4
5 3
(For lights and auxiliary power)
5 7 1 GND4
6 2 10 Hazard warning control unit
X13 4
1 5 X34
11 Rear worklight
2 6 7 12 Lights selector switch
4 3 6
4 3 13 Horn
X14 2
14 Front left lights
3
1 15 Front right lights
2
X28 16 Starter motor
9

2 8
7
X27

1 4
X36 12
5
3 1 +
X29 5 30
9 FS
7 L
8 FD
Fmax
40A

10A

10A

10A

10A

10A
15A

F10
20A

20A

F11

F12
F9

57/58
F3

F4
F2

F8

2
56b
3
56a
4
H
6

X38 X37 X1
8 7 9 10 6
+30
+50

+ -
16
0.009.7624.4

BATTERY

X64 X62 X61

2 1 3 2 1 3 2 1
GND3

15 14 13

D0007040

412
 Systems 8
electrical systems 84

4.4 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH MECHANICAL GOVERNOR - STANDARD CAB)

8
7 10
6

IND. DIR. 2° RIMORCHIO

IND. DIR. 1° RIMORCHIO
OFF
ON
9 G

ILL. CRUSCOTTO
IND. DIREZIONE
2 10

ABBAGLIANTI
+15
+30

49a
49a

-31
0.010.5582.3 0.011.6955.4

C2
C3
49

49
R

C
L
15 30/1 30 50 1 3 6 5 7 4 19 22 24 23 6 7 5 4 1 3 1 4 2 3 5 6
X32 X33 X3 X26 X40
5
X13
5 GND5
7 X4
6 3
1 GND4
2
X27 4
9
8 5
7 6
11 12
4 13 14 15 16
1
2 GND6
3 3 1 3 4 2 1 3 4 2 1 2 2 1 1 2 2 1
4 X85 X78 X121 X124 X122 X123
X14
1
2 2 F8
X28 10A
6 F7
4 10A
1 5
3 X87 X77
X29 X39 3 5
1 1 6
2 2 1
2
Fmax

F10
10A

10A

10A

10A

10A
F12
40A
10A

15A

F11
20A

F9
F7

F3
F2

F8

F X111 X103-30
50A

X38 X37 X1 X36 X103

8 7 9 10 6 6 4 3 2 8 7 9 5 1 30 86 85 87
0.009.7852.3 0.009.7850.4 0.009.7851.4
0.009.7624.4
+30
+50

57/58
56b
56a
H

+
FD

FS
30
M

+ -
22
BATTERY
17
X64 X62 X61
2 1 3 2 1 3 2 1
GND6
18
21 20 19

1 Rear left light 10 Hazard warning control unit 20 Front left lights
2 Number plate light 11 Front worklights control switch 21 Front right lights
3 Rear right light 12 Rear worklights control switch 22 Starter motor
4 Front left sidelight and direction indicator 13 Front left worklight
5 Front right sidelight and direction indicator 14 Front right worklight
6 Starter switch 15 Rear left worklight
7 Hazard warning lights switch 16 Rear right worklight
8 Instrument panel 17 Roof wiring power relay
9 Trailer socket 18 Lights selector switch
(For lights and auxiliary power) 19 Horn

D0007430

413
 8 Systems
84 electrical systems

4.5 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH MECHANICAL GOVERNOR - HIGH-VISIBILITY CAB)

8
6 7 10

IND. DIR. 2° RIMORCHIO

IND. DIR. 1° RIMORCHIO
OFF
ON
9

ILL. CRUSCOTTO
G

IND. DIREZIONE
2 10

ABBAGLIANTI
+15
+30

49a
49a

-31
0.010.5582.3 0.011.6955.4

C2
C3
49

49
R

C
L
15 30/1 30 50 1 3 6 5 7 4 19 22 24 23 6 7 5 4 1 3 1 4 2 3 5 6
X32 X33 X3 X26 X40
5 X13
5 GND5
7 X4
6 3
1 GND4
X27 2
9 4
8 5
7 6

4
11 12
1
2
13 14 15 16
3 3
4
X14 GND7
7 2 3 1 5 6 4 8 7 2 3 1 5 6 4 8 1 2 1 2 1 2 2 1

2 1 X100 X99 X121 X124 X122 X123

2
X28
6 F8
4 10A
1 5 F7
3 10A
X29
X39 X91
2 2
Fmax

F10

F12
40A

10A

10A

10A

10A

10A
F11
10A

15A

X95
20A
F2
F7

F3

F9
F8

4
3
2
F X111 X103-30 1
50A

X38 X1 X36 X103 X104

X37 8 7 9 10 6 30 86 85 87 1 2
6 4 3 2 8 7 9 5 1
0.011.3761.3 0.011.3606.4 0.011.3595.3
+30
+50

FD

FS
56a
56b
H

57/58

+
L

GND7
30
0.009.7624.4

M 40A

+ -
23 17
BATTERY
18
X64 X62 X61
2 1 3 2 1 3 2 1
GND6

19
22 21 20

1 Rear left light (For lights and auxiliary power) 18 Roof wiring power relay
2 Number plate light 10 Hazard warning control unit 19 Lights selector switch
3 Rear right light 11 Front worklights control switch 20 Horn
4 Front left sidelight and direction indicator 12 Rear worklights control switch 21 Front left lights
5 Front right sidelight and direction indicator 13 Front left worklight 22 Front right lights
Starter switch 14 Front right worklight 23 Starter motor
7 Hazard warning lights switch 15 Rear left worklight
8 Instrument panel 16 Rear right worklight
9 Trailer socket 17 Roof wiring power fuse (40 Amp)

D0007440

414
 Systems 8
electrical systems 84

4.6 ACCESSORIES - DIAGNOSTICS (VERSION WITH MECHANICAL GOVERNOR - PLATFORM)

2
3 4
2 1 0
5

GND5
0.011.6986.4
15 30/1 30 50 2 1 1 2 1 2 3

0.011.6955.4
X32 X12 X11 X2
PRESA
DIAGNOSTICA X42
2 1

1 1 2

7 3

ISO 9141 12 1

8 GND 4 2
Fmax

20A
10A

15A

40A

20A

10A
F13

F10
F2
F5

F4
+12 VCC 1 3
X71 X7

0.011.6943.4

X36 X38 X37

6 4 3 2 8 7 9 5 1
+30
+50
+
H

FD
56a

56b

57/58

30
FS
L

6
+ -

BATTERY

1 Diagnostics connector
2 Starter switch
3 Compressor for driver’s seat air suspension
4 Outlet socket (in cab)
5 Cigar lighter
6 Starter motor
7 Lights selector switch
8 Rear lift control unit

D0007060

415
 8 Systems
84 electrical systems

4.7 ACCESSORIES - DIAGNOSTICS (VERSION WITH MECHANICAL GOVERNOR - STANDARD CAB)

2 1

0.009.7851.4
X127

2 X126
3 4 6
2 10
5 2 1

GND5
0.011.6986.4 15 30/1 30 50 2 1 1 2 1 2 3 30 86 85 87 8 7 6 5 4

PRESA
X32 X12 X11 X2 X103
DIAGNOSTICA X42 X103-30
2 1
1 1 2 X39
7 3 2 2
3
X87

10A

10A
F1
F6
ISO 9141 12 1
Fmax
F13
10A

10A

15A

40A

20A

20A

10A

0.009.7850.4
F10
F7

F5

F4

13
F2

GND 4 2
X111
+12 VCC 1 3
X71 X7

50A
F
0.011.6943.4
X36 X37 X83 X81
X38 X74 2 4 3 1
6 4 3 2 8 7 9 5 1 4 3 2 1 1 2
0.011.6955.4 0.009.7852.3
+30
+50
FD

GND6
FS
56a
56b
57/58
H

-
+
30

15
M 30 58

+ -
11 9 8
BATTERY 10

12

1 Diagnostics connector
2 Starter switch
3 Compressor for driver’s seat air suspension
4 Outlet socket (in cab)
5 Cigar lighter
6 Roof wiring power relay
7 Flashing light
8 Rotating beacon control switch
9 Interior roof light
10 Clock
11 Starter motor
12 Lights selector switch
13 Rear lift control unit

D0007450

416
 Systems 8
electrical systems 84

4.8 ACCESSORIES - DIAGNOSTICS (VERSION WITH MECHANICAL GOVERNOR - HIGH-VISIBILITY CAB)

2
3 4 7
2 10
5 6

0.011.6986.4 GND5 GND7

15 30/1 30 50 2 1 1 2 1 2 3 2 1 7 2 3 1 8

0.011.3606.4
X32 X12 X11 X2 X74 X96

PRESA
DIAGNOSTICA X42
2 1
1 1 2 X39 X91
7 3 2 2
3 X104
2
8

40A
X103-30 1

10A

10A
F1
F6

F2
5A
ISO 914112 1
Fmax

14
F13

F10
10A

10A

15A

40A

20A

20A

10A
F7

F5

F4

GND 4 2 87
+12 VCC 1 3 85
X71 X7
X111 86
9
30

50A
F
0.011.6943.4 X103

X36 X38 X37 X101

6 4 3 2 8 7 9 5 1 4 2 3 1
0.011.6955.4 0.011.3761.3
+30
+50
FD
56a
56b

FS
57/58
H

30
+
L

M
GND6
+ -
12 1 2 X126

0.011.3596.3
BATTERY

13
X83 X127
1 3 2 4 1 2
- 15
30 58

10
11

1 Diagnostics connector 8 Roof wiring power fuse (40 Amp)

2 Starter switch 9 Roof wiring power relay
3 Compressor for driver’s seat air suspension 1 Flashing light
4 Outlet socket (in cab) 11 Clock
5 Cigar lighter 12 Starter motor
6 Interior roof light Lights selector switch
7 Rotating beacon control switch 14 Rear lift control unit

D0007460

417
 8 Systems
84 electrical systems

4.9 WIPERS (VERSION WITH MECHANICAL GOVERNOR - STANDARD CAB)

1 2 3
4

0.009.7851.4 5 6 7 8 4 3 2 1 5 6 7 8 4 3 2 1 I T 31 15 53S 53M 2 1

0.009.7850.4
X79 X84 X82 X80
X125 X77
1 3
11 M
2 7
6
5
8

0.009.7854.3
X75
1 3
M
2 2 0.010.4516.3
10 X129 1
X88 X130

2 3 6

2 3 6
X135 5
1 2

1
7.5A

7.5A
F6

F5

9 GND6

X87 X103-30 X103

2 30 86 85 87

X111
0.009.7852.3

8
2 10 6
50A
F

15 30/1 30 50 2
X32 X39
0.011.6955.4

Fmax
40A

10A
F7

X38 X37
+30
+50

+ -
7
BATTERY

1 Rear wiper control switch 8 Starter switch

2 Front windscreen wiper control switch 9 Rear screen washer pump
3 Intermittent wipe timer for windscreen wiper 10 Front windscreen washer pump
4 Windscreen washer pump control switch 11 Rear screen wiper motor
5 Windscreen wiper motor
6 Roof wiring power relay
7 Starter motor

D0007470

418
 Systems 8
electrical systems 84

4.10 WIPERS (VERSION WITH MECHANICAL GOVERNOR - HIGH VISIBILITY CAB)

3
1 2 4

0.011.3596.3 GND6
1 3 2 6 5 1 3 2 6 5 I T 31 15 53S 53M 2 3

0.011.3606.4
X97 X98 X82 X80
2 X101
12 1 2
X125

X75
1 3
M

11
2 2 0.011.3597.3
X129 1

2 3 1 4

2 3 1 4
7.5A

7.5A
F6

F5
5
0.011.3743.3

X92 X130

X135
1 2
X91 X103-30 X103 X104
M 2 30 86 85 87 1 2
GND7
40A

10 X111
0.009.7852.3

9
6
2 10
7
50A
F

15 30/1 30 50 2
X32 X39
0.011.6955.4

Fmax
40A

10A
F7

X38 X37
+30
+50

+ -
8
BATTERY

1 Rear wiper control switch 7 Roof wiring power relay

2 Front windscreen wiper control switch 8 Starter motor
3 Intermittent wipe timer for windscreen wiper 9 Starter switch
4 Windscreen washer pump control switch 10 Rear screen washer pump
5 Windscreen wiper motor 11 Front windscreen washer pump
6 Roof wiring power fuse (40 Amp) 12 Rear screen wiper motor

D0007480

419
 8 Systems
84 electrical systems

4.11 FRONT INSTRUMENT PANEL (VERSION WITH MECHANICAL GOVERNOR)

3 4

BASSA PRESS. OLIO MOT.

RISERVA CARBURANTE

LIVELLO CARBURANTE
2

ALLARME ESTERNO
INTS. FILTRO ARIA
2 1 0

OLIO IDRAULICO
TEMP. MOTORE
+12 VOLT

- VCC
GND4
6 8 5 4 1 2 32 31 9 8 4 15 12 5 33 15 30/1 30 50
1

0.011.6955.4
X41 X3 X32
fN

FMAX
20A
1 3

F6
2

40A
0.009.7624.4

X67 X1
28

27

29

16

X18

X55 X60 X54 X20 X19 X23 X38 X37

1 2 2 4 3 1

GND3

+50

+30
GND5
t
M
P

11 10 9 8 7 6 5 + -

BATTERY

1 Rotation speed sensor

for cooling fan
(Only for version with air conditioning)
2 Alarms ECU
3 Instrument panel
4 Starter switch
5 Starter motor
6 Fuel level sensor
7 Hydraulic oil filter clogging pressure switch
8 Hydraulic oil low pressure switch
9 Coolant temperature sensor
10 Air cleaner clogged sensor
11 Engine oil pressure switch

D0007150

420
 Systems 8
electrical systems 84

4.12 RADIO (VERSION WITH STANDARD CAB) 4.13 RADIO (VERSION WITH HIGH-VISIBILITY CAB)

1
1

GND6
2 4 1 3 1 2
2 4 1 3 2 1
0.011.0729.4

X131 X86

0.011.3606.4
X86 X101

0.009.7850.4

0.011.3596.3
5A X131 3
F2

X132 X132
2

5A
F2
4 1 4
2
1

X133 X87 X133 X91

2 1 3
2 1 3
GND6
3 3
0.009.7852.3

0.009.7852.3
X111 X111
50A
F

50A
F
X37
X37
+30
+50

+30
+50
M
M

+ -
2 + -
2
BATTERY
BATTERY

1 Radio 1 Radio
2 3Starter motor 2 3Starter motor
3 RH speaker 3 RH speaker
4 LH speaker 4 LH speake

D0007500 D0007510

421
 8 Systems
84 electrical systems

4.14 HEATER (VERSION WITH MECHANICAL GOVERNOR - STANDARD CAB)

1 2 1 Heater control potentiometer

2 Heater air temperature sensor
010.2123.2 3 Fan speed selector switch
1 2 3 1 2
X142 X138 X137 4 Resistor for heater fan
87
85 5 Heater fan
12 X139
86
30 1
C 6 Roof wiring power relay
11
2
3
B

H 3 3 7 Starter switch
3 4
5
M
L
2
1
0
8 Starter motor
10
6
1
9 Heating alternator
3
11 8 2
3 4 10 Heater resistance
9
4 4 11 Heater control unit
5 X140 12 Control relay for alternator excitation
7
2
10 2
1 1
M 5
X136 X141
3 1 2 4 1 2 2 1
0.009.7850.4

X107 X106 X89

20A
F4

2 1 X103-30 X103
X108 30
86
2 85 6
X87 87
0.009.7852.3

X111
GND6
7
2 10
50A
F

B- B+ X109 X39
1 2 2 15 30/1 30 50
B- B+ DF D+
+ X32
0.011.6955.4

G
-
Fmax
10A

40A
F7

X38 X37
+30
+50

+ -
8
BATTERY

D0007490

422
 Systems 8
electrical systems 84

4.15 HEATER (VERSION WITH MECHANICAL GOVERNOR -HIGH-VISIBILITY ROOF

010.2558.1 1 Control relay for 3rd heater fan speed

2 Control relay for alternator excitation
X153 X152 X150 X151
2 2 2 2 3 Fan speed selector switch
5 M
1 1 1 1
M
6
4 Resistor for right heater fan
X149 X148
1 1 5 Right heater fan
4 2
3
2
3 7 6 Left heater fan
4 4
7 Resistor for left heater fan
X154 X146
I
1 87b 8 Control relay for maximum fan speed
II
2 87

3
III
86 9 Heater control potentiometer
IV
3
4 85
8
C
5 30 10 Heater air temperature sensor
X145 11 Heater control unit
1
2
12 Heater resistance
X147
3
4
9 13 Roof wiring power relay
30 5
85
14 Starter switch
2 86 X137
87 1
15 Starter motor
87b 2
10
16 Heating alternator
30 8
85 9

1 86
87
12
6
87b 10
3
X157 4 11
5
1
2
7
11

12 X136
3 1 2 4 1 2 2 1
0.011.3606.4

X113 X106 X93

40A
F

X103-30 X103
2 1
30
X108 86
2 85
13
X91 87
0.011.3761.3

X111 GND6

2 10

14
F
50A

B- B+ X109 X39
1 2 2 15 30/1 30 50
B- + B+ DF D+
X32
0.011.6955.4

-
Fmax
10A

40A
F7

16
X38 X37
+30
+50

+ -
15
BATTERY

D0007520

423
 8 Systems
84 electrical systems

4.16 HEATING AND AIR CONDITIONING (VERSION WITH MECHANICAL GOVERNOR - STANDARD CAB)

5 1 Heater control unit

3 4 2 Control relay for alternator excitation
3 Heater control potentiometer
0.010.2130.1 4 Heater air temperature sensor
1 2 3 1 2 30 85 86 87
X138 X137 X143 5 Control relay for air conditioning
X144
X142 1 6 Demister thermostat
87 2 6
85 7 Fan speed selector switch
2 86 X139
30 1 C 8 Resistor for heater fan
B
2
9 Heater fan
11 3 H 3
7
3 4 M
L
2
1
0
10 Heater resistance
10 5
6 11 Roof wiring power relay
12 1
8 2
12 Control relay for air conditioning fan
1 9 8
4
3
4
13 Air conditioning fan
5
X140 14 Air conditioning pressure switch
7
2
10 1 15 Starter switch
1 2
M 9
X136 X141 16 Starter motor
X141 X89
3 1 2 4 1 2 1 2 3 4 2 1
17 Air conditioning compressor
0.009.7850.4

X107 X106 18 Heating alternator

12
30A

20A
F3

F4

13 14
X108
2 1
X103-30 X103

M
30
86
X87 2 11
85 30 86 85 87 2 1 3 2 1 1
1 87 X115 X119 X118 X120
3

X111 GND6
0.009.7852.3

0.009.7853.3
4
2
50A
F

3
1
B- B+ X109 X39 X76
1 2 1 2
B- B+ DF D+
+
0.011.6955.4

-
Fmax
10A

40A
F7

18
X1 X38 X37 X32
15 15 30/1 30 50
+30
+50
0.009.7624.4

2 10
+ -
16
BATTERY
X59 15

17

D0007530

424
 Systems 8
electrical systems 84

4.17 HEATING AND AIR CONDITIONING (VERSION WITH MECHANICAL GOVERNOR - HIGH-VISIBILITY ROOF)
7 8 1 Control relay for 3rd heater fan speed
1 2 1 2
0.010.2562.1 2 Control relay for alternator excitation12
X153 X152 X158 X159 X150 X151
2 2 2 2
3 Control relay for 1st fan speed and air conditioning
6 M
1 1 1 1
M
9 on
X149 X148 4 Fan speed selector switch
1 1

5 2
3
2
3 10 5 Resistor for right heater fan
4 4
6 Right heater fan
X154 X146 7 Air conditioning control switch
I
1 87b
II
2 87
8 Air conditioning thermostat
4 III
3 86
11
IV

C
4
5
85
30
9 Left heater fan
30
X156 X145
10 Resistor for left heater fan
3
85
86
1
2
11 Control relay for maximum fan speed
87 3 12 12 Heater control potentiometer
X147 4
30
85
5 13 Heater air temperature sensor
2 86
87
X137 14 Heater control unit
87b
1
2
13 15 Heater resistance
30
85
8
9
16 Roof wiring power relay
1 86
87
12
6
17 Air conditioning fan
87b 10 18 Control relay for air conditioning fan
X157 3
14
4 19 Control relay for supplementary air conditioning
5
1 fan
2
7 2 Air conditioning pressure switch
11
15 X136 21 Supplementary air conditioning fan
3 1 2 4 1 2 3 2 1 2 1 22 Starter switch
0.011.3606.4

X113 X106 X94 X93

23 Starter motor
24 Air conditioning compressor
20 25 Heating alternator
18 19
7.5A

40A
F4
304
F3

17 21
X108 X103-30
2 1
X103
M

M
30
86
X91 2 85 16 2 1 30 86 85 87 87a 30 86 85 87 87a 1 2 3 4 5 6 1 2
1 87 X114
X117a X115 X116 X117b
3

X111 GND6
1
0.011.3761.3

0.011.3610.3
2
4
50A
F

5
7
8
6
3
B- B+ X39 X102
1 2 1 2
B-+ B+ DF D+
0.011.6955.4

G
Fmax

-
10A

40A
F7

25
X1 X38 X32
X37
15 15 30/1 30 50
0.009.7624.4

+30
+50

M
+ -
210

X59 BATTERY

22
23
24
D0007540

425
 8 Systems
84 electrical systems

4.18 BRAKING SYSTEM - TRAILER BRAKING (VERSION WITH MECHANICAL GOVERNOR)

4 5

PRESS. RIMORCHIO
1 2 3 2 10

FRENO A MANO

+12 VOLT

-VCC
3 5 4 6 4 3 2 1 6 3 15 30/1 30 50 13 10 32 31

0.011.6955.4
X29 X14 X26 X32 X3

GND4

Fmax
10A

20A

40A
F7

F6

X5
1
11 2

X25
1
10 P
2

X24
1
9 2

X41 X38 X37

7 20
+30
+50
FRENO A MANO INS.

GND5 X1
M

+ -
7
8 BATTERY
0.009.7624.4

X66
1 2

GND3

1 Rear left light 7 Starter motor

2 Rear right light 8 Alarms ECU
3 Trailer socket 9 Handbrake switch
(For lights and auxiliary power) 10 Trailer braking low pressure switch
4 Starter switch 11 Brake pedal switch
5 Instrument panel
6 Brake fluid level sensor
D0007030

426
 Systems 8
electrical systems 84

4.19 HML TRANSMISSION (VERSION WITH MECHANICAL GOVERNOR)

1 2 3
0.009.7855.3 X73

5 8 9
OFF OFF
2 3 ON
6 7 ON
2 10

GND5

30b

30b
49

49
30
15

30
15
R

R
L

L
1 2 1 2 1 2 3 6 3 1 4 2 7 2 1 1 2 6 3 1 4 2 7 15 30/1 30 50

0.011.6955.4
H L M X9 X16 X15 X8 X32

X72 X6
+12 Vcc 12 1
GND 1 2
CONFIG 4 3
EV HI 11 4

Fmax
20A

40A
F6
SPIA M 2 5
EV LO 9 6
1 COM EV 3 7
LEVA LO 6 8
LEVA COM. 8
LEVA HI 7
10
5
X3 X38 X37
11 27 26 20 21 32 31
0.009.7627.3

+30
+50
MARCIA LENTA (L)

MARCIA MEDIA (M)

MARCIA VELOCE (H)

BLOCC. DIFF.

