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Same Iron 130s 140s 150s 165s service repair manual workshop
130S
140S
150S
165S
language:english
number of pages: 830 (full digital version)
Main sections:
Introduction
Safety sections
1. TRANSMISSION................................................................. 1
INTRODUCTION.................................................................. 1
1.1 TRANSMISSION (Power Shuttle version) .................... 3
1.1.1 MAIN COMPONENTS .......................................3
1.1.2 TRANSMISSION HYDRAULIC SYSTEM ...........6
1.1.3 GEARBOX..........................................................7
1.1.4 MAIN CLUTCH ..................................................9
1.1.5 HYDRAULIC GEARBOX AND SHUTTLE
DISTRIBUTION VALVE ...................................10
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID
VALVE OPERATION SCHEMATIC...................14
1.1.7 TRANSMISSION ELECTRONIC
SYSTEM SCHEMATIC.....................................15
1.2 REAR AXLE ................................................................ 17
1.3 REAR PTO.................................................................. 19
2. BRAKING SYSTEM.......................................................... 21
2.1 BRAKE MASTER CYLINDER ..................................... 22
2.2 BRAKE ....................................................................... 23
2.3 TRAILER BRAKING SYSTEM .................................... 24
2.3.1 HYDRAULIC TRAILER BRAKING
(ITALY VERSION).............................................24
2.3.2 HYDRAULIC TRAILER BRAKING
(EXPORT VERSION) ........................................26
2.3.3 AIR TRAILER BRAKING (ITALY VERSION)......28
2.3.4 AIR TRAILER BRAKING (EXPORT VERSION) .29
3. HYDRAULIC FRONT AXLE SUSPENSION..................... 35
3.1 FRONT SUSPENSION CONTROL VALVE ................. 36
4. FRONT AXLE.................................................................... 40
4.1 HUB CARRIER AND FINAL REDUCTION UNIT......... 41
4.2 DIFFERENTIAL........................................................... 43
5. HYDRAULIC SYSTEM..................................................... 45
5.1 VARIABLE DISPLACEMENT PUMP........................... 48
5.1.1 BOOST PUMP................................................. 51
5.1.2 HYDRAULIC PUMP......................................... 52
5.1.3 LOAD SENSING VALVE, PRESSURE
CUT-OFF VALVE............................................. 54
5.2 HYDRAULIC SERVICES GEAR PUMP....................... 62
5.3 STEERING GEAR PUMP............................................ 63
5.4 PRIORITY VALVE ....................................................... 64
5.5 AUXILIARY SERVICES CONTROL VALVE................. 65
5.5.1 TYPES OF CONTROL VALVE WITH FIXED DISPLACEMENT
PUMP (CC) ............................... 67
5.5.2 TYPES OF CONTROL VALVE WITH
VARIABLE DISPLACEMENT PUMP (LS)......... 69
5.5.3 SERVICES CONTROL SECTION .................... 70
5.5.4 DESCRIPTIONS OF COMPONENTS .............. 71
5.5.5 INLET MANIFOLD (CC version)....................... 73
5.5.6 LIFT CONTROL VALVE SECTION................... 76
1. DIAGNOSIS TOOLS ALL ROUND TESTER .................. 1
1.1 ALL ROUND TESTER ......................................................... 1
1.2 SERDIA 3.5 LEVEL III SOFTWARE .................................. 7
1.3 EDS EST45 SOFTWARE ................................................. 8
2. CONNECTING THE TESTER TO THE ELECTRONIC
CONTROL UNITS .............................................................. 9
2.1 CONNECTING THE ART TO THE HYDRAULIC LIFT AND
FRONT AXLE SUSPENSION CONTROL UNITS ................ 9
2.2 CONNECTING THE PORTABLE COMPUTER WITH
SERDIA 3.5 SOFTWARE TO THE ENGINE
CONTROL UNIT ............................................................... 10
2.3 CONNECTING THE PORTABLE COMPUTER WITH EDS
SOFTWARE TO THE TRANSMISSION CONTROL UNIT AND
INFOCENTER ................................................................... 11
3. INTRODUCTION TO THE ELECTRONIC SYSTEM OF
THE TRACTOR ................................................................ 13
3.1 ENGINE CONTROL UNIT (DEUTZ EMR2) ........................ 13
3.2 TRANSMISSION CONTROL UNIT ................................... 15
3.3 POWER LIFT CONTROL UNIT ......................................... 16
3.4 INFOCENTER 2 or 3 ......................................................... 18
3.5 FRONT AXLE SUSPENSION CONTROL UNIT ................. 19
3.6 FRONT AND REAR PTO CONTROL UNIT ....................... 20
4. PUTTING THE TRACTOR INTO SERVICE .................... 21
4.1 INTRODUCTION ............................................................... 21
4.2 RENEWAL OF THE ENGINE CONTROL UNIT ................. 21
4.3 RENEWAL OF THE TRANSMISSION CONTROL UNIT .... 26
4.4 RENEWAL OF HYDRAULIC LIFT AND
ASM CONTROL UNIT ...................................................... 32
4.5 RENEWAL OF THE INFOCENTER ................................... 40
4.6 RENEWAL OF AXLE SUSPENSION CONTROL UNIT ...... 42
5. ALARMS .......................................................................... 43
5.1 LIFT AND ASM CONTROL UNIT ALARMS ...................... 43
5.2 LIST OF TRANSMISSION CONTROL UNIT ALARMS ...... 79
5.3 LIST OF ALARMS DISPLAYED BY SERDIA ................... 149
5.4 LIST OF FRONT AXLE SUSPENSION CONTROL VALVE
ALARMS ......................................................................... 171
6. OPERATORS MANUAL EDS
(Electronic Diagnosis System) .................................... 187
1. GENERAL INTRODUCTION ........................................... 187
1.1 FUNCTIONAL SCOPE........................................... 187
1.2 HARDWARE REQUIREMENTS.............................. 188
1.3 STARTING AND TERMINATING OF
THE EDS PROGRAM............................................. 190
2. TRANSMISSION DIAGNOSIS .........................................192
2.1 THE MAIN MENU................................................... 192
2.2 ONLINE HELP ........................................................ 194
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45 .195
3.1 PREPARATIONS FOR TRANSMISSION
DIAGNOSISWITH DEST 45 .................................... 195
3.2 DEST 45 PROGRAM DESCRIPTION..................... 196
3.3 ERROR CODES POWER-SHUTTLE /DEST 45 ...... 211
3.4 DISPLAY POWERSHUTTLE................................... 212