DOPPIA TRAZIONE

+12 VOLT
-VCC

GND4
M

+ -
10
BATTERY
11

1 HML control unit 10 Starter motor

2 Solenoid valve for High range control (HI) 11 Instrument panel
3 Solenoid valve for Low range control (LO)
4 HML control pushbutton
5 DF control switch
6 Differential lock control solenoid valve (DF)
7 4WD control solenoid valve (DT)
8 4WD control switch
9 Starter switch

D0007080

427
 8 Systems
84 electrical systems

4.20 ELECTRONIC LIFT (VERSION WITH MECHANICAL GOVERNOR)

13 14

VEL. DISCESA
MAX ALZATA

POSIZIONE

POSIZIONE
2 10
ISO 9141

SFORZO
+10 VCC

+12 VCC
EV DW
EV UP
GND
MIX

12 5 9 10 11 8 7 3 2 4 1 6 15 30/1 30 50
X71

0.011.6955.4
UP X32
2
12 3
1

Fmax
10A

40A
F5
2
DW
11 3
1

2 C
5
8
1
7 2
10 3
4
1
3
X7
4
2
I
5 3
8
1 2

9 7
3
2 1
4
1
3

3
P1
4.7 Khom

8 1 Khom
2
1 X42 X38 X37
3 1 2
H1

+30
+50
3 GND5
4.7 Khom

1 Khom

7 2
1
M

V + -
3 16 15
4.7 Khom

1 Khom
6 2
BATTERY
1

3
M1
4.7 Khom

1 Khom

5 2
1

3
S1
U
4 2

F 1

U 3
P2
3 2
S 1

1
EV DW
2 2

EV UP
1
1 2

0.011.6943.4

1 Lift UP solenoid valve 9 Rear lift control pushbutton

2 Lift lowering solenoid valve 10 Rear lift control pushbutton
3 Rear lift position sensor 11 Rear lift “down” control pushbutton
4 Lift draft sensor 12 Rear lift “Up” control pushbutton
5 Draft/wheelslip control potentiometer 13 Rear lift control unit
6 Lift lowering speed potentiometer 14 Starter switch
7 Maximum lift height potentiometer 15 Starter motor
8 Lift position adjustment potentiometer 16 Diagnostics connector

D0007140

428
 Systems 8
electrical systems 84

4.21 REAR AND FRONT PTOS (VERSION WITH MECHANICAL GOVERNOR)

2 3 5 6

PTO POST. SYNCRO

OFF OFF
1 ON
4 ON
2 10

PTO 1000 rpm

PTO 540 rpm

PTO POST.
+12 VOLT
PTO ECO
PTO ANT.
-VCC
GND4
30b

30b
GND5
30

30
15

15
49

49
R

R
L

L
1 2 7 2 1 4 3 6 31 16 25 30 29 28 17 32 1 2 3 6 1 4 2 7 15 30/1 30 50
0.009.7624.4

0.011.6955.4
X63 X35 X3 X17 X10 X32

Fmax
X1

20A

40A
F6
14

GND3

S E 1 5 X38 X37
4 3 2 1

+30
+50
M

10 9 8 7 + -
11
BATTERY

1 Front PTO solenoid valve

2 Front PTO control switch
3 Instrument panel
4 Rear PTO control solenoid valve (PTO)
5 Rear PTO control switch
6 Starter switch
7 Starter motor
8 540 PTO engagement sensor
9 1000 PTO engagement sensor
10 750 (ECO) PTO engagement sensor
11 PTO engagement sensor

D0007130

429
 8 Systems
84 electrical systems
4
1 2 3
2 10
4.22 STARTING AND PREHEATING (VERSION WITH ELECTRONIC GOVERNOR)

87a 87 86 85 30 30 86 85 87 87a 87a 87 86 85 30 15 30/1 30 50

0.011.6958.4
RL2 RL4 RL1 X32

10A

15A

40A

40A
F7

F6

F2

F1
X53
3 TEMP. IMPUT
25 -VCC
24 -VCC
44 +12 VOLT
45 +12 VOLT
68 PRES.GLOW PLUG
56 RELE' PRERISCALDO
5
65 ELECTROV.PRESENCE
58 PREIT.RELE' ELECT.
57 PRERISCALDO
43 TEMP. OUTPUT

4 TEMP. MOTORE

7 PRERISCALDO
32 +12 VOLT 6
14 CARICA BATTERIA
GND4 31 - VCC
X3

X31 X1 X38 X37

1 3 2 4 1 16 13 12 11 5 4
+30
+50

12 M

GND3 7
0.009.7624.4

+ -

BATTERY
X54 X58 X57 X65
D+ B+ W
+
t

11 -

10
8
9

1 Relay RL2 7 Starter motor

2 Relay RL4 8 Alternator
3 Relay RL1 9 Glowplug
4 Starter switch 10 Preheating control solenoid valve
5 Engine control unit 11 Start enable switch
6 Instrument panel

D0007550

430
 Systems 8
electrical systems 84

4.23 ELECTRICAL ENGINE CONTROL (VERSION WITH ELECTRONIC GOVERNOR)

10
6 9
3 4 5 7 8 2 10
fN

3 2 4 1 2 1 2 1 2 3 2 1 1 2 3 87a 87 86 85 30 15 30/1 30 50

0.011.6958.4
X50 X46 X47 X48 A X51 RL3 X32

X53
SPEED 11
(-VCC E. SCHERMO) 33
HAND GAS 6
+5 VCC 28
HOLD MEMORY 67
PEDAL SENSOR 5
ATTUATORE 47
ATTUATORE 46
2 PICK UP 10
+12 VOLT 44

10A

15A

40A

40A
15A

F1
F7

F6

F2
F8
+12 VOLT 45
- VCC 24
- VCC 25
RPM VENTOLA 12
RPM OUT 22
LED HOLD 61

MARCIA SEL. 1
GIRI MOTORE 2
SENS. VEL. TRASMISSIONE 3
1 DISPLAY 34
AZZERAMENTO 35
SELEZIONE 36

X3

X1 X52 X45 X44 X38 X37

28 16 29 1 2 7 5 7 5
+30
+50

GND4
M
0.009.7624.4

14 13 12 + -
11
BATTERY

X67
3 2 1
GND3 f

15

1 Instrument panel 10 Starter switch

2 Engine control unit 11 Starter motor
3 Transmission speed sensor 12 Engine governor display pushbutton
4 Throttle lever position sensor 13 Engine governor reset button
5 Memory pushbutton 14 Tyre selection pushbutton
6 Accelerator pedal position sensor 15 Rotation speed sensor
7 Actuator for cooling fan
8 Engine speed sensor (Only for version with air conditioning)
9 Relay RL3
D0007560

431
 8 Systems
84 electrical systems

4.24 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH ELECTRONIC GOVERNOR - PLATFORM)

9 1 Rear left light

8 11 2 Front left headlamp
6
7
OFF 3 Number plate light

IND. DIR. 2° RIMORCHIO

IND. DIR. 1° RIMORCHIO

ON
10 G

4 Rear right light

12

ILL. CRUSCOTTO
2 10

IND. DIREZIONE

ABBAGLIANTI
5 Front right headlamp

+12 VOLT

- VCC
6 Starter switch

+15

+30

49a

49a
0.011.6958.4

-31
49

C2
C3
R

49
L

C
15 30/1 30 50 87a 87 86 85 30 1 3 6 5 7 4 19 22 24 23 6 32 31 7 5 4 1 3 1 4 2 3 5 6 1 2
7 Relay RL3
X32 RL3 X33 X3 X26 X40 X22
8 Hazard warning lights switch
1 2

X21 9 Instrument panel

GND5 10 Trailer socket
X4
5 3 11 Hazard warning control unit
5 7 1 GND4
6 2
12 Rear worklight
X13 4
13 Lights selector switch
1 5
2 6 14 Horn
4 3
4
15 Front left lights
X14 16 Front right lights
1 17 Starter motor
3 2

X28
9

2 8
7
X27
6
4
1 5 X36
1 +
3
30
X29 5
9 FS
7 L
8 FD
13
F11
15A

40A

40A

10A

10A

10A

10A

10A

10A
15A

F10
20A

10A

F12

F13

F14

F14

57/58
F6

F2

F4
F3

F7
F1

2
56b
3
4 56a
H
6

X37 X1
X38 8 7 9 10 6
+30
+50

+ -
17
0.009.7624.4

BATTERY

X64 X62 X61

2 1 3 2 1 3 2 1
GND3

16 15 14

D0007570

432
 Systems 8
electrical systems 84

4.25LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH ELECTRONIC GOVERNOR - STANDARD CAB)

8
7 10
6

IND. DIREZIONE 2° RIM.

IND. DIREZIONE 1° RIM.
OFF
ON
9 G

ILL. CRUSCOTTO
IND. DIREZIONE
2 10

ABBAGLIANTI
+15

+30

49a

49a
0.010.5582.3 0.011.6958.4

-31
49

C2
C3

49
R
L

C
15 30/1 30 50 1 3 6 5 7 4 19 22 24 23 6 7 5 4 1 3 1 4 2 3 5 6
X32 X33 X3 X26 X40
5
5 GND5
7 X4
6 3
X13 1 GND4
2
9 4
8 5
7 6
X27 11 12
13 14 15 16
4
1
2 GND6
3 3 1 3 4 2 1 3 4 2 1 2 2 1 1 2 2 1
4 X85 X78 X121 X124 X122 X123
X14

2 1
2 F8
X28 10A
6 F7
4 10A
1 5
3 X87 X77
X29 X39 3 5
1 1 6
2 2 1
2
F11
10A

40A

40A

10A

10A

10A

10A

10A
F10
10A

15A
20A

F12

F13

F14
F7

F2
F9

F4
F3
F1

F X111 X103-30
50A

RL3 X38 X37 X1 X36 X103

30 85 86 87 87a 8 7 9 10 6 6 4 3 2 8 7 9 5 1 30 86 85 87
0.009.7852.3 0.009.7850.4 0.009.7851.4
+30

FD
0.009.7624.4
+50

FS
56a
56b
57/58
H

+
30
M

+ -
23 BATTERY
17
X64 X62 X61
2 1 3 2 1 3 2 1
22
GND6
18
21 20 19

1 Rear left light 10 Hazard warning control unit 19 Horn

2 Number plate light 11 Front worklights control switch 20 Front left lights
3 Rear right light 12 Rear worklights control switch 21 Front right lights
4 Front left sidelight and direction indicator 13 Front left worklight 22 Starter motor
5 Front right sidelight and direction indicator 14 Front right worklight 23 Relay RL3
6 Starter switch 15 Rear left worklight
7 Hazard warning lights switch 16 Rear right worklight
8 Instrument panel 17 Roof wiring power relay
9 Trailer socket 18 Lights selector switch

D0007590

433
 8 Systems
84 electrical systems

4.26 LIGHTS - STEERING COLUMN SWITCH UNIT (VERSION WITH ELECTRONIC GOVERNOR - HIGH-VISIBILITY CAB)

8
6 7 10

IND. DIREZIONE 2° RIM.

IND. DIREZIONE 1° RIM.
OFF
ON
9 G

ILL. CRUSCOTTO
IND. DIREZIONE
2 10

ABBAGLIANTI

49a
+15

+30

49a

-31
0.010.5582.3 0.011.6958.4

C2
C3
49

49
R

C
L
15 30/1 30 50 1 3 6 5 7 4 19 22 24 23 6 7 5 4 1 3 1 4 2 3 5 6
X32 X33 X3 X26 X40
5
5 GND5
7 X4
6 3
X13 1 GND4
2
9 4
8 5
7 6
X27
4
11 12
1
2
13 14 15 16
3 3
4
X14 GND7
7 2 3 1 8 7 2 3 1 8 1 2 1 2 1 2 2 1

2 1 X100 X99 X121 X124 X122 X123

2
X28
6 F8
4 10A
1 5 F7
3 10A

X29
X39 X91
2 2
F11
F10

F12

F13

F14

X95
F7

F2
F9

F4
F3
F1
10A

40A

40A

10A

10A

10A

10A

10A
10A

15A
20A

4
3
2
F X111 X103-30 1
50A

RL3 X38 X37 X1 X36 X103 X104

30 85 86 87 87a 8 7 9 10 6 6 4 3 2 8 7 9 5 1 30 86 85 87 1 2
0.011.3606.4 0.011.3595.3
0.009.7624.4

0.011.3761.3
+30
+50

GND7
FD

FS
56a
56b
57/58
H

+
30

M 40A

+ -
23 17
24 BATTERY
18
X64 X62 X61
2 1 3 2 1 3 2 1
GND6

19
22 21 20

7 Hazard warning lights switch 16 Rear right worklight

1 Rear left light 8 Instrument panel 17 Roof wiring power fuse (40 Amp)
2 Number plate light 9 Trailer socket 18 Roof wiring power relay
3 Rear right light 10 Hazard warning control unit 19 Lights selector switch
4 Sidelights and direction indicators 11 Front worklights control switch 20 Horn
direction indicator 12 Rear worklights control switch 21 Front left lights
5 Sidelights and direction indicators 13 Front left worklight 22 Front right lights
direction indicator 14 Front right worklight 23 Starter motor
6 Starter switch 15 Rear left worklight 24 Relay RL3

D0007690

434
 Systems 8
electrical systems 84

4.27 ACCESSORIES - DIAGNOSTICS (VERSION WITH ELECTRONIC GOVERNOR - PLATFORM)

4
5 6
2 10
7

+12 VOLT

+12 VOLT
ISO 9141

ISO 9141

-VCC

-VCC
GND5
27 29 24 25 44 45 15 30/1 30 50 2 1 1 2 1 2 3

0.011.6958.4
4 X53 X32 X12 X11 X2
3
2 1
2
7
0.011.6943.4 X30

ISO 9141 12 1
1 GND 4 2
+12 VCC 1 3

X71 X7

F15

40A

20A
15A

10A

10A

40A

20A

10A
F12
F1
F6

F7

F2

F3
F5
GND3 16

X1

0.009.7624.4

X36 X38 X37 RL3

6 4 3 2 8 7 9 5 1 87a 87 86 85 30
+30
+50
FD

FS
H

+
56a

56b

L
57/58

30

+ -
9
8
BATTERY

10
1 Rear lift control unit
2 Diagnostics connector
3 Engine control unit
4 Starter switch
5 Compressor for driver’s seat air suspension
6 Outlet socket (in cab)
7 Cigar lighter
8 Relay RL3
9 Starter motor
10 Lights selector switch

D0007580

435
 8 Systems
84 electrical systems

4.28 ACCESSORIES - DIAGNOSTICS (VERSION WITH ELECTRONIC GOVERNOR - STANDARD CAB)

2 1

0.009.7851.4
X127
3
4
5 6 8
7 2 1
2 10 X126
+12 VOLT
+12 VOLT
ISO 9141
ISO 9141
-VCC
-VCC

GND5
27 29 24 25 44 45 15 30/1 30 50 2 1 1 2 1 2 3 30 86 85 87 8 7 6 5 4
4
X53 X32 X12 X11 X2 X103 X77
3
2 1
2

0.011.6943.4 7
X30
X103-30
ISO 914112 1
GND 4 2
1 +12 VCC 1 3 X39
X71 X7 2 2
3

X87
F15

10A

10A
40A

20A

10A
15A

10A

10A

40A

F1
F12
F1

20A

10A
F6

F7

F2

F3
F5

F6
F9
GND3 16 X111
X1

0.009.7850.4
50A
F
0.009.7624.4

X36 X38 RL3 X83 X74 X81

X37 87 86 85 30 2 4 3 1
6 4 3 2 8 7 9 5 1 87a
4 3 2 1 1 2
0.011.6958.4 0.009.7852.3
+30
+50

GND6
FD

FS
56a
56b
H

57/58

+
L

30

- 15
M 30 58

+ -
14 11 10
BATTERY
13 12

15

1 Rear lift control unit 9 Flashing light

2 Diagnostics connector 10 Rotating beacon control switch
3 Engine control unit 11 Interior roof light
4 Starter switch 12 Clock
5 Compressor for driver’s seat air suspension 13 Relay RL3
6 Outlet socket (in cab) 14 Starter motor
7 Cigar lighter 15 Lights selector switch
8 Roof wiring power relay

D0007670

436
 Systems 8
electrical systems 84

4.29 ACCESSORIES - DIAGNOSTICS (VERSION WITH ELECTRONIC GOVERNOR - HIGH-VISIBILITY CAB)

3
4
5 6 9
7 8
2 10

+12 VOLT
+12 VOLT
ISO 9141
ISO 9141
-VCC
-VCC
GND5 GND7
27 29 24 25 44 45 15 30/1 30 50 2 1 1 2 1 2 3 2 1 7 2 3 1 8

0.011.3606.4
4
X53 X32 X12 X11 X2 X74 X96
3
2 1
2

0.011.6943.4 7
X30
ISO 9141 12 1

1 GND 4 2 X39 X91

+12 VCC 1 3 2 2
X71 X7 3 X104
2

40A
X103-30 1 10
F15

40A

20A

10A
15A

10A

10A

40A

F12
F1

20A

10A
F6

F7

F2

F3
F5

F9

10A

10A
GND3

F2

F1
F6

5A
16
X1 87
85
X111 86
11
0.009.7624.4 30

50A
F
X103

X36 X38 RL3 X101

X37 87 86 85 30 4 2 3 1
6 4 3 2 8 7 9 5 1 87a

0.011.6958.4 0.011.3761.3
+30
+50
FD

FS
56a
56b
H

57/58

+
L

30

M GND6

0.011.3596.3
+ -
15 1 2 X126
BATTERY
14

X83 X127
1 3 2 4 1 2
16 - 15
30 58

12
13

1 Rear lift control unit 10 Roof wiring power fuse (40 Amp)
2 Diagnostics connector 11 Roof wiring power relay
3 Engine control unit 12 Flashing light
4 Starter switch 13 Clock
5 Compressor for driver’s seat air suspension 14 Relay RL3
6 Outlet socket (in cab) 15 Starter motor
7 Cigar lighter 16 Lights selector switch
8 Interior roof light
9 Rotating beacon control switch

D0007680

437
 8 Systems
84 electrical systems

4.30 WIPERS (VERSION WITH ELECTRONIC GOVERNOR - STANDARD CAB)

4 5 6
7

0.009.7851.4 5 6 7 8 4 3 2 1 5 6 7 8 4 3 2 1 I T 31 15 53S 53M 2 1

0.009.7850.4
X79 X84 X82 X80
X125 X77
1 3
3 M
2 7
6
5
8

0.009.7854.3
X75
1 3
M
2 2 0.010.4516.3
2 X129 1
X88 X130
6 6
3 3
2 2 8
1 2
X135 1 1
7.5A

7.5A
F6

F5

1 GND6
X87
X103-30 X103
2 30 86 85 87
0.009.7852.3

12 X111

2 10 9
50A
F

15 30/1 30 50 2

X32 X39
0.011.6958.4

40A

40A

10A
10A

F2

F1

F9
F7

GND5
RL3 X38 X37
30 85 86 87 87a
+30
+50

+ -
10
11 BATTERY

1 Rear screen washer pump 8 Windscreen wiper motor

2 Front windscreen washer pump 9 Roof wiring power relay
3 Rear screen wiper motor 10 Starter motor
4 Rear wiper control switch 11 Relay RL3
5 Front windscreen wiper control switch 12 Starter switch
6 Intermittent wipe timer for windscreen wiper
7 Windscreen washer pump control switch

D0007600

438
 Systems 8
electrical systems 84

4.31 WIPERS (VERSION WITH ELECTRONIC GOVERNOR - HIGH-VISIBILITY ROOF)

6
4 5
7

0.011.3596.3 GND6
1 3 2 6 5 1 3 2 6 5 2 3
I T 31 15 53S 53M

0.011.3606.4
X97 X98 X82 X80
2 X101
3 M
1 2
X125

1 3
M
2
2 2
1
0.011.3597.3
X129
X75
4 4
7.5A

7.5A
F6

F5
0.011.3743.3

1 1
3 3 8
2 2
X92 X130

X135
1 2 X91 X103-30 X103 X104
2 30 86 85 87 1 2
1 M
0.009.7852.3

GND7 40A
X111

2 10 9
50A

13 10
F

15 30/1 30 50 2
X32 X39
0.011.6958.4

40A

40A

10A
10A

F2

F1

F9
F7

GND5
RL3 X38 X37
30 85 86 87 87a
+30
+50

+ -
11
12 BATTERY

1 Rear screen washer pump 10 Roof wiring power relay

2 Front windscreen washer pump 11 Starter motor
3 Rear screen wiper motor 12 Relay RL3
4 Rear wiper control switch 13 Starter switch
5 Front windscreen wiper control switch
6 Intermittent wipe timer for windscreen wiper
7 Windscreen washer pump control switch
8 Windscreen wiper motor
9 Roof wiring power fuse FU??? (40 Amp)

D0007610

439
 8 Systems
84 electrical systems

4.32 FRONT INSTRUMENT PANEL (VERSION WITH ELECTRONIC GOVERNOR)

1 2
3

BASSA PRESS. OLIO MOT.

RISERVA CARBURANTE
LIVELLO CARBURANTE
4
PRESS. ENGINE OIL

INTS. FILTRO ARIA

OLIO IDRAULICO
TEMP. MOTORE

2 10
TEMP.OUTPUT
BELT ALLARM
TEMP.INPUT

+ 12 VOLT
+ 12 VOLT

+12 VOLT
- VCC
- VCC

- VCC
3 66 59 24 25 44 45 43 4 32 15 9 8 31 12 5 15 30/1 30 50 87a 87 86 85 30

0.011.6958.4
X53 X3 X32 RL3

10A

10A
15A

15A

40A

F7

F7
F6

F8

F1
0.009.7624.4

X1
2
3
1
16
X18

X55 X60 X54 X19 X20 X23 X37

1 2 2 4 3 1
+30
+50

GND3 t
GND5
M
P

+ -
11 10 9 8 7 6 5
BATTERY

1 Engine control unit

2 Instrument panel
3 Starter switch
4 Relay RL3
5 Starter motor
6 Fuel level sensor
7 Hydraulic oil low pressure switch
8 Hydraulic oil filter clogging pressure switch
9 Coolant temperature sensor
10 Air cleaner clogged sensor
11 Engine oil pressure switch

D0007620

440
 Systems 8
electrical systems 84

4.33 HEATER (VERSION WITH ELECTRONIC GOVERNOR - STANDARD CAB)

3 4

1 2 3 1 2
010.2123.2
X142 X138 X137
87
85
2 86 X139
C
30 1
B
2
11 3 H 3
M 2 0
5
3 4 1
L
10 5
6
12 1
8 2
1 9 3 6
4 4
5 X140
7
2
8 2
1 1
M 7
X136 X141
3 1 2 4 1 2 2 1 0.009.7850.4
X107 X106 X89
20A
F4

2 1
X103-30 X103
30
X108 X87 86
2 85 9
87

GND6
0.009.7852.3

X111
10
01 2
50A
F

B- B+ X109 X39
1 2 2 50 30 30/1 15
B- B+ DF D+
+
X32
G

-
GND5
0.011.6958.4
10A

40A

40A

10A
F1

F2
F9

F7

13

X37 X38 RL3

87a 87 86 85 30
+30

+50

- +
12
11
BATTERY

1 Heater control unit 8 Heater resistance

2 Control relay for alternator excitation 9 Roof wiring power relay
3 Heater control potentiometer 10 Starter switch
4 Heater air temperature sensor 11 Relay RL3
5 Fan speed selector switch 12 Starter motor
6 Resistor for heater fan 13 Heating alternator
7 Heater fan

D0007630

441
 8 Systems
84 electrical systems

4.34 HEATER (VERSION WITH ELECTRONIC GOVERNOR - HIGH-VISIBILITY ROOF)

010.2558.1 1 Control relay for 3rd speed
for heater fans
X153 X152 X150 X151
2 2 2 2 2 Control relay for alternator excitation
5 M
1 1 1 1
M
6
3 Fan speed selector switch
X149 X148
1 1 4 Resistor for right heater fan
2 2
4 3 3 7 5 Right heater fan
4 4
6 Left heater fan
X154 X146
I
1 87b 7 Resistor for left heater fan
II
2 87
3 III
3 86
8 8 Control relay for maximum fan speed
IV
4 85
C
5 30 9 Heater control potentiometer
X145 10 Heater air temperature sensor
1
2 11 Heater control unit
X147
3
4
9 12 Heater resistance
30 5
85 13 Roof wiring power relay
2 86 X137
87 1 14 Starter switch
87b 2 10
15 Relay RL3
30 8
85 9 16 Starter motor
1 86 12
17 Heating alternator
87 6
87b 10
3
X157 4 11
5
1
2
7
11

12 X136
3 1 2 4 1 2 2 1
0.011.3606.4

X113 X106 X93

40A
F

2 1
X103-30 X103
30
X108 86
X91 2 85 13
87
0.011.3761.3

X111 GND6
14

01 2
50A
F

B- B+ X109 X39
1 2 2 50 30 30/1 15
B-+ B+ DF D+
X32
G GND5
-
0.011.6958.4
10A

40A

40A

10A
F7
F1

F2
F9

17

X37 X38 RL3

87a 87 86 85 30
+30

+50

M
- +

BATTERY 16
15

D0007710

442
 Systems 8
electrical systems 84

4.35 HEATING AND AIR CONDITIONING (VERSION WITH ELECTRONIC GOVERNOR - STANDARD CAB)

1 Heater control unit

5
3 4 2 Control relay for alternator excitation
3 Heater control potentiometer
0.010.2130.1 4 Heater air temperature sensor
1 2 3 1 2 30 85 86 87
X138 X137 X143 5 Control relay for air conditioning
X144
X142 1 6 Demister thermostat
87 2 6
85 7 Fan speed selector switch
2 86 X139
30 1
C 8 Resistor for heater fan
B
2
11 H 3 9 Heater fan
3
3
4 M 2 0 7
10 5
L
1
10 Heater resistance
6
12 1
11 Roof wiring power relay
1 8 2 12 Control relay for air conditioning fan
9 3 8
4 4 13 Air conditioning fan
5
X140
7
10 14 Air conditioning pressure switch
2 2
1 1
M 9 15 Relay RL3
X136 X141
X141 16 Starter motor
3 1 2 4 1 2 1 2 3 4 2 1
0.009.7850.4

X89 17 Starter switch

X107 X106
18 Air conditioning compressor
30A

20A
F3

F4

19 Heating alternator
12
13 14
X103-30 X103
2 1

M
30
X108 X87 86
2 85 11 30 86 85 87 2 1 3 2 1 1
1 87 X115 X119 X118 X120
3
GND6

0.009.7853.3
0.009.7852.3

X111

4
2
F
50A

3
1
B- B+ X109 X39 X76
1 2 1 2
B-+ B+ DF D+

GND5
G

-
0.011.6958.4
10A

40A

40A

10A
F1

F2
F9

F7

19

X1 X32 X37 X38 RL3

15 15 30/1 30 50 87a 87 86 85 30
+30

+50
0.009.7624.4

210

16
15
X59
17 + -

BATTERY

18

D0007720

443
 8 Systems
84 electrical systems

4.36 HEATING AND AIR CONDITIONING (VERSION WITH ELECTRONIC GOVERNOR - HIGH-VISIBILITY CAB)
8 1 Control relay for 3rd heater fan speed
7
1 2 1 2
0.010.2562.1 2 Control relay for alternator excitation
X153 X152 X150 X151 2 3 Control relay for 1st fan speed and air conditioning on
2 2 2
6 M
1 1 1 1
M
9 4 Fan speed selector switch
X149 X148 5 Resistor for right heater fan
1 1

5 2 2
10 6 Right heater fan
3 3
4 4 7 Air conditioning control switch
I X154 X146 8 Air conditioning thermostat
1 87b
II
2 87 9 Left heater fan
4 III

IV
3
4
86
85
11 10 Resistor for left heater fan
C
5 30

X156 11 Control relay for maximum fan speed

30
X145 12 Heater control potentiometer
85 1
3 86 2
87 3 12 13 Heater air temperature sensor
X147 4
30 5 14 Heater control unit
85
2 86
X137 15 Heater resistance
87
87b
1
2
13 16 Roof wiring power relay
30 8 17 Air conditioning fan
85 9
1 86 12 18 Control relay for air conditioning fan
87 6
87b 10 19 Control relay for supplementary air conditioning fan
X157 3
14
4 20 Air conditioning pressure switch
5
1 21 Supplementary air conditioning fan
2
7 22 Relay RL3
11
15 X136 23 Starter motor
3 1 2 4 1 2 3 2 1 2 1 24 Starter switch
0.011.3606.4

X113 X106 X94 X93 25 Air conditioning compressor

26 Heating alternator
20
18 19
7.5A

40A
F4
304
F3

17 21
X108 X103-30
2 1 X103
M

M
30
86
X91 2 85 16 2 1 30 86 85 87 87a 30 86 85 87 87a 1 2 3 4 5 6 1 2
1 87 X114
X117a X115 X116 X117b
3

X111 GND6
X102
0.011.3761.3

0.011.3610.3
1
2
4
50A
F

5
7
8
6
B- B+ X109 X39 3
1 2 1 2
B-+ B+ DF D+
GND5
0.011.6958.4

-
10A

40A

40A

10A
F1

F2
F9

F7

26
X1 X32 X37 X38 RL3
15 15 30/1 30 50 87a 87 86 85 30
0.009.7624.4

+30

+50

210
23
X59 + - 22
24 BATTERY
25
D0007730

444
 Systems 8
electrical systems 84

4.37 BRAKING SYSTEM - TRAILER BRAKING (VERSION WITH ELECTRONIC GOVERNOR)

6
5
4

PRESS. RIMORCHIO
3

FRENO A MANO
01 2

+12 VOLT

- VCC
0.011.6958.4 32 10 13 31
2 1 30 85 86 87 87a 50 30 30/1 15
X24 RL3 X32 X3
GND4
1
P
GND5 2 7
3
X25
1
X5
3
2 2 5
4 8
6
10A

10A

40A

40A

15A
X29
F7

F9

F2

F1

F6
1
(-VCC E. SCHERMO) 33 3
+12 VOLT 45 2 9
+12 VOLT 44 4
1 HAND BRAKE 64 X14
-VCC 24
-VCC 25 6
3 10
X53
X26

X1 X38 X37
16 20
+30
+50

X1
M
0.009.7624.4

+ -
12
BATTERY
0.009.7624.4

GND3
X66
1 2
GND3

11

1 Engine control unit 8 Rear left light

2 Brake pedal switch 9 Rear right light
3 Handbrake switch 10 Trailer socket
4 Relay RL3 11 Brake fluid level sensor
5 Starter switch 12 Starter motor
6 Instrument panel
7 Trailer braking
low pressure switch

D0007640

445
 8 Systems
84 electrical systems

4.38 HML TRANSMISSION (VERSION WITH ELECTRONIC GOVERNOR)

1 2 3
0.009.7855.3

X73

6 8 9
7 OFF OFF
4 5 2 10
ON ON

30b

30b
49

49
30
15

30
15
R

R
L

L
1 2 3 1 2 1 2 15 30/1 30 50 30 85 86 87 87a 6 3 1 4 2 7 6 3 1 4 2 7

M H L X32 RL3 X9 X8
2
1 10
X53 X15
DUAL POWER SEL. 37
LEVA LO 63 2
(-VCC E. SCHERMO) 33 1
11
LEVA HI 62 X16
EV H 53
40A

10A

15A
F7

F8

+12 COM EV 52
15A

40A

F2
F6

F1

2 EV L 54
+12 VOLT 44
+12 VOLT 45
- VCC 24
- VCC 25
SPIA M 60

X3
MARCIA VELOCE (H) 26
MARCIA LENTA (L) 11

0.011.6958.4
+12 VOLT 32
1 BLOCC. DIFF. 20
DOPPIA TRAZIONE 21
MARCIA MEDIA (M) 27
- VCC 31

X1 X38 X37
16
+30
+50

GND4 GND5
M
0.009.7624.4

+ -
12
BATTERY

GND3

1 Instrument panel 11 Differential lock control solenoid valve

2 Engine control unit (DF)
3 HML control pushbutton 12 Starter motor
4 HI gear control solenoid valve
5 LO gear control solenoid valve
6 Starter switch
7 Relay RL3
8 Diff lock control switch
9 4WD control switch
10 4WD control solenoid valve (DT)

D0007650

446
 Systems 8
electrical systems 84

4.39 ELECTRONIC LIFT (VERSION WITH MECHANICAL GOVERNOR)

14 1 Lift UP solenoid valve

2 Lift lowering solenoid valve
13 15
3 Rear lift position sensor

PTO STOP SOLLEVAT.

2 10 4 Lift draft sensor
VEL. DISCESA
MAX ALZATA

POSIZIONE

POSIZIONE
5 Draft/wheelslip control potentiometer

+12 VOLT
+12 VOLT
ISO 9141

SFORZO
+10 VCC

+12 VCC
EV DW
EV UP

-VCC
-VCC
GND
MIX

12 5 9 10 11 8 7 3 2 4 1 6 4 24 25 44 45 15 30/1 30 50
6 Lift lowering speed potentiometer

0.011.6958.4
UP X71 X53 X32 7 Maximum lift height potentiometer
2

12 3 8 Lift position adjustment potentiometer

1
9 Rear lift control pushbutton

40A
10A

15A

F1
F7

F6
DW
2
10 ear lift control pushbutton
11 3
1
11 ear lift “down” control pushbutton
2
C
8
5 12 ear lift “Up” control pushbutton
1

10 7 2 13 Rear lift control unit

3
4
1
3 X7 14 Engine control unit
2
I 4
15 Starter switch
5 3
8
1 2
16 Starter motor
9 7 2 1
3
1
4 17 Diagnostics connector
3

P1
3
4.7 Khom

1 Khom

8 2
1 X30 X1 X38 X37
7 1 2 16
H1

+30
+50
3 GND5
4.7 Khom

1 Khom
7 2 M
1
0.009.7624.4

V + -
3 16
4.7 Khom

1 Khom
6 2
17 BATTERY
1

M1
3
4.7 Khom

1 Khom

5 2
1

S1 GND3
U 3
4 2
F 1

P2
U 3
3 2
S 1

EV DW
1
2 2

EV UP
1
1 2

0.011.6943.4

D0007660

447
 8 Systems
84 electrical systems

4.40 REAR AND FRONT PTO (VERSION WITH ELECTRONIC GOVERNOR)

4 5 8
7
3
OFF
ON
OFF
ON 6 2 10

30b
S1
31

30
15
C

R
L

49
S

1 2 6 7 5 3 6 3 1 4 2 7 1 2 30 85 86 87 87a 15 30/1 30 50

0.011.6958.4
X17 X10 X112 X49 R3 X32

X53
+12 COM EV 52
EV PTO 55

15A

15A

40A

40A
10A
F8

F6

F2

F1
F7
(-VCC E. SCHERMO) 33
PTO POSTERIORE 35
PTO AUTO 9
2 - VCC 24
- VCC 25
+12 VOLT 44
+12 VOLT 45
SELEZ.PTO 36

PTO POST. 17
PTO POST. SYNCRO 25
PTO ANT. 16
PTO ECO 30
1 PTO 1000 rpm 29
PTO 540 rpm 28
+12 VOLT 32
- VCC 31

X3

X1 5 1 E X35 S X38 X37

16 14 6 3 4 1 2 7 4 2 3 1
+30

GND5
+50

GND4
30b
49

15
30
R

M
0.009.7624.4

14 13 12 + -
ON
OFF
10 9
11 BATTERY

X63
1 2
GND3

15

1 Instrument panel 13 750 (ECO) PTO engagement sensor

2 Engine control unit 14 1000 PTO engagement sensor
3 Rear PTO control solenoid valve (PTO) 15 540 PTO engagement sensor
4 Rear PTO control pushbutton
5 PTO AUTO switch
6 Rear PTO control pushbutton
(On fender)
7 Relay RL3
8 Starter switch
9 Starter motor
10 PTO engagement sensor
11 Front PTO control switch

D0007700

448
 Systems 8
electrical system 84

ENGINE WIRING (1/2)

X61
X58

X60

X57 X59

X37
X62
2

1 3
X55
1

X54

TO 0.011.6955.4

2
0.011.6958.4 X63

1
X1
AMP

X67

3 1

X64

X66 X65
GND3

X1 To central wiring X58 Preheating control solenoid valve X64 Front right lights
X37 Starter motor X59 Air conditioning compressor X65 Alternator
X54 Temperature sensor X60 Air cleaner clogged sensor X66 Brake fluid level sensor
engine oil X61 Horn X67 Speed sensor for
X55 Engine oil pressure switch X62 Front left lights Cooling fan
X57 Glowplug X63 Front PTO solenoid valve
D0006600
0.009.7624.4/50

449
 8 Systems
84 electrical system

ENGINE WIRING (2/2)

X54
X37
X57 X58 X59
X55

AMP
R1
1

N 16

VN 1.5
N1

BN 1
RN 1.5
RN 1.5
M1
B1
X60

N1
N1

Z1
X61
X1
R1
TEMPERATURE TEMPERAT. 1
M1
ENGINE OIL PRESS. P. OLIO MOT. 2
N1

1
B1
AIR FILTER FILTRO ARIA 3
HN 1

2
BR 1
RPM INDICATOR W CONTAGIRI 4 V1

3
L1
X62
GENERATOR GENERATORE 5
Z1
HORN AVV. ACUSTICO 6

H1
DIPPED HEAD LIGHTS ANABBAGL. 7 N1
X64

1
HN 1
DIPPED HEAD LIGHTS ANABBAGL. 8 H1

2
V1 V1

3
FULL BEAM HEAD LIGHTS ABBAGLIANTI 9

V1
FULL BEAM HEAD LIGHTS ABBAGLIANTI 10
RN 1.5
PLUG CANDELATTA 11
RN 1.5
PLUG CANDELATTA 12
BN 1
ELECKTROVALVE ELETTROVALVOLA 13 N1
MN 1 N1
FRONT PTO PTO ANT. 14
N1
VN 1.5
COMPRESSOR COMPRESS. 15 N1
GND3
N 1.5 N 1.5
GND GND 16
N1
ZN 1
BRAKES OIL OLIO FRENI 20 N1
HB 1
RPM FAN RPM VENT. 28
MB 1
+12 VOLT +12 VOLT 29

MB 1
N1
HB 1
L1

BR 1
N1
ZN 1

N 16

N1

MN 1
1 2 3
1 2
TABELLA COLORI / COLOURS TABLE
M Marrone/Brown C Arancio/Orange

AMP
AMP
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White

X66 X67 N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow
X65 X63
R Rosso/Red H Grigio/Gray

D0006610
0.009.7624.4/50

450
 Systems 8
electrical system 84

POSITION OF ENGINE WIRING CONNECTORS

1
X1

F0026910

2
X66

F0026920

3
X57

X58

F0026930

451
 8 Systems
84 electrical system

4 X60

F0026940

5
X61

F0026950

6 X62

X64

F0026960

452
 Systems 8
electrical system 84

7
X67

X63

X67: conector
for engine cooling
fan speed with air
conditioning
system F0026970

8
GND3

F0026980

9
X65

F0027020

453
 8 Systems
84 electrical system

10
X54

F0026990

11
X55

F0027000

12
X37

F0027010

454
 Systems 8
electrical system 84

ENGINE WIRING
1
Platform version 2

13 3
4
X59

6
F0027030

12
7

8 X65 10 11

Cab version 1
2

3
X67
4

13

7
12
8 9 10 11
0.009.7624.4/50

455
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

CENTRAL WIRING (VERSION WITH MECHANICAL GOVERNOR) (1/2)

1 1000 rpm PTO engagement sensor TO 0.011.6943.4 GND5 X8 X9 X10

X11
X2 X3 X7
5 540 PTO engagement sensor X43
E 750 PTO (ECO) engagement sensor TO 0.009.7624.4
4 3 2 1
X1
S PTO engagement sensor
X1 To engine wiring
X2 Cigar lighter
X3 Analogue instrument panel
X4 Connector (Platform version) X12
X41
To front light wiring (Version with cab) Z

X5 Brake pedal switch X13

X6 To HML wiring
X7 To electronic lift wiring X40 X42 X5
X8 Four-wheel drive control switch X15 X14
C

X9 Diff lock control switch 3 2 1

X10 PTO control switch

X16
X11 Outlet socket (in cab)
X4 TO 0.009.7627.3
X12 Compressor for driver’s seat air suspension
X13 Front right headlamp X6
GND4 X17
X19
X14 Rear right light
X18
X15 Four-wheel drive control solenoid valve (4WD) TO 0.009.7852.3
0.011.3761.3

1
1
X16 Differential lock control solenoid valve (DF) 2 1 X20
X39 X21 X21
X17 Rear PTO control solenoid valve (PTO)
X18 Connector X22
X19 Pressure switch for hydraulic oil filter clogging
sensor
X20 Hydraulic oil low pressure switch

S
X21 Connector
X22 Rear worklight (platform version)
X23 Fuel level sensor X32
X24 Handbrake switch

E
5

1
1 2 3 4

X25 Trailer braking low pressure switch

X26 Trailer socket X24
30 A

20 A

15 A

20 A

10 A

20 A

10 A

10 A

10 A

10 A

10 A

10 A

X27 Front left headlamp X23

ELECT.2
SERVIZI

STOP

X28 Number plate light X36

15 A
5 1 E
X29 Rear left light RL1 RL2 S
X31 Start enable switch
X32 Starter switch FM1
X33 Hazard warning lights switch X38 X37 TO 0.009.3938.3
X31
X34 Rear worklights switch X25
(Not utilised)
X35 Front PTO control switch X26
S1 N Q
X36 Lights selector switch
X37 Starter motor (+12V) X35 X34 X33
X38 Starter motor (Start)
X29 X28 X27
X39 To cab wiring
X40 Hazard warning lights control unit

D0006690
0.011.6955.4/10

457
 8 Systems
84 electrical system

CENTRAL WIRING (VERSION WITH MECHANICAL GOVERNOR) (2/2)

AN1
X18 X19

1
AN1 AN1

1
AN1
X20

1
H1 H1

AR0.5

N1 Z0.5
1 2 3
X1 X6
X40

BR1
X3

M1
ZB1

B1

C1
R1
S1
V1
R1 1 29 MB1 8 3
4 5 6 M1 2 28 HB1 7

HR1

VR1
MB1
GR1
B1 3 27 BG1 9 8 7 6 5 4 3 2 1
X43
B1.5

RN0.5

SG1.5

BR1 4 26 HV1 10 19 GN1 MB1 6

MV1 MB1
N1 10 1 MB1
L1 5
6
25 ZN1 11 20 HR1
7 7 7
*ZN1 5 2 N1

HV1
Z1 24 HN1 12 21 AR1 1 1 1
12 2 H1 7 23 CN1 13 22 RN0,5 6 6 6 ZV1 4 1 MB1
13 3 S1 H1 8 22 L1 14 23 AR0,5

HR1
14 4 V1 9 21 AN1 15 24 Z0,5 2 5 2 5 2 5

GR1
5 V1 10 20 MN1 16 25 HG1
15
16
6
7 RB0.5
RN1,5 11 19 GR1 17
18
26
27
ZB1
ZV1
X10 3 4
X9 3 4 3 4
X8

MB1
MB1
MB1
MB1
16 8
17 9
12 13 14 15 17 18 AR1
RN1.5 AR1

HR1
36 35 34 33 32 31 30 29 28

GR1
MN1
NH1

MB1

AG1
VB1
VN1

N1

N1

N1
VN1.5

N1
MB1
BR1 BR1 MB1
MB1
MB1

MB1.5
X41

MB1

MB1
MB1

RV1
MB1

HN1
BG1 MB1

AG1
VB1

VN1
N1
C1
5

HB1 N1
6

H1 L1 1 2 1 2 1 2
7

L1
BG1 M1 N1 2
RN1.5

RN1.5

X24
8

BG1
4

M1 H1 1

X23 E 1 5
X17 X16 X15
87 87

RN1
N1

N1

RB0.5 85 86 MB1
BN1.5
X33 A1 GN1
1

30 1 7
A1 3 X14

GV1.5
GV1.5
M2.5 6 N1

N1
HG1
4
RL1

AN1
2
X34

MB1
X35

N1

N1

N1
N1
MB1

GND4 1 7 1 7 G1 5
MB1

3 4 6 6

B1.5

GV1.5
X13

MN1
MB1 2 A1

M1
SG1.5 2
VB1.5

5 6
5

GV1.5
,
M1 N1
2 1 7
MB1 3 4 3 4
X36 S
MB1.5

A1
MN1
H1.5
X11 X12

M1
3 9 AN1.5 X9
MN1
2 3 M1 M1
G1.5 2 8 A1.5 A1.5

1
A1.5 X22
A1.5
R1.5 1 B1.5

HN1
7

2
N1 N1
R1.5 5
4
6 Z1
AN1.5
A1.5
VN1.5
R6 GN1
X37 GN1.5 N1
1
X28
2
G1.5
GV1.5
GV1.5
VB1.5

MB1.5

MB1.5

RN1
GN1.5
R1.5

R1.5
M2.5

M0.5
M1.5

BN1.5

3
LB1.5

G1
R4

MN1.5
H1

H1

VN1.5

V1.5
GN1

RL2
4

87 87
AN1 5 X29
N1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 6
30A

20A

15A

20A

10A

20A

10A

10A

10A

10A

10A

10A

10A

86 85 MV1
H2.5 GN1

M1
R6 7
FM1
40A

H1.5

AR1.5
VN1.5

AN1
3

X27
G1
GN1.5

RN1.5 8
AR4

N1
X38 M1 RL2 9

N1.5
L4

L4

M
4

N1

N1
CN1

N1

N1
N1
LB1.5
N1

MV1

MV1
15 AR4
M 1 2
L4 30/1

AN1

RN1
19

17
X5 X25 GND5
GN1.5

50 M4 2 1
LB1

L4 30 N1 3

A1 4
X26
N 1.5
1 2 7 5

MN 1.5 X2 GN1

G1
X32 AN 1.5
N1 G1
X39
N1
X4 N1
1
4
1

A 1.5 AGGANCIARE A1
2
5

5
2

6
7
7

G1 G1
3
8
3

GN 1 AN 1
GN 1
N1 TABELLA COLORI / COLOURS TABLE
M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
HG 0.5
3

Z Viola/Violet B Bianco/White
N1
X42 N Nero/Black L Blu/Dark Blue
2

M 0.5 S Rosa/Pink G Giallo/Yellow

1

R Rosso/Red H Grigio/Gray
4

M 1.5
3

N1 X7
2

HG 0.5
1
30 A

20 A

15 A

20 A

20 A

10 A

10 A

10 A

10 A

10 A

10 A
10
A

40 A 50
SERVIZI

ELECT.2

STOP

D0006700
0.011.6955.4/10

458
 Systems 8
electrical system 84

FRONT LIGHT WIRING (VERSION WITH CAB)

X4
TO 0.011.6955.4

X13 X27

X4 To central wiring
X13 Front right sidelight and direction indicator
X27 Front left sidelight and direction indicator

D0006720
0.010.5582.3

459
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

CONNECTOR POSITIONS

1 X1
GND4

F0027560

2 X32

X2

F0027630

3 X41

F0027640

461
 8 Systems
84 electrical system

4 X13-X27

F0027590

5 X43

F0027570

6 X3

F0027620

462
 Systems 8
electrical system 84

X4

F0027580

8 X33
X35

X34

X6

F0027660

9 X8

X10

X9

F0027690

463
 8 Systems
84 electrical system

10 GND5

X7

F0027800

11
X11

X12

F0027700

12

X28

F0027730

464
 Systems 8
electrical system 84

13

X14-X29

F0027720

14 X26

F0027740

15
X25

F0027770

465
 8 Systems
84 electrical system

16 5

F0027760

17
X23

F0027780

18 X24

F0027710

466
 Systems 8
electrical system 84

19
X19

F0027810

20

X20

F0027750

21 X17

X16

X18

X15

F0027790

467
 8 Systems
84 electrical system

22

X42

F0027650

23 X39

F0027550

24

X38

X37

F0027820

468
 Systems 8
electrical system 84

25 X40

F0027610

26

X36

F0027600

27 X5

F0027680

469
 8 Systems
84 electrical system

28

X31

F0027670

29
X21

F0028540

470
 Systems 8
electrical system 84

CENTRAL WIRING (VERSION WITH MECHANICAL GOVERNOR)

CAB
5 6 7 8 9 10 11 12 13
30 4

RL1 RL2

14
3 15

2
1 16
FM1
25
F0028700

27

26
17
30
28 24 23 22 21 20 19 18 17

4 X22 4
Platform 13
13

29

0.011.6955.4/10
0.010.5582.3
471
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

CENTRAL WIRING (VERSION WITH ELECTRONIC GOVERNOR) (1/2)

1 1000 rpm PTO engagement sensor
5 540 PTO engagement sensor
A Actuator
X3 GND5 X8 X9 X10 X47 X11 X12
E 750 PTO (ECO) engagement sensor X2
X7
H Solenoid valve for High range (HI) control V1
TO 0.011.6943.4 X46 2 1

L Solenoid valve for Low range (LO) control X1

M To HML wiring TO 0.009.7624.4 X48
4 3 2 1
S PTO engagement sensor X53
X1 To front wiring
X2 Cigar lighter
X3 Digital instrument panel
X4 Connector (Platform version)
To front light wiring (Version with cab) X13
X5 Brake pedal switch P1 X44
X7 To electronic lift wiring
X8 Four-wheel drive control switch X40

M
X9 Diff lock control switch C X15 X14
X10 PTO control pushbutton P2
X45
X11 Outlet socket (in cab)
X12 Compressor for driver’s seat air suspension 1 2 3 X16
X4 X5 L H
X13 Front right headlamp

AMP

AMP
1 2 3

X14 Rear right light M

X39 GND4 X17
X15 Four-wheel drive control solenoid valve (4WD) X19

1
X49
X16 Differential lock control solenoid valve (DF) TO 0.009.7852.3 X18
0.011.3761.3
X17 Rear PTO control solenoid valve (PTO)

1
1
2 1
X20

1
H
L
X18 Connector
X19 Pressure switch for hydraulic oil filter clogging sensor X22
X21 X21
X20 Hydraulic oil low pressure switch
X21 Connector
X52
X22 Rear worklight (platform version)
X23 Fuel level sensor A

S
X24 Handbrake switch
X25 Trailer braking low pressure switch
X26 Trailer socket X32
X27 Front left headlamp GUAINA MONOBACK

E
5
X28 Number plate light 1 2 3 4

1
ELECT.1

SERVIZI

X29 Rear left light X51 X24

STOP

X30 Diagnostics connector A X50

10 A

10 A

10 A

10 A

15 A

10 A

15 A

20 A

15 A

20 A

40 A

40 A
X23
X31 Start enable switch 10 A 10 A 10 A
X36
X32 Starter switch 15 START 5 1 E
X33 Hazard warning lights switch ELECTROVALVE
ELECT.1 STOP
S
X35 Front PTO control switch RL4 RL3 RL2 RL1
X36 Lights selector switch X30
X37 Starter motor (+12V) X38
X25
X38 Starter motor (Start)
X39 To cab wiring
X40 Hazard warning lights control unit X26
X44 Engine governor display pushbutton
X45 Engine governor reset pushbutton X28
X46 Throttle lever position sensor
S1 Q
X47 Memory pushbutton
X48 Accelerator pedal position sensor X35 X33 X29 X27
S11
X31
X49 Rear PTO control pushbutton (on fender)
X112
X50 Transmission speed sensor
X51 Engine speed sensor
X52 Tyre selection pushbutton
X53 Engine control unit
X112 PTO AUTO switch
D0006910
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473
 8 Systems
84 electrical system
CENTRAL WIRING (VERSION WITH ELECTRONIC GOVERNOR) (2/2)
X18
AN1 AN1 AN1
X19

1
N1 N1
AN1
X20

MN0.8

1
1 7 1 7
6
X44 2
5
X45 2
6
5 X52
3 4 3 4

MG0.5
CB1

N1

N1
AR0.5
Z0.5
H1

N1

CB0.8
X40 X1

B1

R1
V1
1 2 3

HG0.8
4 5 6

GV0.8
S0.5
B1.5

M1

C1
X3

RN0.5
SG1.5
R1 1 29 MB 1
M1 2 28 HB1

1
9
8
7
6
5
4
3
2
B1 3 27

MB1
RV1
MB1

GR1
4

HR1
26 HV1 10 19 GN1 G1
L1 5 25 ZN1 11 20 HR1

HV1
Z1 6 24 HN1 12 21 AR1 1 7 1 7 1 7
H1 7 23 CN1 13 22 RN0,5 6 6 6
H1 8
9
22 L1 14 23 AR0,5
X10 2
5 X9 2
5
2
5 X8

GR1
V1 21 AN1 15 24 Z0,5
V1 10 20 MN1 16 25 HG1

V1

HR1
RN1.5 11 19 GR1 17 26 ZB1 3 4 3 4 3 4
18 27 ZV0.5 AR1

MB1
12 13 14 15 16 17 18 AR1

31

29
AG1 28
36
MG0.5 35
34
33

VB1 30
HR1 32
RN1.5

VN1.5
MN1

N1.5
HN1

HR1
MN0.8

N1

N1
CB1

MB1
VN1
N1

HR1.5
MB1.5
AG1
VB1

VN1

HR1

RV1
MB1

HN1

HR1
GR1
N1
C1

R1
X23 1 2 1 2 1 2

N1 2

E 1 5 H1 1 X24
RN0.5

RN1.5
RN1.5

X17 X16 X15

RL1 87A 87

M1 RN1
MV1
N1
N1
BN1.5 A1 1
N0.5
N0.5

85
RB0.5 N1 N1
GN1 2

R4 30
1 7
X33 1 4
A1 3 X14
6 N1
GND4 2 4

GV1.5
AN1

N1

N1
5

MB1
G1

N1
1

N1
7 5
3 4 6
A1
X35 X13

MN1
2

SG1.5
VB1.5
5 6

GV1.5
B1.5
N1
4 MN1
2 1
X12 7

A1
3

H1.5
X36
3 9 AN1.5 AN1.5 MN1 MN1
X11 GV 1.5 GV 1
G1.5 2 8 A1.5
B1.5
X22

1
R1.5 1 7 B1.5

A1.5
A1.5
N1 N1

2
R1.5 5 4 6 Z1
AN1.5

VN1.5
A1.5 X21
GN1
GN 1.5 GN 1.5 GN1.5 N1
1

2
X28
G1.5
GV1.5

HR2.5
VB1.5

RN1
M1.5
R1.5

R1.5

MB1.5
M1
R4

R4

3
L4

L4

G1
LB1.5

MN1.5
GN1.5
NB1.5

H1

H1

4
G1.5

X29
V1.5

AN1
87 87 5
N1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 6
40A

40A

20A

15A

20A

15A

10A

15A

10A

10A

10A

10A

10A

10A

10A

86 85 MV1
GN1
X38 H2.5
7

M1
AN1
X27
VN1.5

VN1.5
AR4

G1.5

H1.5

RN1.5 8
G1

R6 30
RL2 N1
LB1

M1 9
R6
X37

M4

N1

N1

N1
N1

N1
GV0.8
1
N1

V1

CN1

N1
15

N1
X39 N1.5

RN1.5
LB1.5
M

HG1
MV1

MV1
1 2

N1
L4 30
2 3

AN1
19

17
HG0.5 X50
X31 X5 S X25 GND5 GND5
BN 1

50 M4 HN0.5 2 1 6
H4

11 10 7 6
87 87 14 3 H1 N1
L4 30/1
87
M1 RL4 X30 13 2 HR1 A1
3

4
X26
M1 M1 86 HR0.5 5
86 N1 85
12 1 N1
7
M1 85
X32 30 HR 1.5
VN1
9 8 5 4
GN1

G1
R4 30

RL3 PREIT.RELE' ELECT. 58

HR05
N1
M05 HN05 N1 N1.5
59 BELT ALLARM ELECTROV.PRESENCE 65
R1 N1
AN 1.5
N 0.5
36 SELEZ.PTO COM EV HML 52
RB05
56 RELE'PRERISCALDO (SPEED) 11
GV 0.5 Z 0.5 1
N1
RN05 VN 1 4
68 PRES.GLOW PLUG (RX) 27 V 0.5
M05 H1 2
N 1.5
R05
66 PRESS. ENGINE OIL (TX) 29
HR 1.5
5
X48 N1 N1

1
X2

4
1
3 TEMP.INPUT 3

4
BN05
43 TEMP.OUTPUT
+12 VOLT 44
45
HR 1 6 A 1.5 X4 A1 MN 1.5

2
5
2
+12 VOLT

5
ZV05 60 SPIA M 6
G 0.5 G 0.5
HAND GAS

6
ZN1 Z 0.5
54 EV L +5VCC 28
CB 0.5

7
ZB1 53 EV H (RPM OUT) 22
G1 G1 G1
N 1.5

3
8
S05 57 PRERISCALDO (-VCC) 24
HB05 12 RPM VENTOLA (-VCC) 25
N1
GN 1 GN 1
H05 64 (-VCC E. SCHERMO) 33
V1 AN 1
HAND BRAKE V 0.5
HG05 G1 N1
Z1
BL1
61
63
(LED HOLD)
LEVA LO
PTO POSTERIORE
(HOLD MEMORY)
35
67 LN 0.5
GR1
LN 0.5 X47
62 LEVA HI EV PTO 55
N 0.5 HV 0.5
37 DUAL POWER SEL. PEDAL SENSOR 5
SN 0.5 S1
BV 0.5
HG 0.5

9 (ATTUATORE) 47

G1
PTO AUTO
ZB1

ZB1

V1
M 1.5

BV 1
B1

R1

R1
V1

S1
Z1

4 PTO STOP SOLLEVAT. (ATTUATORE) 46 V 0.5 3

N1

B1
HV 0.5
X53 (PICK UP) 10
Z 0.5
2
1 X46
1 2 3 4 1 2 3
TABELLA COLORI / COLOURS TABLE
S1
M H L S1 A M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
X7 X49
3

V1 2
X51 N Nero/Black L Blu/Dark Blue
1 2

B1 1

S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

HR0.5
SN0.5

1 7
6
2
SN0.5

3 4
V0.5

X112

D0006920
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474
 Systems 8
electrical system 84

POSITION OF CENTRAL WIRING CONNECTORS (ELECTRONIC GOVERNOR)

1 X1
GND4

F0027560

2 X44

X45

X2

X32

F0027870

3 X13-X27
X13 -X27

F0027590

475
 8 Systems
84 electrical system

X53

F0027880

5 X3

F0027620

X4

F0027580

476
 Systems 8
electrical system 84

7 X112
X35

X33

F0028070

8
X47

F0027900

9 X8

X10

X9

F0027690

477
 8 Systems
84 electrical system

10
X49

F0028080

11
X46

F0027920

12 GND5

X7

F0027800

478
 Systems 8
electrical system 84

13
X11

X12

F0027700

14

X28

F0027730

15

X14-X29

F0027720

479
 8 Systems
84 electrical system

16 X26

F0027740

17
X25

F0027770

18 5

F0027760

480
 Systems 8
electrical system 84

19
X23

F0027780

20 X24

F0027710

21
X50

F0027930

481
 8 Systems
84 electrical system

22
X19

F0027810

23

X20

F0027750

24

F0027940

482
 Systems 8
electrical system 84

25

X18

F0027950

26 X17

X16

X15

F0027960

27
H
L

F0027970

483
 8 Systems
84 electrical system

28 X39

F0027550

29

X38

X37

F0027820

30

X51

F0027980

484
 Systems 8
electrical system 84

31

X48

F0028200

32 X40

F0027610

33
X30

F0028000

485
 8 Systems
84 electrical system

34 X5

F0027680

35
A

F0027990

36 X52

X36

RL3 RL2

RL4 RL1

F0028690

486
 Systems 8
electrical system 84

CENTRAL WIRING (VERSION WITH ELECTRONIC GOVERNOR)

CAB

37 4
5 6 7 8 9 10 11 12 13 31 14 15

X31 16
2 17
1
32 18
36

35
34
33
19
37

F0027670 30 29 28 27 26 25 24 23 22 21 20 19

38 PLATFORM
3 3
X22
15 14

X21 15

F0028540

38

0.011.6958.4/21

487
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LEFT BLANK
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LASCIATA BIANCA
 Systems 8
electrical system 84

AGROSHIFT WIRING (VERSION WITH MECHANICAL GOVERNOR) (1/2

X6
TO 0.011.6955.4
M
TO 0.009.7855.3 L H

3 2 1 2 1 2 1

H
L
X72

H Solenoid valve for High range (HI) control

L Solenoid valve for Low range (LO) control
M To HML lever wiring
X6 To central wiring

D0006660
0.009.7627.3/10

489
 8 Systems
84 electrical system

AGROSHIFT WIRING (VERSION WITH MECHANICAL GOVERNOR) (2/2)

M L H

3 2 1 2 1 2 1
X6

1 2 3

4 5 6 7 8

ZN 1

ZB 1
M1

M1
B1

H1

Z1
MB 1

ZN 1

ZB 1
TABELLA COLORI / COLOURS TABLE

ZV 1

N1
M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray

N1
1

ZV 1
2

M 1.5
3

N1
4

Z1
6

B1
X72 7

H1
8

ZN 1
9

10

ZB 1
11

12 MB 1

D0006670
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490
 Systems 8
electrical system 84

CONNECTOR POSITIONSI AGROSHIFT WIRING (VERSION WITH MECHANICAL GOVERNOR)

1
M

L H
2

F0027830

2
X72

F0028530

3
1

X6

F0028550

0.009.7627.3/10

491
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LASCIATA BIANCA
 Systems 8
electrical system 84

AGROSHIFT LEVER WIRING

HI
M

3
TO 0.009.7627.3

2
AMP LO X73
(VERSIONE MECCANICA)
TO 0.011.6958.4

1
(VERSIONE DUAL POWER)
COM.

X73
B 0.5
3 HI

H 0.5
M 2
Z 0.5
LO

Z 0.5 H 0.5
1
COM.

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

M To Agroshift wiring (Version with mechanical governor)

M To central wiring (Dual Power version)
X73 HML control pushbutton

D0006680
0.009.7855.3/10

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LASCIATA BIANCA
 Systems 8
electrical system 84

CONNECTOR POSITIONS AGROSHIFT LEVER WIRING

M 1

F0027840

X113

F0026850

0.009.7855.3/10

495
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LEFT BLANK
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LASCIATA BIANCA
 Systems 8
electrical system 84

ELECTRONIC LIFT WIRING (1/2)

1
I

2
I

3
4
5
P
1
P1
2
3

H
1

H1
2
3

V
1

V
2
3

M
1

M1
2
3

S
1

C
2

C
3
4
5

1 2 3
4

TO 0.011.6955.4

DW
UP
3

0.011.6958.4 S1
2

X7
1

DW
UP

P
1 2 3 1 2 3

1 2 1 2 1 2 3

X71

UP DW EV UP EV DW P2

C Rear lift control pushbutton I Rear lift control pushbutton V Lift lowering speed potentiometer
DW Rear lift “Down” control pushbutton M1 Draft/wheelslip control adjustment potentiometer X7 To central wiring
EV DWLift DOWN solenoid valve P1 Lift position adjustment potentiometer X71 Rear lift control unit
EV UPLift UP solenoid valve P2 Rear lift position sensor
H1 Maximum height adjustment potentiometer S1 Lift draft sensor
$ UP Rear lift “Up” control pushbutton
D0006640
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 8 Systems
84 electrical system

ELECTRONIC LIFT WIRING (2/2)

TABELLA COLORI / COLOURS TABLE

X71 M Marrone/Brown C Arancio/Orange

VEL.DISCESA
MAX ALZATA

POSIZIONE
POSIZIONE
V Verde/Green A Azzurro/Blue

ISO 9141

+12 VCC
SFORZO
+10VCC
Z Viola/Violet B Bianco/White

EV DW
EV UP

GND

MIX
N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow
2 4 3 5 7 6 9 8 10 11 12 1 R Rosso/Red H Grigio/Gray

MB1
M1

HR1
N1
AB1

AN1

BN1
B1

S05

V05
H05
L05

BN 1
MB1

MB1

MB1
MB1

MB1
VO5

HR1

HR1
M05

M05

M05

M05
H05
N05

N05

N05

N05

H05
S05

S05

V05
L05

L05

H05
V05
M1

N1
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5 4 3 2 1 1 2 3 4 5 1 2 3 1 2 3

H1 V M1 P1 I C UP DW

X7
M1
N1

B1
BN1
M1
N1
AB1

N1

1 2 3
AN1
N1

1 2 3
1 2

1 2
S1
EV UP P2
EV DW

D0006650
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498
 Systems 8
electrical system 84

POSITION OF ELECTRONIC LIFT CONNECTORS

1 P1 H1

V M1

I
F0027440

2
C

X71

F0027420

X71

X7

F0027430

499
 8 Systems
84 electrical system

UP
DW

F0027410

P2

F0027400

EV DW

EV UP
F0027380

500
 Systems 8
electrical system 84

ELECTRONIC LIFT WIRING

7
3 4

S1 2

F0027390

7 6

0.011.6943.4/10

501
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

ROOF WIRING (STANDARD CAB) (1/2)

X79
1 2 3 4

X78
5 6 7 8
X80 X81

4
8
TO 0.009.7851.4

3
7
X77

2
6
1
5
TO 0.009.7853.3

1
3
X76

4
2
TO 0.009.7854.3

3
X75

1
2
X82

X74
30
A H
85 86

87
1 8
X103

1 2 3 4

1
5
2
6
3
7
4
8
X83

X74Interior roof light X85 X84

X75 To screenwash pumps wiring
X76 To air conditioning fans wiring
X77 To worklights wiring

2
X78 Rear worklights switch X86

1
1

TO 0.010.2130.1
2

X79 Rear screen wiper control switch

3

X90
4

X80 Windscreen washer pump control switch

X81 Rotating beacon control switch TO 0.010.2123.2
GND4
2

X82 Intermittent wipe timer for windscreen wiper 010.2130.1

1

X89
X83 Clock
X84 Front windscreen wiper control switch
3
6

TO 0.010.4516.3
X85 Front worklights switch
2
5

X88
4
1

X86 Radio
X87 To heater power supply wiring
X88 To windscreen wiper wiring
TO 0.009.7852.3
1

X89 To heater or air conditioning wiring

X87
3

X90 To air conditioning wiring

X103 Relay for roof wiring power

D0006890
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 8 Systems
84 electrical system

ROOF WIRING (STANDARD CAB) (2/2)

X85 X78 X81 X84
X79
A-N 1
A-N 1 X80 X83
1 2 4 43 32 21 1
3 4 1 2 3 4
5 6 7 8 5 6 7 8

V1

N1
R1
A1
AR1
AR1
AN1
R-N 1

G-R 1

A-N 1
V-N 1
V1
M-G 1.5

G-N 1.5

G-N 1.5
G-V 1.5

H-N 1

H-N 1
M 1.5

M 1.5
R1.5

A1
A1

C1
G1

G1

N1

N1

N1
H-N 1
M 1.5

N 1.5
4
8
3
7

X77
2
6
1
5

N 2.5
G-N 1.5 RN1
G 1.5
GR1
I
53N
AR1
T 53S X82
A-N 2.5 V1 15 31

N 2.5 AN1
1
3

X76 V1
4
2

V1 N1

N 1.5
N1
3

X75 A-R 1
1
2

C1

N1
1

V1
X90
2

V-N 1.5
4 3

V1

R4
2

X89 N4
1

G-R 1
AN 1
N1
3
6

X88
2
5
1
4

V-N 1

V-N 1.5
L-B 1
X87
1
2
3
R 2.5

TABELLA COLORI / COLOURS TABLE

A-N 1

A-N 1

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
N 2.5
N 2.5
N1
N4
N1

N1
N1
N1
N1
N1

Z Viola/Violet B Bianco/White
M-G 1.5
A-N-2.5

G-V 1.5
R1

LB 1
R1.5

N Nero/Black L Blu/Dark Blue

N1

R1

A1
A1
R1

R1

R4
R1
N1

X103 S Rosa/Pink G Giallo/Yellow

1 2
30 R Rosso/Red H Grigio/Gray
A H 85 86
X86 87

X74 1 8
GND6
R 2.5 M 2.5

M 2.5
5 A RADIO
10 A

30 A

7.5 A
20 A

7.5 A

10 A

10 A

D0006900
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 Systems 8
electrical system 84

POSITION OF ROOF WIRING CONNECTORS (STANDARD CAB)

X86

F0027290

X88

F0027300

3
X74

F0027310

505
 8 Systems
84 electrical system

4 X77

X75

X87

F0027320

5 X83

X103

F0027330

X76

F0027340

506
 Systems 8
electrical system 84

7
X89

X90

F0027350

X82

F0028180

GND

F0027370

507
 PAGE INTENTIONALLY
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LASCIATA BIANCA
 Systems 8
electrical system 84

ROOF WIRING (STANDARD CAB)

10 X84
X79
X81

10
9 7
8 6

X78
X85
X80
2 5
F0028170

3
4

0.009.7850.4/50

509
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LASCIATA BIANCA
 Systems 8
electrical system 84

WORKLIGHTS WIRING (STANDARD CAB) (1/2)

X124

X121
TO 0.009.7850.4
X77

X126 X127
X122

X123

1 2

X125

X77 To roof wiring X124 Front right worklight

X121 Front left worklight X125 Rear screen wiper motor
X122 Rear left worklight X126 Connector
X123 Rear right worklight X127 Rotating beacon

D0006770
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 8 Systems
84 electrical system

WORKLIGHTS WIRING (STANDARD CAB) (2/2)

GN 1.5

X122
N 1.5

N 1.5 GN 1.5

1
GN 1.5

X123 N 1.5 G 1.5

2
N 1.5

N 1.5 HN 1

3
G 1.5

N 1.5 M 1.5

8
X124

4
N 1.5

X77

G 1.5

X121
N 1.5

M 1.5 M 1.5

X127
N 1.5 N 1.5
N 1.5
1

X125
2
HN 1 X126

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0006780
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 Systems 8
electrical system 84

POSITION OF WORKLIGHTS CONNECTORS (STANDARD CAB)

1 X121-X122
X123-X124

F0027200

X77

F0027270

X126

F0027180

513
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LASCIATA BIANCA
 Systems 8
electrical system 84

WORKLIGHTS WIRING (STANDARD CAB)

5
4 X127

4
3
F0027170

5 2

X125

F0027280

0.009.7851.4/40

515
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LASCIATA BIANCA
 Systems 8
electrical system 84

SCREENWASH PUMPS WIRING (STANDARD CAB)

X129 X135

1 2 1 2

TO 0.009.7850.4
1

X75 TABELLA COLORI / COLOURS TABLE

3

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

2
1
C 1.5 X135
1
AR 1.5
X75 2
N 1.5 N1
3 1
X129
2

X75 To roof wiring

X129 Front windscreen washer pump
X135 Rear screen washer pump

D0006750
0.009.7854.3/10

517
 8 Systems
84 electrical system

WINDSCREEN WIPER WIRING (STANDARD CAB)

G-R 1

M-N 1
G-R 1 V-N 1
(+MOT) (AZZ.)

R-N 1 G-R 1
R-N 1
(+AZZ) (+MOT)
TO 0.009.7850.4 (+AZZ)

X130 X88 3 2 1
V-N 1 M-N 1
(AZZ.) (GND) V-N 1 6 5 4

M-N 1
(GND)

R-N 1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

X88 To roof wiring

X130 Windscreen wiper motor

D0006740
0.010.4516.3/1

518
 Systems 8
electrical system 84

SPEAKER WIRING (STANDARD CAB)

X131

X132 X133

X131 Radio
X132 Left speaker
X133 Right speaker

D0006760
0.011.0729.4/10

519
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

CONNECTOR POSITIONS

X130

F0027120

X88

F0027240

3 X131

F0027250

521
 PAGE INTENTIONALLY
LEFT BLANK

PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

WIRING FOR SCREENWASH PUMP - WINDSCREEN WIPER - SPEAKERS (STANDARD CAB)

4 4

X132-X133

F0027260

5 3

X135
X129
2

X129
F0027130

6 1

X75

0.009.7854.3/10
F0028060 0.010.4516.3/1
0.011.0729.4/10

523
PAGE INTENTIONALLY
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

HEATER POWER SUPPLY WIRING (STANDARD CAB) (1/2)

X108 X108
X109

2
1 2

1
TO 010.2123.2
010.2130.1 SOLO PER 65A
X107

B+

X106

B-

X106

3
TO 0.009.7850.4
X111 X111 X37
X87 1 2

50A

TO 0.009.7850.4
R6 1
(X103) 2 X39
X103-30

B+ Heater alternator (+)

B– Heater alternator (–)
X37 Starter motor
X39 To central wiring
X87 To roof wiring
X103-30 To roof wiring (X103)
X106 Heater resistance
X107 To heater or air conditioning power wiring
X108 Connector
X109 Heater alternator
X111 Connector

D0006800
0.009.7852.3/40

525
 8 Systems
84 electrical system

POSITION OF HEATER POWER CONNECTORS (STANDARD CAB)

X108 X108
L1
1

G-R 1 G-R 1
2

G-R 1
X107 AMP

2
N-L 1
3

B1
B1 B1

1
4

1 2

X109

L1
N 16 N 16
X106 B+

TABELLA COLORI / COLOURS TABLE

N-L 1
M Marrone/Brown C Arancio/Orange
N 16 N 16 V Verde/Green A Azzurro/Blue
X106 B- Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

R 2.5

3
V-N 1.5
X87

2 1
1 2 L-B 1 LB1 X39
V-N 1.5

X111 X111 X37

R 2.5
R6
X103-30

D0006790
0.009.7852.3/40

526
 Systems 8
electrical system 84

POSITION OF HEATING CONNECTORS (STANDARD CAB)

1
X106

F0028150

X106

F0027050

X107

X103-30

F0028160

527
 8 Systems
84 electrical system

X87

F0027070

5
X111

X37

X39

F0026880

6 X108

X109

F0028720

528
 Systems 8
electrical system 84

HEATER POWER SUPPLY WIRING (STANDARD CAB)

1
7 B+
2 3 4

B-

X108

F0026890

5
6

0.009.7852.3/40

529
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

HEATER WIRING (STANDARD CAB) (1/2)

X141 X140 X136

12 11 10 9 8 7 6 5 4 3 2 1

30
3

TO 0.009.7852.3 85
86 X142
X107
2

87
1

1 2

TO 0.009.7850.4
X89
1 2 3

2
X138 X137

X139

X89 To roof wiring X139 Fan speed selector switch

X107 To heater power wiring X140 Heater fan resistor
X136 Heater control unit X141 Heater fan
X137 Heater air temperature sensor X142 Relay for alternator excitation
X138 Heater control potentiometer

D0007780
0.010.2123.2

531
 8 Systems
84 electrical system

HEATER WIRING (STANDARD CAB) (2/2) X136

8 9 12 6 10 3 4 5 1 2 7 11

L1
1

N 0.5 GR 1
2

X137 N 0.5 NL 1
3 X107
B1
4

N4
1

C4
X89
2

H 0.5

C 0.5
X138
V 0.5

N4

X141 M R4

B1
87

Z 0.5
86

C 0.5
85
X142
R1
30

M 2.5

LR 1.5
R 2.5

B 0.5
R4

C4

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue
3
Z Viola/Violet B Bianco/White

2 N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

1 R Rosso/Red H Grigio/Gray

X140
0

X139
D0007770
0.010.2123.2

532
 Systems 8
electrical system 84

POSITION OF HEAITING CONNECTORS (STANDARD)

1
X107 X89

F0028260

2 X141

X140

F0028230

3 X138

X137

X139

F0028240

533
 PAGE INTENTIONALLY
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

HEATER WIRING (STANDARD CAB)

4 2
X136

X142
1

F0028250
3

0.010.2123.2

535
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

AIR CONDITIONING WIRING (STANDARD CAB) (1/2)

X90
TO 0.009.7850.4 X141 X140 X136

12 11 10 9 8 7 6 5 4 3 2 1

1 2 3 4

30
3

TO 0.009.7852.3 85
86 X143
2

X107 87
1

1 2

TO 0.009.7850.4
X89 30 85 86 87
1 2 3

2
X138 X137

1
X142

X144

X139

X89 To roof wiring X139 Fan speed selector switch

X90 To roof wiring X140 Heater fan resistor
X107 To heater power wiring X141 Heater fan
X136 Heater control unit X142 Relay for alternator excitation
X137 Heater air temperature sensor X143 Air conditioner control relay
X138 Heater control potentiometer X144 Demister thermostat

D0007750
0.010.2130.1

537
 8 Systems
84 electrical system

AIR CONDITIONING WIRING (STANDARD CAB) (2/2) X136

8 9 12 6 10 3 4 5 1 2 7 11

L1
1

N 0.5 GR 1
2

X137 N 0.5 NL 1
3 X107
B1
4

N4
1

C4
X89
2

H 0.5

C 0.5 BV 0.5
X138 1

V 0.5 NZ 0.5
2

CR 1 X90
3

B 0.5
4

B 0.5

B 0.5
X144

N4

X141 M R4

B1
87

Z 0.5
86

C 0.5
85
X142
R1
30

CR 1
87
NZ 0.5
86

M 2.5 BV 0.5 X143

85

C1
30
LR 1.5
R 2.5

B 0.5
R4

C4

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue
3
Z Viola/Violet B Bianco/White

2 N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

1 R Rosso/Red H Grigio/Gray

X140
0

X139
D0007760
0.010.2130.1

538
 Systems 8
electrical system 84

AIR CONDITIONING WIRING (STANDARD CAB)

1
X107 X89

X90

F0028270

2 X141

X140

F0028230

3
X137
X138

X144 X139

F0028290

539
 PAGE INTENTIONALLY
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

AIR CONDITIONING WIRING (STANDARD CAB)

4 2
X136

X142

X143

F0028280
3

0.010.2130.1

541
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

AIR CONDITIONING FAN WIRING (STANDARD CAB) (1/2)

X120

X118
X115 X119
TO 0.009.7850.4
X76

WHITE
BIANCO
1
3 2 1
85 87 87

86 30

ITALAMEC 037

D0006620
0.009.7853.3/21

543
 8 Systems
84 electrical system

AIR CONDITIONING FAN WIRING (STANDARD CAB) (2/2)

X120

X118
TABELLA COLORI / COLOURS TABLE X119
M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

WHITE
BIANCO
S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
X115 3 2 1 1

AN 2.5 AN 1

30

N 2.5
A 2.5
85 87 86
CB 1

CB 1

VN 1
N1
V1
87

A 2.5

V1

N 2.5

N1

2 1
X76
4 3

AN 2.5

VN 1

D0006630
0.009.7853.3/21

544
 Systems 8
electrical system 84

AIR CONDITIONING FAN WIRING (STANDARD CAB)

1 1
2

X118

X120

F0028210

2
3
X115

X119

F0028220

X76

F0027340

0.009.7853.3/21

545
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

ROOF WIRING (HIGH VISIBILITY CAB) (1/2)

TO 0.011.3595.3 X74
X95

TO 010.2562.1
X94

TO 010.2558.1
010.2562.1
X93
X80

GND7
X82 X96

TO 011.3597.3
X92
X97

TO 011.3743.3
X75
X98

ROOF WIRING (HIGH VISIBILITY CAB) (2/2)

X74 Interior roof light TO 011.3761.3
X91
X75 To screenwash pumps wiring X99
X80 Windscreen washer pump control switch
X82 Intermittent wipe timer
PTO
X91 To heater power supply wiring X100
X92 To windscreen wiper wiring
X93 To heater wiring
X94 To heater or air conditioning wiring
X95 To worklights wiring TO 011.3596.3
7.5A
10A

10A

7.5A

10A
7.5A

30A

5A

X96 Rotating beacon control switch X101

X97 Rear screen wiper control switch
FREON

RADIO

X98 Windscreen wiper control switch

X99 Rear worklights control switch TO 0.011.3610.3
X100 Front worklights control switch X102
X101 To speaker and radio wiring
X102 To air conditioning fan wiring
X103 Relay for roof wiring power X103
X104 Roof wiring power fuse (40 Amp)

X104

D0006850
0.011.3606.4/51

547
 8 Systems
84 electrical system

ROOF WIRING (HIGH VISIBILITY CAB) (2/2)

X100 X99 X96 X98 X97 X80

2 3 8 7 2 3 8 7 2 3 8 7 1 6 5 3 2 3 5 2 6 2 3

MG 1.5

GN 1.5
GV 1.5

AR 1
M 1.5

M 1.5

AR 1
AN 1
R 1.5
GN 1

AN 1

AN 1

HN 1
RN 1
VN 1
G1

G1

A1

A1
N1

N1

N1

C1
V1
A1
4

R1
3

X101 HN 1
2

M 1.5
1

G1
4

G1
3

X95 GN 1
2

GN 1
1

R1
R1
AN 1.5
4
8

V1
3
7

X102 N 1.5

7.5A
10A

10A

7.5A

10A
7.5A

30A

5A
2
6

N 1.5
1
5

FREON

RADIO
AN 1.5
V1 RN1

GR1 I
AR 1 53N
2

X75 AR1
3

C1 53S
T
X82
1

N1 31
V1 15
N1

LAMPEGGIANTE
POMPA TERGI

POSTERIORE
FARI LAVORO

FARI LAVORO
AN1

ANTERIORE

ANTERIORE
ANTERIORI

POSTERIRI

TERGI

TERGI
V1
1

N1
V1
X94
2

VN 1.5
3

R6
A

X93 N6
B

VN 1
GR 1
53

X92
N1
AN 1

R6
TABELLA COLORI / COLOURS TABLE
LB 1 M Marrone/Brown C Arancio/Orange
X91 1 2

3 V Verde/Green A Azzurro/Blue
R4 Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
VN 1.5
MG 1.5
AN 1.5
AN 1.5

GV 1.5
VN 1.5

S Rosa/Pink G Giallo/Yellow
R 1.5

AN 1

LB 1
A1
A1
R1

R1

R Rosso/Red H Grigio/Gray
X103
5
N 1.5
N 1.5

40A
N1
N6

N1
N1
N1
N1

A H
1
3
2 X104
N1

R1

1 8
M 10

R4 M4

VN 1.5

GND7 X74

D0006880
0.011.3606.4/51

548
 Systems 8
electrical system 84

POSITION OF ROOF WIRING CONNECTORS (HIGH VISIBILITY CAB)

1 X75
GND7
X103

X91

F0026770

2
X99 X97

X80
X96
X100 X98

F0026780

X82

X104
F0026790

549
 8 Systems
84 electrical system

4 X93

X94

X95
F0026800

5
X101

X102

F0026820

X74

F0026810

550
 Systems 8
electrical system 84

ROOF WIRING (HIGH VISIBILITY CAB)

4
7 1
3

2
5
1

3
6
X92
7
F0026830

0.011.3606.4/51

551
PAGE INTENTIONALLY
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

WORKLIGHTS WIRING (HIGH VISIBILITY CAB)

X124

1
X123 TO 0.011.3606.4

2
X95

3
4
GND7

X122

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
GN 1.5 N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
X123 R Rosso/Red H Grigio/Gray
N 1.5

X121

GN 1.5

1
X122
N 1.5

2
X95

3
4
G 1.5

X124
N 1.5

GND7
G 1.5

X121
N 1.5

X95 To roof wiring

X121 Front left worklight
X122 Rear left worklight
X123 Rear right worklight
X124 Front right worklight
D0006840
0.011.3595.3/10

553
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

WORKLIGHTS WIRING (HIGH VISIBILITY CAB)

1 X121-X122
X123-X124
3

F0027200

2
GND7

F0027210

X95

F0027220

0.011.3595.3/10

555
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

SCREENWASH PUMP WIRING (HIGH VISIBILITY CAB)

X129 X135

1 2 1 2

TO 0.011.3606.4
1

X75 TABELLA COLORI / COLOURS TABLE

3

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

2
1
C 1.5 X135
1
AR 1.5
X75 2
N 1.5 N1
3 1
X129
2

X75 To roof wiring

X129 Front windscreen washer pump
X135 Rear screen washer pump

D0006820
0.011.3743.3

557
 8 Systems
84 electrical system

WINDSCREEN WIPER WIRING (HIGH VISIBILITY CAB)

G-R 1

G-R 1
M-N 1
V-N 1

R-N 1 G-R 1
(+AZZ) (+MOT)

TO 0.011.3606.4
X130 X92
V-N 1 M-N 1 V-N 1
(AZZ.) (GND) R-N 1

M-N 1

R-N 1

CORRISPONDENZA TRA CAVI CABLAGGIO E CAVI TERGI ANTERIORE

G-R (+MOT) G

CABLAGGIO (GND) MOTORINO

M-N M
TERGI
WIRES
R-N (+AZZ) V-N Wiper

V-N (AZZ.) N

X92 Al cablaggio linea tetto

X130 Motore tergicristallo anteriore

D0006830
0.011.3597.3/33

558
 Systems 8
electrical system 84

CONNECTOR POSITIONS WIRING FOR SCREENWASH PUMP & WINDSCREEN WIPER (HIGH VISIBILITY CAB)ù

1
X75
1

X92

F0027110

X130

F0027120

3
3 2

X135
X129

X129
F0027130 0.011.3743.3
0.011.3597.3/33

559
PAGE INTENTIONALLY
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

HEATER WIRING (HIGH VISIBILITY CAB) (1/2)

1
TO 0.011.3606.4

2
X101

3
3
GND7

X83
4 3 2 1

N1
R1
A1
X101
M 1.5

1
HN 1

2
R1

3
A1

4
N1

X126 X83 N 1.5

N 1.5

N1

GND7
X132 X133

2xR 1
M 1.5
N 1.5

N 1.5

CN 1

BN 1

BN 1
HN 1

CN 1
1 2 X125

C1

B1

B1
N1

C1
3 4
3 4 X86 1 2
1 2
1 2

X131 X132 X133

X125
X126

X86

X131

X127 TABELLA COLORI / COLOURS TABLE

M 1.5
N 1.5
M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

X127

X83Clock X127Rotating beacon

X86Radio X131Radio
X101To roof wiring X132Left speaker
X125Rear screen wiper motor X133Right speaker
X126Connector
D0006810
0.011.3596.3/30

561
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LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

POSITION OF SPEAKER AND RADIO WIRING CONNECTORS (HIGH VISIBILITY CAB)

1
GND7

X101
F0027140

2
X132-X133

F0027150

X125

F0027160

563
 PAGE INTENTIONALLY
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

CABLAGGIO ALTOPARLANTI E RADIO (ALTA VISIBILITÀ)

2
4 X127 3
1

1 2

F0027170

4
5
5
6

X126

F0027180

6
X131
X86
X83

F0027190

0.011.3596.3/30

565
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

HEATER POWER SUPPLY WIRING (HIGH VISIBILITY CAB) (1/2)

X108 X108
X109

2
2
4
TO 010.2558.1 1 2

1
1
010.2562.1
3
2

X113
1

B+

X106
B-

3
TO 0.011.3606.4
X111 X111 X37
X91 1 2

50A

TO 0.011.3606.4 R 10 1

X103-30 2 X39

B+ Heater alternator (+)

B– Heater alternator (–)
X37 Starter motor
X39 To central wiring
X91 To heater power supply wiring
X103-30 To roof wiring (X103)
X106 Heater resistance
X108 Connector
X111 Connector
X113 To heater or air conditioning wiring

D0007210
0.011.3761.3/30

567
 8 Systems
84 electrical system

HEATER POWER SUPPLY WIRING (HIGH VISIBILITY CAB) (2/2)

B1

4
NL 1 X108 X108

3
GR 1 GR 1 G-R 1

2
2
L1 B1 B1

1
1
1

1 2
X113
X109
L1
N 16 N 16
B+

X106
NL 1
N 16 N 16
B-

R4

3 VN 1.5
X91

2 1
1 2
LB 1 LB 1 X39

VN 1.5

X111 X111 X37

R4
R 10
X103-30 R 10

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0006710
0.011.3761.3/30

568
 Systems 8
electrical system 84

SPEAKER AND RADIO WIRING (HIGH VISIBILITY CAB)

1
X103-30

X91

F0026840

X113

F0026850

X106

F0026860

569
 8 Systems
84 electrical system

4
X106

F0026870

5
X111

X37

X39

F0026880

6 B+

B-

X108

F0026890

570
 Systems 8
electrical system 84

HEATER POWER SUPPLY WIRING (HIGH VISIBILITY CAB)

2
1 3
4
7 X108

X109

F0028720

5
7

0.011.3761.3/30

571
PAGE INTENTIONALLY
LEFT BLANK
PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

HEATER WIRING (HIGH VISIBILITY CAB) (1/2)

TO 0.011.3606.4
X93
TO 0.011.3761.3 X157 X147 X146
X113

4 3 2 1
X145
85 86 30 87 87a 85 86 30 87 87b 85 86 30 87 87B A B

1 2 3 4 5 6

1
5

2
4

3
X148
3

X154

4
2

5
1

5
4
3
B A 1 2 2
1

X137 X149 B A
X150

1
2
3
4
5
6
7
X152

8
9
X150

10
X136

11
12
X152

B A

B A
A

X151
B

A
X153

B
X93 To heater power supply wiring X146 Control relay for maximum fan speed X151 Left heater fan
X113 To roof wiring X147 Control relay for alternator excitation X152 Connector
X136 Heater control unit X148 Resistor for left heater fan X153 Right heater fan
X137 Heater air temperature sensor X149 Resistor for right heater fan X154 Fan speed selector switch
X145 Heater control potentiometer X150 Connector X157 Relay for 3rd fan speed and air conditioning on

D0007850
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573
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84 electrical system

HEATER WIRING (HIGH VISIBILITY CAB) (2/2)

X136

X146
X151 X148 X145
X137
M 8 9 12 6 10 3 4 5 1 2 7 11
87b 87 86 85 30
X93

BR 2.5

B 1.5
R 2.5

N 0.5

C6

N6

C6
GR 0.5

GR 0.5
V 1.5

CB 0.5
BR 2

AR 2

LN 0.5

LN 0.5
CB 0.5

Z 0.5

Z 0.5

Z B0.5
H 0.5

A 0.5
V 0.5
Z 0.5

Z 0.5
H 0.5

C 0.5

L 0.5
A1

A 0.5
B 2.5

N 2.5

V 0.5
X150
BR 2.5

L 0.5

GR 1

LN 1 X113
B1
N 2.5
R 1.5

TABELLA COLORI / COLOURS T ABLE

X152
M Marrone/Brown C Arancio/Orange
ZB 0.5
C 1.5

N 0.5
S 1.5

AR 2
GL 2
B 1.5

C 2.5
A 1.5

S 1.5
R 1.5

N 2.5

LR 2

V Verde/Green A Azzurro/Blue
R1

B1

B1

C4
V 1.5
GL 2
R2

A 1

Z Viola/V iolet B Bianco/White

30 85 86 87 87b 30 85 86 87 87b N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Y ellow
R Rosso/Red H Grigio/Gray
I II III IV C

X153 X149 X154 X147 X157

D0007840
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electrical system 84

POSITIONOF HEATER CONNECTORS (HIGH VISIBILITY CAB

1
X154

X145

F0028300

2 X146

X147
X157

F0028570

3
X113

X93

F0028330

575
 8 Systems
84 electrical system

4
X148-X149

X151-X153

F0028340

X150-152

F0028350

X137

F0028360

576
 Systems 8
electrical system 84

HEATER WIRING (HIGH VISIBILITY CAB)

7 3 5

4
6
2 7
1

X136

F0028370

0.010.2558.1

577
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LASCIATA BIANCA
 Systems 8
electrical system 84

AIR CONDITIONING WIRING (HIGH VISIBILITY CAB) (1/2)

TO 0.011.3606.4
X93
X157 X147 X146 X156
TO 0.011.3606.4
X94

X137
A B 85 86 30 87 87a 85 86 30 87 87b 85 86 30 87 87b 85 86 30 87 87a 1 2 3

2 1
X158
2
1

1
5

2
4

3
X148
3

X154

4
2

5
1

1
2
1

3
2
3

4
4
5
6

B A
TO 0.011.3761.3 X145
X113 5
4
3
X159 2
1
B A
X150

1
2
3
4
X149

5
6
7
X152

8
9
X150

10
X136

11
12
X152

B A

B A
A

X151
B

A
X153

B
X93 To heater power supply wiring X147 Control relay for alternator excitation X154 Fan speed selector switch
X94 To roof wiring X148 Resistor for left heater fan X156 Relay for1st fan speed and air conditioning on
X113 To roof wiring X149 Resistor for right heater fan X157 Relay for 3rd fan speed and air conditioning on
X136 Heater control unit X150 Connector X158 Air conditioning control switch
X137 Heater air temperature sensor X151 Left heater fan X159 Air conditioning thermostat
X145 Heater control potentiometer X152 Connector
X146 Control relay for maximum fan speed X153 Right heater fan
D0007820
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 8 Systems
84 electrical system

AIR CONDITIONING WIRING (HIGH VISIBILITY CAB) (2/2)

X136

X146
X151 X148 X145
X137
M 8 9 12 6 10 3 4 5 1 2 7 11
87b 87 86 85 30
X93

BR 2.5

B 1.5
R 2.5

N 0.5

C6

N6

C6
GR 0.5

GR 0.5
V 1.5

CB 0.5
BR 2

AR 2

LN 0.5

LN 0.5
CB 0.5

Z 0.5
Z 0.5

Z B0.5
H 0.5

A 0.5
V 0.5
Z 0.5

Z 0.5
H 0.5

C 0.5

L 0.5
A1

A 0.5
B 2.5

N 2.5

V 0.5
X150
BR 2.5

L 0.5

GR 1

LN 1 X113
B1

GB 1
N 2.5
R 1.5

V 0.5
X94
B 0.5

X152
ZB 0.5

C 1.5

N 0.5

V 0.5

GB 1
C 1.5

N 0.5
S 1.5

AR 2
GL 2
B 1.5

C 2.5
A 1.5

S 1.5
R 1.5

VN 0.5

VN 0.5
N 2.5

LR 2

R1

B1

B1

C4

A 0.5

B 0.5
V 1.5
GL 2
R2

A 1

30 85 86 87 87b 30 85 86 87 87b 30 85 86 87
TABELLA COLORI / COLOURS T ABLE

M Marrone/Brown C Arancio/Orange
I II III IV C
V Verde/Green A Azzurro/Blue

M Z
N
Viola/V iolet
Nero/Black
B
L
Bianco/White
Blu/Dark Blue
S Rosa/Pink G Giallo/Y ellow
R Rosso/Red H Grigio/Gray
X153 X149 X154 X147 X157 X156 X158 X159

D0007810
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 Systems 8
electrical system 84

POSITION OF AIR CONDITIONING CONNECTORS (HIGH VISIBILITY CAB)

X158

F0028310

2
X154

X145

F0028300

3
X156

X157

X146

X147

F0028320

581
 8 Systems
84 electrical system

4
X113

X93

F0028330

5
X148-X149

X151-X153

F0028340

X150-152

F0028350

582
 Systems 8
electrical system 84

AIR CONDITIONING WIRING (HIGH VISIBILITY CAB)

7 4 6

5
7
3 8
2

X137

F0028360

8 9

X136

F0028370

X159

F0028380

0.010.2562.1

583
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
electrical system 84

AIR CONDITIONING FAN WIRING (HIGH VISIBILITY CAB) (1/2)

X116
TO 0.011.3606.4
X102
1 2 3 4 3 2 6
A B A B

5 6 7 8
1 4

X117a X117b
X114 X115

85 87 87 85 87 87

86 30 86 30

ITALAMEC 037 ITALAMEC 037

X102 To roof wiring

X114 Relay for supplementary air conditioning fan
X115 Relay for air conditioning fan
X116 Air conditioning pressure switch
X117a Air conditioning fan
X117b Supplementary air conditioning fan
D0006860
0.011.3610.3/20

585
 8 Systems
84 electrical system

X117a X117b
X116

AN 1.5 AN 1.5

3 2 6
A B A B

X114 X115
1 4

30 30

85 87 86 85 87 86
C1 R1 CB 1 R1

N 2.5

N 1.5
A 1.5

L 1.5
87 87

CB 1

VN 1
C1
N1
V1
A 1.5

L 1.5

V1

N 1.5 N 1.5

N 1.5 N1

N 1.5
1 2 3 4

X102 5 6 7 8

AN 1.5 AN 1.5

AN 1.5

VN 1

R1

R1
TABELLA COLORI / COLOURS TABLE
M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0006870
0.011.3610.3/20

586
 Systems 8
electrical system 84

AIR CONDITIONING FAN WIRING (HIGH VISIBILITY CAB)

1 1 2
3
3

X114

X115
F0027080

X102

F0027090

3 X117b
X117a

X116

F0028190

0.011.3610.3/20

587
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PAGINA INTENZIONALMENTE
LASCIATA BIANCA
 Systems 8
Electrical system 84

General specifications Electrical system DORADO 60 - 65(up to serial number 1111) - 70

The electrical system is fully equipped for use on the road, with sidelights, main/dipped beam headlamps, direction indi-
cators doubling as hazard warning lights, and work lights, all fully in compliance with legal requirements as embodied in
the highway code.

There are four essential components and assemblies: battery, alternator, starter motor, and auxiliaries.

The system operates at a nominal 12 Volts (the maximum voltage in operation is 14,3÷0,5 V).

The battery charge level is indicated by a relative meter on the instrument panel.

specifications

battery
type maintenance free
voltage V 12
discharge capacity over 20 hours Ah 100
rated current
for DORADO 60-70 A 440 - 470
for DORADO 65 A 450

starter motor
code voltage nominal rated power
for DORADO 60-65 (BOSCH) 2.9619.300.0/10 12 V 2,6 kW
for DORADO 60-65 (ISKRA) 2.9619.360.0 12 V 2,7 kW
for DORADO 60-65 (MARELLI) 2.9619.370.0 12 V 2,5 kW
for DORADO 70 (ISKRA) 2.9619.350.0 12 V 3 kW
for DORADO 70 (BOSCH) 2.9619.290.0/10 12 V 3 kW
for DORADO 70 (MARELLI) 2.9619.340.0 12 V 3,5 kW

electromagnetic control electro-magnetic with translation and rotation of pinion

alternator
RECHARGE SYSTEM
code 65A MARELLI 2.9439.400.0
65A ISKRA 2.9439.420.0/10
70A ISKRA 2.9439.440.0/10
85A ISKRA 2.9439.450.0/10

HEATING SYSTEM
code 65A 2.9439.480.0 (MARELLI)
2.9439.490.0 (ISKRA)
70A 2.9439.440.0/10
type three-phase
nominal rated voltage V 12
pulley nut tightening torque kgm 5,5 (62 Nm)

589
 8 Systems
84 Electrical system DORADO 60-65(up to serial number 1111) - 70

GENERAL SAFETY DIRECTIONS

PRECAUTIONS AGAINST DAMAGE TO ELECTRICAL AND ELECTRONIC EQUIPMENT

— Disconnect any electronic equipment from the system when the tractor is placed in any environment where tempe-
ratures are likely to exceed 80 °C.

— Remove battery connections when carrying out servicing or repair operations on the electrical system.

— Avoid overvoltages in the electrical system. Always remove battery and alternator connections before carrying out
welding operations or when recharging the battery from the mains.

— Never disconnect the battery while the engine is running.

— In the event that the battery needs topping up, use only distilled or demineralized water; top up only when the battery
is AT REST and at AMBIENT TEMPERATURE (allow time for cooling after operation and following recharge).

— Never carry out servicing operations on the electric heating system with the engine running.

— When washing the tractor, ensure that the alternator and starter motor are well protected. These components must
not be sprayed or splashed directly with water.

PRECAUTIONS AGAINST ACCIDENT AND INJURY

WHEN COMMENCING ANY KIND OF WORK:

— Turn off the main ignition switch.

— Disconnect the battery; remember that electric shocks discharged through the human body will damage pacema-
kers.

— The battery generates powerful and inflammable gases when recharging, which if ignited can cause the battery itself
to explode.

— Do not make temporary or makeshift connections to the battery, as these can cause dangerous sparks.

— The electrolyte in the battery is a solution of dilute sulphuric acid; if splashed on the skin, wash straight away with
plenty of water and sodium bicoarbonate.

— Seek attention immediately from a doctor if electrolyte is splashed into the eyes.

— Never allow the battery near a naked flame.

— Keep a safe distance from a recharging battery when testing or measuring, and always wear suitable eye protection.

— Make certain that the electrical system and all its components are inspected and serviced periodically; any faults
must be eliminated without delay, and parts subject to everyday wear replaced at the recommended intervals.

— Ensure that trailers are fitted with regulation lights.

IMPORTANT REMINDERS
The maker declines all liability in respect of any damages resulting from operations performed other than in the recom-
mended manner and/or by unskilled hands.

— To ensure smooth operation of the machine, use only genuine replacement parts.

590
 Systems 8
DORADO 60-65 (up to serial number 1111) - 70 Electrical system 84

JUMP START UTILIZING ANOTHER BATTERY

NB: Emergency starting with the aid of a battery charger is not recommended.

PRECAUTIONS
The battery may be that of another tractor, but must in any event have the same rated voltage (and therefore an identical
number of cells).

1 - Make certain the two vehicles are not in contact with one another.

2 - Ensure that all auxiliary services are switched off.

3 - Make certain the flat battery is securely connected to earth, that the filler caps are properly tightened and that the
electrolyte is up to the correct level.

PROCEDURE:
A - Connect the two batteries as indicated in figure 1 (part A).

B - If the jump battery is that of another tractor, start the engine and run at approximately 1/4 of full throttle.

C - Turn the ignition key to start the engine of the stranded tractor, following the procedure given in the operator’s
handbook.
D - Remove the jump leads following the sequence as indicated in figure 1 (part B).

A - connection of leads to the 2 batteries B - disconnection of leads from the 2 batteries

Separate connected batter.

Batteries

STEP 1 STEP 4

STEP 5

STEP 2

STEP 6

STEP 3

connected batteries separate batteries

Fig. 1 - Diagram of battery connections and relative leads.

591
 8 Systems
84 Electrical system

PRACTICAL HINTS

Before installing a battery, and periodically thereafter:

— Check over the electrical system, giving particular attention to connections; make certain there are no traces of oxi-
dation and that there is no loss of current.
— Check the alternator and the voltage regulator setting. If the charging voltage is inordinately high, distilled water will
be consumed at a high rate, whereas a low voltage will not charge the battery sufficiently.
— Check the charge level of a new battery with a density indicator or voltmeter; if the density is less than 1.25 kg/l or the
no-load voltage after at least 3 - 4 hours at rest is lower than 12.5 V, proceed to recharge.
Install the battery in the machine with care, utilizing the anchorages provided.

When connecting the battery to the system:

— secure the clamp.
— before connecting the negative, make certain there is no sparking on contact with the corresponding terminal of the
battery. Sparks are due to insulation defects that must be located and eliminated.
— Tighten the clamps on the terminals, smearing with petroleum jelly.

TABELLA DEI CODICI DEI COLORI DEI FILI ELETTRICI

BK =BLACK ESEMPIO:
BL=BLUE
BR=BROWN DK BL/WH 1 680
DK BL=BLACK/BLUE
DK GN=BLACK/GREEN DK BL/WH = DARK BLUE WITH WHITE LINE
GN=GREEN
GY=GREY 1 = CROSS SECTION OF WIRE (mm)
OR=ORANGE 680 = LENGTH OF WIRE (mm)
PK=PINK
RD=RED
VL=VIOLET
WH=WHITE
YL=YELLOW

EXAMPLE OF CONNECTORS (CAN BE 4-PIN, 6-PIN OR 8-PIN)

592
 Systems 8
DORADO 60-65(up to serial number 1111) - 70 Electrical system 84

RECHARGE SYSTEM

65A ALTERNATOR

code 2.9439.400.0 Marelli

code 2.9439.420.0/10 Iskra

HEATING SYSTEM

85A ALTERNATOR

ISKRA 15V 85A

code 2.9439.450.0

HEATING SYSTEM

65A ALTERNATOR

M ARELLI 12V 65A

code 2.9439.480.0

593
 8 Systems
84 Electrical system DORADO 60-65
- (up to serial number 1111)-70

HEATING SYSTEM

65A ALTERNATOR

ISKRA AAK1228 12V 65A

code 2.9439.490.0

HEATING AND
CONDITIONING SYSTEM

70A ALTERNATOR

ISKRA AAK5112 12V 70A

code 2.9439.440.0/10

STARTING SYSTEM

ISKRA
code 2.9619. 350.0 for 70 CV
2.9619. 360.0 for 60-65 CV

MARELLI
code 2.9619. 340.0 for 70 CV
2.9619. 370.0 for 60-65 CV

BOSCH
code 2.9619.290.0/10 for 70 CV
2.9619.300.0/10 for 60-65 CV

594
 Systems 8
DORADO 60-65 (up to serial number 1111) - 70 Electrical system 84

Fig. 2 - Check panel with digital display

Ignition switch

Electtrical system deenergized - key removable

(On version with electronic RPM control, the engine shuts off automatically;
On versio with machanical throttle linkage, the engine is stopped by pulling the knob on the right of the in-
strument panel).

Active electric circyit: - Lamps indicating operation of the alternator and low engine oil pressure light up on
the instrument panel. A lamp indicating pre-heating lights up when ambient temperature is below 10°C; wait
until the lamp has gone out (approx. 55 seconds) before turning the key to the next position. If the ignition
key is turned to the start position with the thermostart indicator still alight, the heater cuts out and power is
supplied to the starter motor.

Engine starting

595
 8 Systems
84 Electrical system DORADO 60-65(up to serial number 1111) - 70

IGNITION KEY
code 2.7659.127.0

VENTILATION CONTROL
code 009.4743.1
for tractors equipped with
standard cab

PUSH BUTTON CONTROL

code 2.7659.110.0

HAZARD WARNING LIGHTS

596
 Systems 8
DORADO 60-65(up to serial number 1111) - 70 Electrical system 84

PUSH BUTTON CONTROL

P.T.O. CLUTCH
code 2.7659.108.0/10
code 2.7659.142.0 rear P.T.O.
with dual power system
code 2.7659.177.0/10

DIFFERENTIAL LOCK
code 008.1335.0

4WD COUPLER
code 007.5945.0/20

2-SPEED WINDSCREEN
WIPER SWITCH

code 2.7659.092.0 for 60-70 CV

code 2.7659.146.0 for 65 CV

597
 8 Systems
84 Electrical system DORADO 60-65(up to serial number 1111) - 70

WORK LIGHTS

FRONT
code 2.7659.078.0

REAR
code 2.7659.079.0

SCREEN WASHER SWITCH

FRONT
code 2.7659.145.0

FRONT
code 2.7659.146.0

BEACON PUSH BUTTON

code 2.7659.126.0

598
 Systems 8
DORADO 60-65 (up to serial number 1111) - 70 Electrical system 84

RELAY

code 010.2089.2

ELECTRONIC FLASHER UNIT

Schema-funzionale
code 2.8639.007.0 Functional diagram
C C2 C3 49a

SCHEMA DI COLLEGAMENTO
31 49
WIRING DIAGRAM
Spie
warning lights
Motrice Rimorchio 1 Rimorchio 2
Tractor Trailer trailer

1
C C2 C3 49a 0
31
49a
destra
right

R interruttore degli
G L indicatori di direzione
49a side lamps
switch
sinistra

49
left

15 30

31 49
15/49 30

lampeggiatore di interruttore per

direzione e d'emergenza lampegg.d'emmergenza
TB83
BLINKGEBR direction and emergency
flasher
emergency
main switch
4DN 006 208-01
12V21W2+1+1(8)P
Made In Germany
lampade motrice
tractor lamps
A 71458

49 C 49a
lampade rimorchio 1
C3 C2 31
trailer 1 lamps

lampade rimorchio 2
trailer 2 lamps

599
 8 Systems
84 Electrical system DORADO 60-65(up to serial number 1111) - 70

INTERIOR ROOF LIGHT code 2.8339.032.0

SWITCH CONTROLLING: differential lock - 4RM - 540 1000 rpm/min P.T.O. speed selector -
Economy P.T.O. - Live P.t.o. - electric starter system.

code 2.7659.097.0

SWITCH FOR EMERGENCY BRAKE code 2.7659.501.0

600
 Systems 8
DORADO 60-65(up to serial number 1111) - 70 Electrical system 84

Fuse box

Tractor fuse box

F1 - Key
F2 - Thermostart
F3 - Side/tail lights - horn
F4 - Hazard warning lights
F5 - Work light - 12 V socket
F6 - Engine ECU
F7 - Check panel
F8 - Engine RPM control unit
F9 - Engine STOP
F10 - Flashers
Tractor fuse box with electronic governor F11 - Side/tail lights
F12 - Side/tail lights
F13 - Cigar lighter
F14 - Dipped beam
F15 - Main beam
F16 - Glowplug
F17 - Starter key
F18 - Keyswitch/engine stop/ direction
indicators/engine control unit
F19 - Termostarter solenoid valve
F20 - Thermostart/panel/HML

Tractor fuse box without electronic governor

Cab fuse box

F1 - Flasher unit
F2 - Radio
F3 - Air conditioning
F4 - Blower/heater
F5 - Front wiper
F6 - Rear wiper
F7 - Front work lights
F8 - Rear work lights

Cab fuse box

601
 8 Systems
84 Electrical system DORADO 60-65(up to serial number 1111) - 70

Instrument panel with digital display

The basic panel is the same as described above, except that the dial is replaced by a 4-digit display showing:

— Lapsed time (hours)

— Ground speed (speedometer)
— P.T.O. speed
— Trip meter (distance in metres)

There are also 4 high brightness Leds which indicate the function currently being displayed.
Any specifications not individually listed below will be the same as for the basic panel.

Operation
The selection and content of the functions displayed are governed by pressing buttons, denoted P1, P2 and P3.

Button P1 - Red - Positioned to right of panel.

Button P2 - Red - Positioned to right of panel.
Button P3 - Red - Positioned near fuse box (cover must be removed to gain access).

Auxiliary electrical systems on (turn the ignition key to position ) the current total of working hours lapsed will be
displayed.

Then, turn the ignition key to position , when the engine is started, the display sets itself to indicate ground speed
(speedometer).

To display a function other than ground speed, simply press P1 repeatedly to select the function required.

1 - Lapsed work time indicated by 4 digits, to the nearest hour.

2 - Ground speed indicated by 3 digits, one of which after the decimal point (XX.X), in km/h. In the event that bigger or
smaller rear tyres are fitted, the new size must be entered (see directions point 5 page 373).

602
 Systems 8
DORADO 60-65(uptoserialnumber1111) - 70 Electrical system 84

IMPORTANT: If a function other than speedometer is currently selected, the panel will revert automatically to displa-
ying ground speed if 20 km/h is exceeded.

3 - P.T.O. speed is indicated by 4 digits (XXX0), in revolutions per minute.

4 - The trip meter uses 4 digits (XXXX), indicating the distance covered by the tractor in metres. The trip meter can be
reset; this is done by selecting the function then pressing and holding P2 for at least 3 seconds, during which time the fi-
gures will blink before returning to zero. If P2 is released before the 3 seconds have passed, there will be no reset.

5 - Entering the speed constant according to the tyre size.

This operation becomes necessary only if the rear tyres are replaced with others of a different size.

With the engine at standstill and the ignition key in the off position , press and hold button P3 while turning the key

to the auxiliary position (without starting the engine), then release the button only when the tyre code appears in
the display. This code will correspond to the type of rear tyre currently fitted.
Now press button P1 repeatedly to view the permissible tyre sizes, which will be displayed in sequence.
When the size displayed matches that of the new tyres, press P3 again to memorize.
If the key is returned to the off position without completing this last step, the tyre size code will not be updated.
Listed below are the tyre options specified for the tractor. Each size has a relative display code which corresponds to the
number of impulses per 100 metres picked up by the speedometer sensor.

Tyre Impulses for 100 metres

480/65 x 28
14.9 x 32 1100
14.9 x 28
14.9 x 30 1058
420/70/30
16.9 x 28
1050 A - Button P 1, used to select the fun-
480/70/28 ction displayed - Colour red.
540/65 x 28 The 3 available functions (speedometer,
12.4 x 36 1020 P.T.O. speed, trip meter) are displayed
540/65 x 30 cyclically by pressing P1 repeatedly.
1050 The function selected is indicated by a relati-
16.9 x 30
ve Led on the instrument panel.
480/70/30
13.6 x 28 1153 B - Button P 2, used to reset the function
380/70/28 selected - Colour red
420/70/24 1192 Press this to select another function.
14.9 x 24
13.6. X 36 984

1 Diagnostics socket (on version with electronic RPM control only)

-

2 Tyre size selection button (on version with the Instrument panel
-

with digital display)

603
 8 Systems
84 Electrical system DORADO 60-65(up to serial number 1111) - 70

Operation of the broken belts alarm control unit

IMPORTANT: (for tractors equipped with air conditioning) if the engine fan belt breaks:
a safety device will activate the emergency warning light on the dashboard (red triangle) and a warning buzzer will so-
und;

(on tractors also equipped with electronic governors) with the handbrake on, the engine will also stop.
This control unit allows the operator to leave the tractor with the engine running.

The control unit acquires signals from the sensors and generates alarm conditions and may also stop the engine when
necessary.

control unit connections

INPUTS
- engine oil pressure NOTE: the auxiliary input is optional. If it is not to be utilised,
- alternator d+ leave the relative contact on the control unit free. This input
- broken fanbelt sensor can be connected to a relay which connects the signal to
- auxiliary input earth in the event an alarm.
handbrake

OUTPUTS
- control signal for engine oil pressure warning light
- engine stop control signal
- buzzer

Input and output operation

Inputs
Input D+ serves two functions:
- alarms control enabling
- alarms.
When the engine is switched off, this signal is low to illuminate the alternator warning light. The control unit considers
the signal status low when it is below 3 volts. On starting the engine, this signal goes to +12 volts. If the signal voltage re-
mains high (+12V) for 7 seconds, the control unit is enabled to check for alarm conditions.
Once the alarm check has started, this input becomes itself a potential cause of an alarm; an alarm will be generated if
the +12V is absent for at least 2 seconds.
If the alternator is faulty, the signal D+ will never be activated and consequently control unit operation will not be initiated.

The broken fanbelt input is connected to a sensor on the cooling fan on air-cooled engines.
The broken fanbelt alarm is activated when a frequency below 10 Hz ( 10 pulses/second) is detected on the input.

The oil pressure input is considered activated when it is low (earth) for at least 2 seconds, and deactivated when it stays
high (12V) for the same duration.

The auxiliary input is considered activated when it remains low (earth) for at least 2 seconds, and deactivated when it
stays high (12V) for the same duration.

The handbrake input is used by the control unit to determine the type of output in the event of an alarm condition.

Outputs
The engine stop command output is activated when one off the alarm inputs is activated while the handbrake is on. The
control unit is capable of determining if this output is connected or not.

The engine oil pressure warning light is used to generate a diagnostic code if the alarm is activated when the handbrake
is released.

If the alarm is caused by the absence of engine pressure, the warning light will illuminate steadily.

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DORADO 60-65(up to serial number 1111) - 70 Electrical system 84

The buzzer is used to alert the operator to the status of the control unit.
The buzzer emits three different signals:
- two short acoustic signals (0.3 seconds) each time the handbrake is released to indicate that the control unit is in
alarm signalling condition (diagnostic code on oil pressure warning light) but without generating the engine stop output.
- one long acoustic signal (1 second) each time the handbrake is applied to indicate that the control unit will activate the
engine stop output in the event of an alarm.
- intermittent signal ( 3 Hz) to signal that the control unit has activated the engine stop output.

OPERATION
The control unit only operates after the engine has been started. The control unit uses the D+ signal of the alternator to
determine whether the engine is running.
This signal must stay at high voltage for a duration of 7 seconds before control unit operation is initiated.
If there is an alternator fault (signalled by the alternator warning light staying on when the engine is started), control unit
operation will not be initiated.
The start of control unit operation is signalled by an acoustic signal which will depend on the handbrake status:

- two short acoustic signals (approx. 0.3 sec) id the handbrake is released.

- one long signal (1 sec.) if the handbrake is on.

At this point, the control unit will monitor the status of the broken fanbelt input, the oil pressure input, the auxiliary input
and the D+ input.

If one of these inputs is activated, the control unit will signal an alarm.
There are two levels of alarm:

Level 1 alarm - handbrake released.

Level 1 alarm monitoring is activated when the handbrake is released, and is signalled by two short acoustic signals
(0.3 seconds).
If the handbrake is not on:

- and the fanbelt is broken, the engine oil pressure warning light will flash with diagnostic code 2.

- and the auxiliary input is activated, the engine oil pressure warning light will flash with diagnostic code 4.

- and the D+ input voltage is low (earth), the engine oil pressure warning light will flash with diagnostic code 3.

- and the oil pressure is low, the engine oil pressure warning light will illuminate steadily (controlled by the pressure
switch).

The warning light will stop flashing the moment the alarm condition ceases to exist.

Level 2 alarm 2 - handbrake on.

Level 2 alarm monitoring is activated when the handbrake is applied, and is signalled by a long acoustic signal (1 se-
cond).

If the handbrake is on:

- and any alarm is activated, the control unit will generate the ENGINE STOP signal. Consequently the engine oil pres-
sure warning light will be steadily illuminated (as when the engine is stopped, the oil pressure will fall and thus the war-
ning light will come on) unless there is no connection between the control unit and the engine stop device.
The control unit will signal the ENGINE STOP condition with an intermittent acoustic signal (approx. 3 signals per se-
cond).

To deactivate the ENGINE STOP, switch off and then restart the engine.

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84 Electrical system DORADO 60-65(up to serial number 1111) - 70

ENGINE STOP DEVICES

The alarm control unit can generate an output signal to control a device which stops the engine.
The alarm control unit output can be connected to an engine control unit type 2MH (manufacturer’s code for control unit
with 26 contact connector) and is also capable of operating a relay with currents up to 250mA.

ENGINE STOP OPERATION WITH A TYPE 2MH ENGINE CONTROL UNIT

The operation of the engine control unit in the presence of a STOP signal is very simple.

The control unit starts to monitor the STOP signal 2 seconds after the engine has been started, i.e. when it has attained idling
speed.

The control unit checks for a STOP signal which remains active for at least 1 second.

On detection of a STOP signal, the control unit switches off the engine.

The engine control unit signals operation of the engine stop by 7 flashes of the HOLD led on the keypad.

The engine control unit will ignore the STOP signal if the engine is switched off. For example, if the engine stalls (under
excessive load), a STOP signal may be generated but it will be ignored.

Using the ALL ROUND TESTER it is possible to check that the STOP signal is connected correctly.
One of the following messages will also appear on the monitor:

1) STOP NOT CONNECTED

2) STOP CONNECTED
3) STOP ACTIVE

On models equipped with STOP control units, the valid messages are nos. 2 and 3. Should message no. 1 “STOP NOT
CONNECTED” appear, check the connection between pin 5 of the alarm control unit and pin 11 of the engine control
unit.

If none of the above messages appears, this means that the engine control unit does not have the correct program.

DIAGNOSTICS

To enable the operator to identify the problem which caused the intervention of the engine stop, the control unit provides
a diagnostic code by means of the oil pressure warning light, but only when the handbrake is released.
The diagnostic code is only given after the engine has been re-started and the control unit has given the first acoustic si-
gnal, typically 7 seconds after the alternator warning light goes out.
The diagnostic code consists of a series of flashes each with a duration of 0.3 seconds at 1 second intervals.
The oil pressure input does not provide a diagnostic code as the illumination of the warning light is forced by the pressu-
re switch.

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DORADO 60-65(up to serial number 1111) - 70 Electrical system 84

Diagnostic codes

Below is a list of the diagnostic codes and their meanings:

flashes

WARNING LIGHT

2 Broken fanbelt sensor

3 Alternator signal D+
4 Auxiliary input
5 Engine STOP output

example of code 2

ON

OFF

Description of faults

This chapter provides useful information for fault tracing.

Code 2 - Broken fanbelt sensor

This fault is signalled when the input signal from the fanbelt sensor fails to arrive at the control unit.
If this fault occurs :
- Check that the battery voltage is present between pins 1 and 2 of the sensor connector.
- Check that pin 3 of the sensor connector is connected to pin 6 of the alarm control unit.

Code 3 - Alternator signal D+

This fault is signalled when the alternator signal D+ is no longer present after the alarm control unit has entered into
operation.
If this fault occurs:
- Check the alternator warning light: if on, the problem concerns the alternator itself; if off, the wire carrying the signal to
the control unit may have come disconnected.

Code 4 - Auxiliary input

This fault is signalled when the voltage on pin 8 of the control unit falls below 12V.
This input is not currently utilised, consequently if this fault is signalled, check that pin 8 of the control unit is at +12V. If
necessary, remove the contact from the connector and test again.

Code 5 - Engine STOP output

This fault is signalled when the control unit does not detect any connection to its STOP output.
If this fault occurs:
- Check that pin 5 of the alarm control unit is connected to pin 11of the engine control unit.

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84 Electrical system DORADO 60-65(up to serial number 1111) - 70

Broken belt alarm system and diagnostic codes. (If the light stays on continuously this indicates low engine oil pressure).

A - Alternator H - Electro stop

B - Engine oil pressure I - Connection for engines with electronic governor
C - Fan pick-up L - Diagnostic codes
D - Brake fluid level M - N* of flashes
E - Handbrake 2 - Broken belt sensor
F - Alarm control unit 3 - Alternator signal
G - Engine control unit 5 - Engine stop output

608
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DORADO 60-65(up to serial number 1111) - 70 Electrical system 84

ELECTRICAL WIRING for tractors DORADO 60 - 65 (1st version) - 70

TRACTOR ELECTRICAL SYSTEM DIAGRAM

KEY TO ELECTRICAL SYSTEM DIAGRAM

TRACTOR WIRING

COMPLETE CENTRAL UNDERBODY WIRING 009.7622.4

SIMPLE CENTRAL UNDERBODY WIRING 009.7623.4

COMPLETE FRONT WIRING 009.7624.4

BATTERY WIRING, 3-CYLINDER 009.7625.3

BATTERY WIRING, 4-CYLINDER 009.7849.3

AGROSHIFT CONTROL UNIT WIRING 009.7627.3

AGROSHIFT CONTROL WIRING 009.7855.3

CAB WIRING

CAB WIRING DIAGRAM

CENTRAL WIRING 009.7850.4

CLIMATE CONTROL SYSTEM WIRING

WORK LIGHTS - SCREEN WIPER - ROTATING LIGHTWIRING 009.7851.4

AIR CONDITIONING SYSTEM WIRING 009.7853.3

AIR HEATING WIRING 009.7852.3

SCREENWASH PUMPS WIRING 009.7854.3

FRONT SCREEN WIPER WIRING 010.4516.3

CAB POWER SUPPLY WIRING 010.1359.3

FUEL LEVEL SENDER 2.7059.730.0

609
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84 Electrical system DORADO 60-65(up to serial number 1111) - 70

PAGE INTENTIONALLY
LEFT BLANK

610
 APPENDIX

ENGINE ELECTRONIC CONTROL UNIT

POWER LIFT TESTER

 Appendix
Engine electronic control unit

ENGINE ELECTRONIC CONTROL UNIT

I
 Appendix
Engine electronic control unit

Engine electronic control unit

TESTER manual

CONTENTS

Presentation screen...............................................................................................................................III

Functional diagram................................................................................................................................IV

1 Main Menu ..........................................................................................................................................V

1 Engine menu ......................................................................................................................................VI

1 Configuration .................................................................................................................................VII
1 Engine type ...............................................................................................................................VIII
2 Hand throttle calibration ...............................................................................................................X
3 Accelerator pedal calibration .......................................................................................................XI
4 Idle speed calibration .................................................................................................................XII
2 Calibration....................................................................................................................................XIV
3 Monitor ..........................................................................................................................................XV

2 HML menu .......................................................................................................................................XVI

1 Configuration ...............................................................................................................................XVII
2 Tests ..........................................................................................................................................XVIII
3 Monitor ..........................................................................................................................................XX

3 Preheating menu .............................................................................................................................XXI

1 Configuration ...............................................................................................................................XXII
2 Tests ..........................................................................................................................................XXIV
3 Monitor.......................................................................................................................................XXVI

4 Alarms menu ................................................................................................................................XXVII

1 Initialisation ..............................................................................................................................XXVIII
2 Monitor........................................................................................................................................XXX

5 Belts control system menu ............................................................................................................XXXI

1 Configuration ............................................................................................................................XXXII
2 Tests ........................................................................................................................................XXXIII
3 Monitor ....................................................................................................................................XXXIV

6 Wheels menu (maximum speed limiting system).........................................................................XXXV

1 Configuration ...........................................................................................................................XXXVI
2 Monitor ..................................................................................................................................XXXVIII

7 P.T.O. menu................................................................................................................................XXXIX
1 Calibration .....................................................................................................................................XL
2 Tests .............................................................................................................................................XLI
3 Monitor.........................................................................................................................................XLII

Engine Type/Wheels Constant tables ...............................................................................................XLIII

Alarms list .........................................................................................................................................XLIV

II
 Appendix
Engine electronic control unit

Scope

The scope of this document is:

— To present the diagnostic information that can be accessed through the All Round Tester (ART®)

— To list the alarm conditions that the electronic control unit is able to diagnose, along with the possible causes of the alarms and the relative actions of the electronic control unit.

Electronic Controller

Engine Speed Control, Pre-Heating, Belt alarm, HML, PTO

46 47 33 10 37 6 28 5 22 12 11 3 43 36 67 8 35 9 66 64 62 63 58 65 56 68 57 59 60 61 44 45 24 25 53 52 54 55 29 27 21
Actuator +

Engine Speed Output

Engine Speed Frequency

Engine Temperature

Engine Temperature Out PWM

Low Engine Oil Pressure

Sensors GND

Wheel speed input

Glow Plug presence

Pre-Heating Glow-Plug
Engine Belt Frequency

PTO auto

Common HML
Actuator -

+5Vcc OUT

Pre-Heating Lamp Out

GND
Lamp M

+VCC
+VCC
GND
Rear Lift Position (On/Off)

Lamp HOLD
PTO
Hand Gas Position
Dual Power Slection

Belt alarm lamp

HML Dwn
Vpp

Hand brake
Memory Hold

HML Up

Electrovalve presence

Electrovalve L
PTO Selection

Pre-Heating electrovalve

RxD

Alarm Output Code

Electronic PTO

TxD
Throttle Pedal Position

Electrovalve H
4 3 4 33
12V 12V
1.2W 1.2W

12V 12V
1.2W 1.2W

Relay Relay

12V 12V
1.2W 1.2W
+ -
Battery

1 2 1 2 2 1 4 2 1 4 1 2 3 1 2 3 1 2 - + S 1 2 1 2
M F V V F F
F F F
t
Fuel Pumps Engine Speed Hand Throttle Engine belt Wheel speed Engine Teperature To Pre-Heating To Pre-Heating
Actuator Ev H Ev L
Sensor Gas Pedal speed sensor sensor Temperature Instrument electrovalve Glow plug

ELECTRONIC CONTROL UNIT

46 - actuator+ 47 - actuator - 33 - sensor GND 10 - engine speed frequency 37 - dual power selection 6 - hand throttle position 28 - 5Vdc OUT
5 - accelerator pedal position 22 - engine speed output 12 - belts rotation frequency 11 - engine speed input 3 - engine temperature input 43 - engine temperature OUT PWM
36 - P.T.O. selection 67 - memorised engine speed

III
 Appendix
Engine electronic control unit

Presentation screen
The presentation screen displays preliminary information about the electronic control unit:

— Software version
— Date of software issue

The screen appears as follows:

E n g i n e
= = = = = = = = = = = = = = = =

V e r s i o n :

D A T E
- T Y P E : ( )

- E N G :

- H B : - P L :

= = = = = = = = = = = = = = = =
P R E S S A N Y K E Y

Where:

Version: software version

Date: date of software issue
Type: engine table
Eng: type of engine installed on tractor
HB: hardware batch
PL: production launch

IV
 Appendix
Engine electronic control unit

Main Menu

From this menu you can select the component on which diagnosis is to be performed or display the general list of alarms
detected up until that point.

M A I N M E N U

1 E N G I N E
2 H M L
3 P R E H E A T I N G
4 A L A R M S
5 B E L T S
6 W H E E L S
7 P T O

S E L E C T

E E X I T

By selecting one of these options you access the menus described in the following pages.

V
 Appendix
Engine electronic control unit

Engine menu

From this menu you can check the operation of the engine.

E N G I N E

1 C O N F I G U R A T I O N

2 C A L I B R A T I O N

3 M O N I T O R

S E L E C T

E E X I T

The various functions are described below.

VI
 Appendix
Engine electronic control unit

Engine menu

Configuration menu

From this menu you can configure and calibrate the following parameters:
1 engine type
2 hand throttle calibration
3 accelerator pedal calibration
4 idle speed calibration

The following menu is displayed on the ART.

C O N F I G U R A T I O N

1 E N G I N E T Y P E

2 H A N D T H R O T . C A

3 A C C . P E D . C A L .

4 I D L E S P E E D C A L

S E L E C T

E E X I T

The various functions are described below.

VII
 Appendix
Engine electronic control unit

Engine menu

Configuration menu

Engine type

This screen p. lists all the possible engine types that can be controlled by the ECU. The operator should select the type
of engine installed on the tractor.

E N G I N E T Y P E

1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 -
0 - O T H E R

S E L E C T

E E X I T

VIII
 Appendix
Engine electronic control unit

Once you have selected the engine type, the program automatically displays the parameters menu which contains the
parameters stored in memory for the selected engine type:

P R O G R A M M I N G

- E N G
E N G I N E T Y P E

M I N . R P M X X X X
M A X . R P M X X X X
D R O O P X X X
M I N . C U R R E N T X X X X

C C O N F I R M

E E X I T

Pressing “C” him confirmation the type of selected engine.

IX
 Appendix
Engine electronic control unit

Engine menu

Configuration menu

Hand throttle calibration

In this menu you can calibrate the potentiometer of the hand throttle.

The following menu is displayed on the ART:

H A N D T H R O T . C A L .

V A L U E :
X X X X m V

C A L I B . P O S I T I O N :
M I N : X X X X m V
M A X : X X X X m V
P O S I T I O N T H E
L E V E R

B P A R A M E T E R
C C O N F I R M

E E X I T

This screen displays the following values:

. Value potentiometer voltage in mV

To calibrate the potentiometer, proceed as follows:

1- Press B to select the parameter you wish to calibrate:

. minimum position
. maximum position

the value in mV corresponding to the selected position will be highlighted in reverse video.

2- Move the hand throttle to the correct position, as instructed on the screen.

Press "C" to save the value in memory.

X
 Appendix
Engine electronic control unit

Engine menu

Configuration menu

Accelerator pedal calibration

In this menu you can calibrate the potentiometer of the of the accelerator pedal.

The following menu is displayed on the ART:

A C C . P E D A L C A L .

V A L U E :
X X X X M V

C A L I B . P O S I T I O N
M I N : X X X X M V
M A X : X X X X M V
P O S I T I O N T H E
L E V E R

B P A R A M E T E R
C C O N F I R M

E E X I T

This screen displays the following values:

. Value Potentiometer voltage in mV

To calibrate the potentiometer, proceed as follows:

1 Press B to select the parameter you wish to calibrate:

. minimum position
. maximum position

the value in mV corresponding to the selected position will be highlighted in reverse video.

2 Move the accelerator pedal to the correct position, as instructed on the screen.
Press "C" to save the value in memory.

XI
 Appendix
Engine electronic control unit

Engine menu

Configuration menu

Idle speed calibration

In this menu you can calibrate the engine idle speed.

The following menu is displayed on the ART:

I D L E S P E E D
- D E A C T I V A T E
C O N T R O L V A L U E S
- S W I T C H O F F C A B
V E N T I L A T I O N
- E N G I N E O I L T E M P
7 0 / 7 8
C C O N F I R M
- - - - - - M O N I T O R - - -

E N G I N E R P M X
R P M D I F F . X X X X

E E X I T

Where:

Engine rpm rpm detected by engine speed sensor

Rpm diff. Difference between required rpm and actual rpm

This operation, as indicated on the ART screen, must be carried out with the engine in no-load condition, i.e. without hy-
draulic or electrical loads.

XII
 Appendix
Engine electronic control unit

Calibration procedure:

1 Wait until the rpm difference value stabilises.

2 Press "C" on the ART to save the value in EEprom.
3 There are three possible outcomes:

Parameter correctly programmed: the ART displays the following message:

P A R A M E T E R
P R O G R A M M E D

If the rpm difference exceeds 40, the following message is displayed:

R P M D I F F . > 4 0

To repeat the operation and if condition persists is necessary to intervene on the motor (pomps, excessive frictions
etc...)

If the electronic control unit has problems writing to the EEprom, the calibration operation is not performed and the
following message is displayed:

E e P R O M F A U L T

To replace the electronic unity

XIII
 Appendix
Engine electronic control unit

Engine menu

Calibration calibration

In this menu you can calibrate the operating parameters of the Engine Governor.

The following menu is displayed on the ART:

C A L I B R A T I O N
W I T H E N G . R U N N I N G

1 M I N . R P M
2 M I N . C U R R .
3 D R O O P

A D E F A U L T V A L U E
F I N C R E A S E V A L U E
D D E C R E A S E V A L U E
B S E L E C T P A R A M .
C C O N F I R M

E E X I T

Once an engine type has been saved in memory, it is possible to permanently modify certain parameters.

Min. rpm: minimum engine speed

Min. curr: current supplied to actuator to maintain engine rotation

Droop: parameter that regulates variations in engine speed according to the load

The selected parameter is highlighted in reverse video. Press "B" to scroll through the parameters. Press "F" or "D" to
respectively increase or decrease the value of the selected parameter. Press "A" to restore the default factory-set value
for the selected parameter.

The ART may display the following messages:

P A R A M E T E R
P R O G R A M M E D

XIV
 Appendix
Engine electronic control unit

Engine menu

Monitor menu

From this menu you can monitor the operating parameters of the engine governor.

The following menu is displayed on the ART:

M O N I T O R
E N G I N E T Y P E
M I N . R P M
M A X . R P M
M I N . C U R R .
M A X . C U R R .
D R O O P

A C T U A L R P M
A C T U A T O R I
A C C . P E D A L
E N G . T E M P .

B A T T E R Y m V

E E X I T

Where:
Engine type engine type code
Min rpm Minimum engine speed given in engine characteristics table
Max rpm Maximum engine speed given in engine characteristics table
Min. Curr.. Current supplied to actuator to maintain engine at idle speed
MAX. CURR.. Maximum engine electronic control unit current (factory setting)
Droop parameter that regulates variations in engine speed according to the load
Actual rpm Actual engine speed
Actuator I Current supplied to actuator
Acc. Pedal. Position of accelerator pedal
Eng. Temp. Engine temperature
Battery Battery voltage

XV
 Appendix
Engine electronic control unit

HML menu

From this menu you can

configure
test
monitor
the HML clutches control system.

The following menu is displayed on the ART:

H M L

1 C O N F I G U R A T I O N

2 T E S T S

3 M O N I T O R

S E L E C T

E E X I T

The various submenus are described below.

XVI
 Appendix
Engine electronic control unit

HML menu

Configuration menu

From this menu you can configure the HML control.

The following menu is displayed on the ART:

H M L C O N F I G .

H M L C O N T R O L E N A B

B - P A R A M .
F - I N C R . D - D E C R .
C C O N F I R M
S E L E C T

E E X I T

Press "B" to select the HML configuration parameter:

H M L C O N T R O L E N A B

press "F" or "D" to enable or disable the HML function

H M L C O N T R O L D I S A B

To confirm and save the new configuration, press "C".

XVII
 Appendix
Engine electronic control unit

HML menu

Tests menu

From this menu you can test the operation of the HML system.

The following menu is displayed on the ART:

T E S T S

U P P B O F F
D O W N P B O F F

1 H S V m A
2 L SV m A
3 M L A M P O F F

E E X I T

The following components of the HML system may be tested directly:

UP pushbutton Press this pushbutton to test the electrical continuity and mechanical
integrity of the pushbutton.

With pushbutton on joystick pressed:

U P P B O N

With pushbutton released

U P P B O F F

XVIII
 Appendix
Engine electronic control unit

DOWN pushbutton Press this pushbutton to test the electrical continuity

and mechanical integrity of the pushbutton.
With pushbutton on joystick pressed:

D O W N P B O N

With pushbutton released

D O W N P B O F F

Ev H. H clutch solenoid valve

By pressing "1" on the ART you can energise or de-energise the solenoid valve of the H clutch.
The ART display is as follows:

Solenoid energised

1 E v H X X X X m A

Solenoid de-energised

1 E v H m A

Ev L. L clutch solenoid valve

By pressing "2" on the ART you can energise or de-energise the solenoid valve of the L clutch.
The ART display is as follows:

Solenoid energised

21 E v L X X X X m A

Solenoid de-energised

2 E v L m A

M lamp M clutch indicator lamp

by pressing "3" on the ART you can test the operation of the M clutch indicator lamp

XIX
 Appendix
Engine electronic control unit

HML menu

Monitor menu

From this menu you can monitor the operating status of the HML system.

The following menu is displayed on the ART:

M O N I T O R

U P P B O F F
D O W N P B O F F

H S V m A
L S V m A
M L A M P O F F

E E X I T

The screen is similar to that described in the previous paragraph, the sole difference being that this menu does not pro-
vide the possibility to control the solenoid valves.

This screen displays the operating status of the HML system components.

XX
 Appendix
Engine electronic control unit

Preheating menu

From this menu you can

· configure
· test
· monitor

the preheating system.

The following menu is displayed on the ART:

P R E H E A T I N G

1 C O N F I G U R A T I O N

2 T E S T S

3 M O N I T O R

S E L E C T

E E X I T

The various submenus are described below.

XXI
 Appendix
Engine electronic control unit

Preheating menu

Configuration menu

From this menu you can configure the preheating function.

The following menu is displayed on the ART:

P R E H E A T . C O N F I G .

T H E R M O S T A R T E N A B

E N G I N E W A T E R

B - P A R A M .
F - I N C R . D - D E C R .
C C O N F I R M
S E L E C T

E E X I T

Thermostarter configuration.

Press "B" to select the thermostarter configuration parameter:

T H E R M O S T A R T E N A B

press "F" or "D" to enable or disable the function

T H E R M O S T A R T D I S .

To confirm and save the new configuration, press "C".

XXII
 Appendix
Engine electronic control unit

Engine cooling configuration

The type of engine cooling (water or air) determines the type of sensor used to measure the engine temperature.

Press "B" to select the engine cooling configuration parameter. The ART screen appears as follows:

E N G I N E W A T E R

press "F" or "D" to change the cooling type

E N G I N E A I R

XXIII
 Appendix
Engine electronic control unit

Preheating menu

Tests menu

From this menu you can test the operation of the preheating system.

The following menu is displayed on the ART:

P R E H E A T I N G
T E S T S

T E M P . S E N S . C
1 G L O W P L U G R . O F F
2 P R E H E A T . S V . O F F
3 P R E H E A T . L . O F F

T E S T S
A W I T H E N G I N E
O F F

E E X I T

The various functions are described below:

Temp. Sens. engine temperature expressed in degrees centigrade

Glowplug rel. directly controls the glow plug relay.

By pressing "1" on the ART you can energise or de-energise the glow plug relay.
The corresponding line of the display changes as follows:

XXIV
 Appendix
Engine electronic control unit

Relay not energised

1 G L O P L U G R E L O F F
Relay energised

1 G L O P L U G R E L O N

Preheat. SV Directly controls the preheating solenoid valve.

By pressing "1" on the ART you can energise or de-energise the preheating solenoid.
The corresponding line of the display changes as follows:

Preheating solenoid valve not energised:

2 P R E H E A T S V O F F

Preheating solenoid valve energised:

2 P R E H E A T S V O N

Preheat. lamp Directly controls the preheating lamp.

By pressing "1" on the ART you can energise or de-energise the preheating lamp.
The corresponding line of the display changes as follows:

Preheating lamp not energised:

3 P R E H E A T . L . O F F

Preheating lamp energised:

3 P R E H E A T . L . O N

WARNING: all these tests are to be performed with the engine switched off, as indicated on the ART display.

XXV
 Appendix
Engine electronic control unit

Preheating menu

Monitor menu

In this menu you can monitor the operation of the preheating system.

The following menu is displayed on the ART:

P R E H E A T I N G
M O N I T O R

T E M P . S E N S . C
G L O P L U G R E . O F F
P R E H E A T . S V . O F F
P R E H E A T . L . O F F

E E X I T

The screen is similar to that described in the previous paragraph, the sole difference being that this menu does not pro-
vide the possibility to control the various functions trough ART®. .

This screen displays the operating status of the preheating system components.

XXVI
 Appendix
Engine electronic control unit

Alarms menu

From this menu you can:

initialise the alarms
display the alarms log.

The following menu is displayed on the ART:

A L A R M S

1 I N I T I A L I S .
2 M O N I T O R

S E L E C T

E E X I T

The various functions are described below.

XXVII
 Appendix
Engine electronic control unit

Alarms menu

Initialisation menu

This operation is only required as part of the putting into the service procedure, generally after installing a later version
of the software.

If the new and previous software versions are compatible, the ART will display the following screen:

A L A R M S

E E P R O M O K

E E X I T

Otherwise:

A L A R M S

E E P R O M E R R O R
T O E L I M I N A T E
P R E S S C

E E X I T

On pressing "C" on the ART, the electronic control unit will reset this alarm.

XXVIII
 Appendix
Engine electronic control unit

The ART will display the following screen:

A L A R M S

E E P R O M E R R O R
T O E L I M I N A T E
P R E S S C

R E S E T O K

T U R N O F F E N G .

E E X I T

XXIX
 Appendix
Engine electronic control unit

Alarms menu

Monitor menu

This screen displays the list of alarms detected by the system. The most recent alarm is first in the list.
Pressing "A" cancels the list and resets the alarm log.

The screen displayed on the ART is as follows:

A L A R M S L O G

O . C . A . = O p e n C i r c
S . C . = S h o r t C i r c .
A - R E S E T A L . L O G
E E X I T

Heading 4 contains a list of all the alarms that can be detected by the electronic control unit.

XXX
 Appendix
Engine electronic control unit

Belts menu

From this menu you can

· configure
· test
· monitor

the drive belts control system.

The following menu is displayed on the ART:

B E L T S

1 C O N F I G U R A T I O N

2 T E S T S

3 M O N I T O R

S E L E C T

E E X I T

The various submenus are described below.

XXXI
 Appendix
Engine electronic control unit

Belts menu

Configuration menu

From this menu you can configure the Belts Alarm function.

The following menu is displayed on the ART:

C O N F I G U R A T I O N

B E L T S D I S A B .

B - P A R A M .
F - I N C R . D - D E C R .
C C O N F I R M

E E X I T

The various functions are described below:

Configuration::
By pressing "B" on the ART you can enable or disable the broken belts alarm system. The ART display will change as
follows:

On pressing "D"

B E L T S D I S A B .

On pressing "F"

B E L T S E N A B .

Saving:
Press "C" to confirm and save the new configuration.

XXXII
 Appendix
Engine electronic control unit

Belts Menu

Tests Menu

From this menu you can test the operation of the Belts Alarm system.

The following menu is displayed on the ART:

B E L T S

D I S A B L E D

H A N D B R A K E O N
B E L T S R P M 0

1 B E L T S L A M P O F F

E E X I T

The various functions are described below:

Handbrake Handbrake with tractor at standstill

Belts rpm Drive belt rotation speed

Belts lamp Directly controls the belts alarm lamp.

By pressing "1" on the ART you can energise or de-energise the broken belt warning lamp.
The corresponding line of the display changes as follows:

Lamp not energised

1 B E L T S L A M P . O F F

Lamp energised

1 B E L T S L A M P O N

XXXIII
 Appendix
Engine electronic control unit

Belts menu

Monitor menu

B E L T S

D I S A B L E D

H A N D B R A K E O N
B E L T S R P M 0

B E L T S L A M P O F F

E E X I T

The screen is similar to that described in the previous paragraph, the sole difference being that this menu does not pro-
vide the possibility to control the various functions trough ART®. .

This screen displays the operating status of the belts alarm system components.

XXXIV
 Appendix
Engine electronic control unit

Wheels menu

From this menu you can:

· configure
· monitor

the Wheel Speed system.

The following menu is displayed on the ART:

W H E E L S

1 C O N F I G U R A T I O N

2 M O N I T O R

S E L E C T

E E X I T

The submenus are described below.

XXXV
 Appendix
Engine electronic control unit

Wheels menu

Configuration menu

From this menu you can configure the Maximum Speed Control function.
The following menu is displayed on the ART:

C O N F I G U R A T I O N

L . 3 0 K m / h E N A B .

W H E E L C A L I B , X X X X

A R E S E T B - P A R A M .
F - I N C R . D - D E C R .
C C O N F I R M

E E X I T

The various functions are described below:

by pressing "B" on the ART you can select the parameter to be modified. The ART display changes as follows:

on pressing "B" the selected parameter is highlighted in reverse video

L . 3 0 K m / h E N A B .

press "F" to enable the 30 km/h limit

L . 3 0 K m / h E N A B .

or press "D" to disable the 30 km/h limit

L . 3 0 K m / h D I S A B .

Only if the 30 km/h limit is enabled will it be necessary to calibrate the wheel diameter by following either the putting into
service procedure or the following instructions.

XXXVI
 Appendix
Engine electronic control unit

Modification of the wheels parameter:

press "A" on the ART; the value displayed will be set to zero:

W H E E L S C A L . 0 0 0 0

Enter the wheel parameter value K, which is listed in the paragraph "Engine type and Wheels Parameter" in this man-
ual.

Press "C" to confirm and save the change.

Then press "E" to exit.

XXXVII
 Appendix
Engine electronic control unit

Wheels menu

Monitor menu

In this menu you can monitor the operation of the Maximum Speed Control function.

The menu displayed on the ART is as follows:

W H E E L S

S P E E D

E E X I T

Where:

SPEED Tractor speed

XXXVIII
 Appendix
Engine electronic control unit

P.T.O. menu

From this menu you can:

· calibrate
· Tests
· monitor

the Automatic P.T.O. control system.

The following menu is displayed on the ART:

P T O

1 C A L I B R A T I O N

2 T E S T S

3 M O N I T O R

S E L E C T

E E X I T

The various submenus are described below.

WARNING
This system may be used on tractors equipped with electronic lift control and electronic engine governor.

XXXIX
 Appendix
Engine electronic control unit

P.T.O. menu

Configuration menu

From this menu you can configure the Automatic P.T.O. function.

The menu is displayed on the ART as follows:

C O N F I G U R A T I O N

L I F T P O S I Z X X X X
M E M O R I S E D X X X X

E E X I T

To configure this function, refer to the putting into service procedure.

See point 4 - AUTO P.T.O. calibration.

XL
 Appendix
Engine electronic control unit

P.T.O. menu
Tests menu
From this menu you can test the operation of the Automatic P.T.O. system.
The menu is displayed on the ART as follows:

P T O

A U T O P T O O F F
P T O S W I T C H O F F
L I F T P O S I T . X X X X

1 P T O m A

E E X I T
P.T.O. menu
Monitor menu
In this menu you can monitor the operating status of the Automatic P.T.O. system.
The menu is displayed on the ART as follows:

P T O

A U T O P T O O F F
P T O S W I T C H O F F
L I F T P O S I T . X X X X

P T O m A

E E X I T

The screen is similar to that described in the previous paragraph, the sole difference being that this menu does not pro-
vide the possibility to control the various functions trough ART®..
This screen displays the operating status of the belts alarm system components.

XLI
 Appendix
Engine electronic control unit

Engine Type/Wheels Constant tables

Engine type configuration

POWER ENGINE
55 A/W-60W 1000.3A7 11
55 A/W-60W 1000.3W2 11
55 A/W-60W 1000.3A2 11
55 A/W-60W 1000.3W1*E 11
63-A/63-W 1000.3AT2 26
63-A/63-W 1000.3WT2 26
67 CV A (3C) 1000.3AT1 29
70 CV W (4C) 1000.3WT1*E 29
70 CV W (3C) 1000.4W4 21
75 CV A (4C-DO) 1000.4A3*E 10
80 CV W (DO) 1000.4W3 24
85 CV A (GO) 1000.4AT1*E 16
85 CV A (DO) 1000.4AT3 46
85 CV W (DO) 1000.4WT4 44
87 CV W 1000.4WT1*E 31
DO = Dorado
GO = Golden

Wheels Constant

TYRE model K
480/65 x 28 1100
14.9 x 32 1100
14.9 x 28 1100
420/70/28 1100
14.9 x 30 1058
420/70/30 1058
16.9 x 28 1050
480/70/28 1050
540/65/28 1050
12.4 x 36 1020
540/65 x 30 1050
16.9 x 30 1050
480/70/30 1050
13.6 x 28 1153
380/70/30 1153
420/70/24 1192
14.9 x 24 1192
13.6 x 36 984

XLII
 Appendix
Engine electronic control unit

Fault signalling by flashing of the HOLD indicator light

code ALARM TYPE ECU action EFFECT

1 OVER SPEED · - engine switched off · - ENGINE SPEED OVER
· - fault signalled 3200 RPM
2 ACTUATOR · - engine switched off · - SHORT CIRCUIT
· - fault signalled · - OPEN CIRCUIT
3 ACCELERATOR PEDAL · - normal operation · - SHORT CIRCUIT
· - fault signalled · - OPEN CIRCUIT
4 ENGINE PICKUP · -engine switched off · - OPEN CIRCUIT
· - fault signalled · - INTERMITTENT PULSES
5 EEPROM · - operation with default parameters · - CHKSUM ERROR
· - fault signalled · - WRITING ERROR
6 WHEELS PICKUP · - max engine speed 1500 rpm · - OPEN CIRCUIT
· - fault signalled · - INTERMITTENT PULSES
7 BELTS · - handbrake applied: · - BELT BROKEN
engine switched off and fault · - NO PULSES FROM BELT
signalled SENSOR
· - no handbrake · - LOW OIL PRESSURE
· - fault signalled AND ENGINE RUNNING
8 HAND THROTTLE · - NORMAL OPERATION · - SHORT CIRCUIT
· - FAULT SIGNALLED · - OPEN CIRCUIT
9 HML SOLENOID VALVES · - NORMAL ENGINE OPERATION · - SHORT CIRCUIT ON
· - M GEAR SOLENOID
· - FAULT SIGNALLED · - SOLENOID NOT CONNECTED
· - COMMAND DOES NOT
CORRESPOND TO OUTPUT
STATUS
· - NO VOLTAGE ON HML
COMMON

XLIII
 Appendix
Engine electronic control unit

Tester alarm messages and possible causes of malfunction

N° Tester message Possible cause of fault ECU action lampeggi

1 Overspeed RPM OVER 3200. ACTUATOR CONTROL REMOVED. 1
RESTART ENGINE.
2 Actuator O.C. ACTUATOR NOT CONNECTED. ACTUATOR NOT CONTROLLED. 2
WIRING ERROR. RESTART ENGINE.
CHECK PINS 46 47
3 Actuator S.C. ACTUATOR FAULTY. ACTUATOR CONTROL REMOVED. 2
WIRING ERROR RESTART ENGINE
CHECK PINS 46 47
4 RPM sensor O.C. PICKUP NOT CONNECTED. ACTUATOR CONTROL REMOVED. 4
CHECK PIN 10 RESTART ENGINE.
5 RPM sensor interm. PICKUP FAULTY. ACTUATOR CONTROL REMOVED. 4
POOR CONTACT. RESTART ENGINE.
CHECK PIN 10.
6 Hand throt. S.C. Hand throttle potentiometer short cir - Loss of hand throttle function. 8
cuit.
WIRING ERROR.
CHECK PIN 6
7 Acc. manuale C.A. Hand throttle potentiometer not con- Loss of hand throttle function. 8
nected.
Wiring error.
CHECK PIN 6.
8 Acc. pedal S.C. Accelerator pedal potentiometer short Loss of accelerator pedal function. 3
circuit.
Wiring error.
CHECK PIN 5.

9 Acc. pedal O.C. Accelerator pedal potentiometer not Loss of accelerator pedal function. 3
connected.
Wiring error.
CHECK PIN 5.
10 Hold lamp O.C. Lamp disconnected. No limitations. -
Lamp faulty.
Check pin 61.
11 Speed sens. O.C. Wheel speed sensor disconnected. Speed limited. 6
Sensor faulty.
Check pin 11.
12 Speed sens. interm. Sensor faulty. Speed limited. 6
Poor contact.
Check pin 11.
13 Glowplug rel. O.C. Electrical system fault. Preheating system operation limited. 13
Relay faulty.
ECU faulty.
Check pin 56.
14 Glowplug O.C. Electrical system fault. Preheating system operation limited. -
Glow plug faulty.
ECU faulty.
Check pin 68.
15 Glowplug rel. fault Electrical system fault. Preheating system operation limited. -
Relay faulty.
ECU faulty.
Check pin 68.

XLIV
 Appendix
Engine electronic control unit

N° Tester message Possible cause of fault ECU action lampeggi

16 Preheat.rel. O.C. Electrical system fault. Preheating system operation
Relay faulty. limited.
ECU faulty.
Check pin 58.
17 Preheat. S.V. O.C. Electrical system fault. Preheating system operation
Solenoid faulty. limited.
ECU faulty.
Check pin 65.
18 Preheat.rel. fault Electrical system fault. Preheating system operation
Relay faulty. limited.
ECU faulty.
Check pin 65.
19 Preheat. lamp O.C. Electrical system fault. No limitations.
Lamp faulty.
ECU faulty.
Check pin 57.
20 Temp.sens. O.C. Electrical system fault. Preheating permanently acti-
Temperature sensor faulty. vated.
ECU faulty.
Check pin 3.
21 Lift.pos.sens. O.C. Electrical system fault. Operation of automatic P.T.O.
Position sensor faulty. system limited.
ECU faulty.
Check pin 4.

22 Temp.sens. S.C. Electrical system fault. Preheating permanently acti -

Temperature sensor faulty. vated.
ECU faulty. Incorrect indication on console.
Check pin 3.
23 Belt speed sens. O.C. Not utilised. 7
24 Belt lamp O.C. Electrical system fault. No limitations.
Belts warning lamp faulty.
ECU faulty.
Check pin 59.
25 H SV S.C. Electrical system fault. H gear cannot be utilised. 9
H clutch solenoid faulty.
ECU faulty.
Check pin 53.
26 H SV O.C. Electrical system fault. HML and P.T.O. systems not 9
H clutch solenoid faulty. functioning.
ECU faulty.
Check pin 53.
27 L SV S.C. Electrical system fault. L gear cannot be utilised. 9
L clutch solenoid faulty.
ECU faulty.
Check pin 54.
28 L SV O.C. Electrical system fault. HML and P.T.O. systems not 9
L clutch solenoid faulty. functioning.
ECU faulty.
Check pin 54.

XLV
 Appendix
Engine electronic control unit

N° Tester message Possible cause of fault ECU action lampeggi

29 M lamp O.C. Electrical system fault. No limitations.
M lamp faulty.
ECU faulty.
Check pin 50.
30 P.T.O. SV S.C. Electrical system fault. P.T.O. system not functioning.
P.T.O. solenoid faulty.
ECU faulty.
Check pin 55.
31 P.T.O. SV O.C. Electrical system fault. P.T.O. and HML systems not
P.T.O. solenoid faulty. functioning.
ECU faulty.
Check pin 55.
32 HL P.T.O. SV lock Electrical system fault. P.T.O. and HML systems not 9
Solenoid faulty. functioning.
ECU faulty.
Check pin 52.
33 Flash fault ECU faulty. All systems inhibited.
Software error.
34 EEPROM fault ECU faulty. Default values used.
Updated software version. Parameters for default engine
type used.
35 General alarm ECU faulty. LAMPS AND RELAYS DIS-
ABLED.
36 EEP B1B2 bench ECU faulty. Use of CORRECT BENCH val-
(SAME only) Updated software version. ues

37 Low oil press. Low oil pressure. Belts warning light on. 7
Electrical system fault. If handbrake on, engine
Oil pressure sensor faulty. switched off.
ECU faulty.
Check pin 66.
38 Instr. temp. S.C. Electrical system fault. No limitations.
Sensor faulty.
ECU faulty.
Check pin 43.
39 EEPROMparamLimit ECU faulty. Default values utilised.
Incorrect calibration value.
Updated software version.

XLVI
POWER LIFT ELECTRONIC CONTROL UNIT
 Appendix
Power lift tester

Power Lift Electronic Control Unit

TESTER manual

CONTENTS

Functional diagram .............................................................................................................................IL

Presentation screen .............................................................................................................................L

Initialisation menu ...............................................................................................................................LI

1 Main menu......................................................................................................................................LIII
1 Calibrations menu .........................................................................................................................LIII
2 Monitor menu................................................................................................................................LVI
1 Lift menu...................................................................................................................................LVII
2 Draft menu.................................................................................................................................LIX
3 Position menu.............................................................................................................................LX
3 Position menu............................................................................................................................LXI
3 Tests menu..................................................................................................................................LXII
1 Sensors menu .........................................................................................................................LXIII
2 Power supply menu ................................................................................................................LXIV
3 Inputs menu
4 Alarms menu ..............................................................................................................................LXVI

Scope

The scope of this document is:

- to present the diagnostic information that can be accessed through the All Round Tester (ART®);

- to list the alarm conditions that the electronic control unit is able to diagnose, along with the possible causes of the
alarms and the relative actions of the electronic control unit.

XLVIII
 Appendix
Power lift tester

PIN OUT

REAR LIFT ECU

1 2 3 4 12 6 7 8 9 10 11 5

Mix
Max H.
GND

ISO 9141

+Vcc Sensors
Vcc

L. Speed
Draft
Position

Main Control
Electrovalve DOWN
Electrovalve UP

1K2

Lock/Alarm

Extern up
Extern down

Down Up

1 2 1 2 1 3 2 1 3 2 1 2 3 1 2 3 1 2 3 1 2 3
V V
+ -
EVup EVdown Tester Position Draft Lowering Maximum Mix Main Down/Up
In/Out Sensor Sensor Speed Height Draft/Pos Control Control lever

A B C D E F G H I L
Functional diagram of the lift ECU.

1 - Vdc A - UP solenoid valve

2 - UP solenoid valve B - DOWN solenoid valve
3 - DOWN solenoid valve C - Tester IN/OUT
4 - GND D - Position sensor
5 - Sensor Vdc E - Draft sensor
6 - Position F - Lowering speed
7 - Draft G - Maximum height
8 - Speed limit H - DRAFT/POSITION MIX control
9 - Maximum height I - Main control
10 - Mix L - UP/DOWN control
11 - Main control
12 - ISO 9141

IL
 Appendix
Power lift tester

Presentation screen

The presentation screen displays preliminary information about the electronic control unit:

· Software version
· Date of software issue

The screen appears as follows:

L i f t
= = = = = = = = = = = = = = = =

S o f t w a r e X . x x x
D a t e d d / m m / y y

P a r a m e t e r s f o r
T R A C T O R x x x

= = = = = = = = = = = = = = = =
= = = = = = = = = = = = = = = =
[ C ] C H A N G E P A R A M .
[ E ] C O N T I N U E

Where:
Version software version
Date: date of software issue

The various functions are described below:

Pressing "C"
displays the initialisation menu for the tractor type:
- lift for tractor 10N (Golden)
- lift for tractor 10S (Dorado)
As described on page LI

Pressing "E"
displays the menu described on page LII

L
 Appendix
Power lift tester

Initialisation menu

From the Initialisation menu you can configure the lift in accordance wit the type of tractor.

The menu is displayed on the ART as follows:

I N I T I A L I S A T I O N
C u r r e n t
P a r a m e t e r s
f o r 1 0 X

C h a n g e
P a r a m e t e r s

1 - L i f t f o r 1 0 N

2 - L i f t f o r 1 0 S

= = = = = = = = = = = = = = = =
[ C ] C O N T I N U E

Where:

Current parameters defines the configuration currently saved in memory

To change and save the configuration, press "1" or "2".

Press "1" to configure the lift for the 10N tractor. (Golden)
Press "2" to configure the lift for the 10S tractor. (Dorado)

Press "C" to pass to the main menu.

LI
 Appendix
Power lift tester

1 - Main menu

From this menu you can select the component on which diagnosis is to be performed or display the general list of alarms
detected up until that point.

The menu displayed on the ART is as follows:

M A I N M E N U

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

S E L E C T

E E X I T

The various menus and submenus are described below.

LII
 Appendix
Power lift tester

1 - Calibrations menu

From this menu you can calibrate the lift system.

The menu displayed on the ART is as follows:

C a l i b r a t i o n s M e n u
- - - - - - - - - - - - - - - -

1 - M a x . h e i g h t

P e r s o n a l i s a t i o n
L i f t i n g s p e e d
2 - L i f t i n g s p e e d

[ E ] E X I T

These operations are to be performed with the lift lock released.

The various calibration functions are described below.

LIII
 Appendix
Power lift tester

Maximum height calibration:

On pressing "1" on the ART, the following screen is displayed:

1 - M a x . H e i g h t
- - - - - - - - - - - - - - - -

C u r r e n t : x x x x

N e w : x x x x

[ A ] C a n c e l
[ C ] C O N F I R M

Where:

Current The position value between 0 and 1000 saved in memory.

New The position value between 0 and 1000 read by the position sensor.

Operation: To decontrol the lifter pressing for 3 second the key of command basculante on the position UP.
With the keys of controls manual, to position the lifter to the maximum desired height.
To press the key [E] on the tester and the key [C] to confirm the new value.

Press:
· "A" to cancel the operation;
· "C" to save the new value in the Eeprom.

LIV
 Appendix
Power lift tester

Implement lifting speed

This parameter regulates the speed at which the lift is raised when using the manual controls only.

On pressing "2" on the ART, the following screen is displayed:

2 - L i f t s p e e d
- - - - - - - - - - - - - - - -

C u r r e n t : x x x x

N e w : x x x x

[ A ] C a n c e l
[ C ] C O N F I R M

Where:

Current The speed value between 300 and 400 saved in memory.
New The actual speed value between 300 and 400.

Press:
· "A" to cancel the operation;
· "C" to save the new value in the Eeprom.

LV
 Appendix
Power lift tester

2 - Monitor menu
From this menu you can display the operating parameters of the lift system.

The menu displayed on the ART is as follows:

M o n i t o r M e n u

1 L i f t

2 D r a f t

3 P o s i t i o n

[ E ] E X I T

The various functions are described below.

LVI
 Appendix
Power lift tester

2 - Monitor Menu

1 - Lift menu

From this menu you can display the following values:

Set Point
Position
Draft
Maximum height

The menu displayed on the ART is as follows:

L i f t
- - - - - - - - - - - - - - - -
P o t e n t i o m e t e r s
S e t P o i n t . . . . x x x x
M a x . h e i g h t . . . x X
L o w . s p e e d . . . . x X
M i x . . . . . . . . . x x x X
S E N S O R S
P o s i t i o n . . . . . x x X
D r a f t . . . . . . . x x x X
P W M O U T P U T
P w m x x X
L I F T S T A T U S . .
S t a t u s . . . . . . . . x X

E E X I T

POTENTIOMETERS
Set Point Reference value for automatic control of the lift.
On turning the potentiometer, the value displayed varies between 0 and 1000
(this operation must be performed with the lift lock released).
The value modifies the positions of equilibrium during the operation in control.

Max. height Represents the maximum height to which the lift can be raised.
On turning the potentiometer, the value displayed varies between 0 and 100.

Lowering speed Represents the lowering speed as a percentage of the maximum speed.
On turning the potentiometer, the value displayed varies between 0 and 100.

Mix This parameter allows you to select the type of control, passing continuously from position
to draft control.
On turning the potentiometer, the value displayed varies between 0 and 1000.

LVII
 Appendix
Power lift tester

· SENSORS
Position Signal read by the position sensor; values range from 0 to 100.
Draft Signal read by the draft sensor; values range from 0 to 1000.

· PWM OUTPUT
PWM Value that controls the current supplied to the proportional solenoid valves.
Value ranges 290 to 600.
when the lfting is in movement; 0 if the elettrovalvoles are not commanded.

· LIFT STATUS
Status Displays the operating status of the lift system.
Press the control button to view the following status information
LOCK lift locked
STOP lift operative awaiting command
CNTRL lift operating in automatic control mode
FLOAT lift in float mode

LVIII
 Appendix
Power lift tester

2 - Monitor menu
2 - Draft menu

From this menu you can display the following values:

· Pwm Base Up
· PWM Base Down
· PWM Max Up
· PWM Max Down
· Gain Up
· GainDown

The menu displayed on the ART is as follows:

D r a f t
- - - - - - - - - - - - - - - -

1 - P W M B a s e U p x x x
2 - P W M B a s e D o w n x x x
3 - P W M M a x U p x x x
4 - P W M M a x D o w n x x x
5 - G a i n U p x x
6 - G a i n D o w n x X

[ E ] E X I T

These are the characteristic values of the electronic lift control system.

The default values are as follows:

Values 10N 10S

PWM BaseUp 390 360
PWM BaseDown 400 420
PWM MaxUp 600 600
PWM MaxDown 600 600
Gain Up 25 18
Gain Down 45 35

LIX
 Appendix
Power lift tester

2 - Monitor Menu
3 - Position Menu

From this menu you can display the following values:

· Pwm Base Up
· PWM Base Down
· PWM Max Up
· PWM Max Down
· Gain Up
· GainDown

The menu displayed on the ART is as follows:

P o s i t i o n
- - - - - - - - - - - - - - - -

1 - P W M B a s e U p
2 - P W M B a s e D o w n
3 - P W M M a x U p
4 - P W M M a x D o w N
5 - G a i n U p
6 - G a i n D o w n

[ E ] E X I T

These are the characteristic values of the electronic lift control system.

The default values are as follows:

Values 10N 10S

PWM BaseUp 315 315
PWM BaseDown 310 320
PWM MaxUp 600 600
PWM MaxDown 600 600
Gain Up 10 10
Gain Down 50 50

LX
 Appendix
Power lift tester

3 - Tests Menu
From this menu you can test the operation of the:
1 - sensors
2 - actuators connected to the ECU.
3 - inputs

The menu displayed on the ART is as follows:

T e s t s M e n u
- - - - - - - - - - - - - - - -

1 - S e n s o r s
2 - P o w e r s u p p l y
3 - I n p u t s

[ E ] E X I T

The various functions are described.

LXI
 Appendix
Power lift tester

3 - Tests Menu
1 - Sensors menu

In this menu you can check the operation of the sensors.

The menu displayed on the ART is as follows:

S e n s o r s
- - - - - - - - - - - - - - - -

P o s i t . . . . . . . . x x x
D r a f t . . . . . . . x x x x

[ E ] E X I T

Where:

Position Position sensor value ranging from 0 to 100

Draft Draft sensor value ranging from 0 to 1000

LXII
 Appendix
Power lift tester

3 - Tests Menu
2 - Power supply

In this menu you check the power supply to the ECU.

The menu displayed on the ART is as follows:

P o w e r S u p p l y
- - - - - - - - - - - - - - - -

+ 1 0 v o u t m V x x x x

[ E ] E X I T

Where:

+10V represents the output voltage value in the range 0 to 1000 mV.

LXIII
 Appendix
Power lift tester

3 - Tests menu
3 - Inputs

In this menu you can check the operation of the ECU inputs.

The menu displayed on the ART is as follows:

I n p u t s
- - - - - - - - - - - - - - - -
P u s h b u t t o n s

U P / D W
E x t U P / D W

P o t e n t i o m e t e r s

S e t P o i n t . . . . x x x x
M a x . h e i g h t . x x x x
L o w . s p e e d . . x x x x
C o n t r o l t y p e. . x x x x

[ E ] E X I T

Where:

Up/Down rocker switch on console

LXIV
On pressing the UP side of the rocker switch with the lift lock released, the display will appear as follows:

U P / D W U P

On pressing the DOWN side of the rocker switch with the lift lock released, the display will appear as follows:

U P / D W D o w n

ExtUP/DW ground-operated pushbuttons

On pressing the button with the UP arrow when the lift lock is released, the display will appear as follows

E x t U P / D W U P

On pressing the button with the DOWN arrow when the lift lock is released, the display will appear as follows

E x t U P / D W D o w n

Set Point on turning the potentiometer, the value varies in the range 0 to 1000

Max. height on turning the potentiometer, the value varies in the range 0 to 100

Lowering speed on turning the potentiometer, the value varies in the range 0 to 100

CONTROL TYPE On pressing the control pushbutton, the following conditions are displayed

C o n t r o l t y p e L O C K

C o n t r o l t y p e S T O P

C o n t r o l t y p e C O N T RL

C o n t r o l t y p e F L O A T
 Appendix
Power lift tester

5 - Alarms menu

The screen displayed on the ART is as follows:

A L A R M S L O G
- - - - - - - - - - - - - - - -

1 - C a n c e l l o g
[ E ] E X I T

LXVI
 Appendix
Power lift tester

Tester message Possible cause of fault ECU action N° of flashes

UP proportional solenoid valve

disconnected.
- Wiring error.
UPSV DISCONN. Check electrical continuity Loss of lift system function. 11
-Solenoid faulty.
Check solenoid
-ECU faulty.

Short circuit of UP proportional

solenoid valve.
- Wiring error.
UPSV S.C. Check electrical continuity. Loss of lift system function. 12
- Solenoid faulty.
Check solenoid.
- ECU faulty.

DOWN proportional solenoid

valve disconnected.
- Wiring error.
DWSV DISCONN. Check electrical continuity. Loss of lift system function. 13
- Solenoid faulty.
Check solenoid.
- ECU faulty.

Short circuit of DOWN propor-

tional solenoid valve.
- Wiring error.
DWSV S.C. Check electrical continuity. Loss of lift system function. 14
- Solenoid faulty.
Check solenoid.
- ECU faulty.

EPROM CHECK EPROM error. Total lockup of lift system 15

- ECU faulty.

POS.SENS.S.C. Short circuit of position sensor.

- Wiring error.
Check electrical continuity.
- Sensor faulty. Loss of lift system function. 21
Check sensor.
- ECU faulty.

LXVII
 Appendix
Power lift tester

Tester message Possible cause of fault ECU action N° of flashes

Position sensor disconnected.

- Wiring error.
Check electrical continuity. Loss of lift system function.
POS.SENS. DIS. - Sensor faulty. 22
Check sensor.
- ECU faulty.

General failure of CPU.

GEN.FAIL.CPU - ECU faulty. Loss of lift system function. 23

Draft sensor not connected.

- Wiring error.
Check electrical continuity.
DRAFT SENS. DIS. - Sensor faulty. Loss of draft control function. 41
Check sensor.
- ECU faulty.

Draft sensor short circuit.

- Wiring error.
Check electrical continuity.
DRAFT SENS. S.C. - Sensor faulty. Loss of draft control function. 42
Check sensor.
- ECU faulty.

EEPROM CHECK EEPROM error. Default values (for 10N) uti- 45

- ECU faulty lised

NO V. SENSOR No voltage at sensor.

- Wiring error.
Check electrical continuity. Loss of lift system function. -
- ECU faulty.
Check using Tests menu on
ART.

LXVIII
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Because of the possible time lag between the introduction of technical modifications (an on-going process the aim of
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La differenza tra i tempi di aggiornamento in stampa e i tempi delle modifiche tecniche (variando queste ultime conti-
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A diferença entre os tempos necessãrrios para actualizar a impressão e os tempos das modificacões técnicas (que se
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dos contidos neste manuel são susceptiveis de variacão em qualquer momento e que portanto não são vinculatórios.
NOTES

02 - 2002 cod. 307.1064.3.0

By Personal computing Technical Publications Dep.
307. 1064. 3. 0