3.5 ERROR CODE LIST WITH DESCRIPTION ............. 213
3.6 OTHER INFORMATIONS........................................ 224
3.7 SENSORS AND SOLENOID VALVES AT
THE TRANSMISSION T-7100 ................................ 225
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100 ....... 226
3.9 SENSORS AND SOLENOID VALVES AT
THE TRANSMISSION T-7200 ................................ 227
3.10 ELECTRO-HYDRAULIC GEAR
SHIFT T-7200 / T-7300 .......................................... 228
3.11 ERROR ANALYSIS.................................................. 229
4. PREPARATIONS FOR DIAGNOSIS OF
THE INFOCENTER ..........................................................231
4.1 PROGRAM DESCRIPTION..................................... 232
4.2 CONSTANT VALUES FOR INFOCENTER.............. 242
7. ALL ROUND TESTER FOR LIFT AND
ASM CONTROL UNIT ................................................... 247
PRESENTATION SCREEN .............................................. 247
MAIN MENU.................................................................... 247
1. MONITOR............................................................... 248
2. CONFIGURATION .................................................. 252
3. CALIBRATIONS...................................................... 254
4. ALARMS LIST......................................................... 259
8. ALL ROUND TESTER FOR AXLE SUSPENSION
CONTROL UNIT ............................................................ 261
PRESENTATION SCREEN .............................................. 261
MAIN MENU.................................................................... 261
1. MONITOR............................................................... 262
2. PARAMETERS........................................................ 263
3. ALARMS LIST......................................................... 265
4. CONFIGURATIONS................................................ 265
9. SERDIA (LEVEL III) ...................................................... 267
1. SETUP AND COMMUNICATIONS ..................................267
1.1 MINIMUM EQUIPMENT REQUIRED ...................... 267
1.2 ORDERING............................................................. 268
1.3 SWITCHING ON AND INSTALLING
THE SOFTWARE .................................................... 269
1.4 USING THE PROGRAM ......................................... 273
1.5 CLOSING THE PROGRAM..................................... 276
2. ECU SELECTION ............................................................277
2.1 SELECTING TWO CONTROL UNITS..................... 277
2.2 PRINTING............................................................... 278
2.3 PROTOCOL............................................................ 279
2.4 IDENTIFICATION AND MEASUREMENT DATA..... 279
3. MEASURED VALUES ......................................................281
3.1 ACTUAL MEASURED VALUES (GENERAL)........... 281
3.2 RAM-VALUES ........................................................ 286
3.3 DATA LOGGER (ONLY EMS2) ............................... 290
3.4 INPUT/OUTPUT ASSIGNMENT............................ 290
3.5 CAN STATUS ......................................................... 290
4. PARAMETERS ................................................................293
4.1 CONFIGURATION (GENERAL)............................... 293
4.2 OVERALL PROGRAMMING................................... 294
4.2 CALIBRATION........................................................ 295
5. ERROR MEMORY ...........................................................296
5.1 GENERAL............................................................... 296
5.2 ERROR TABLE....................................................... 297
6. EXTRAS ..........................................................................307
6.1 MAXIMUM SPEED ................................................. 307
6.2 LOGISTIC DATA.................................................... 307
6.3 LOAD SPECTRUM................................................. 308
6.4 MAINTENANCE INTERVAL EXCEEDED ................ 308
6.5 OVERRIDE MEMORY ............................................ 308
6.6 MAINTENANCE DATA ........................................... 308
7. TASKS .............................................................................309
7.1 EMR1 ..................................................................... 309
8. WHAT TO DO IF...? .........................................................313
8.1 SERDIA GENERAL................................................. 313
8.2 EMR1 ..................................................................... 315
ACCESSORIES
AIR COMPRESSOR
Removal.................................................................... 21
Refitting .................................................................... 22
AIR PRESSURE REGULATING/REDUCTION
VALVE FOR CAB LIFTING
Removal and refitting ............................................... 26
FRONT PTO ASSEMBLY
Removal and refitting ............................................... 93
FRONT PTO FLEXIBLE COUPLING
Removal.................................................................... 56
Refitting ................................................................... 57
HYDRAULIC TRAILER BRAKING VALVE
(CUNA VERSION)
Removal.................................................................... 28
Refitting .................................................................... 29
REINFORCING SIDE MEMBERS
Removal and refitting ............................................. 105
PRESSURE TRANSDUCER
Removal and refitting ............................................... 25
TRAILER PARKING AND
SERVICE AIR BRAKE CONTROL VALVES
Removal.................................................................... 23
Refitting .................................................................... 24
TRAILER AIR BRAKES COUPLING VALVE
Removal and refitting ............................................... 27
AIR CONDITIONING AND HEATING
AIR CONDITIONING EVAPORATOR
Removal.................................................................. 185
Refitting .................................................................. 186
AIR CONDITIONING SYSTEM
Operation.................................................................. 31
Maintenance............................................................. 32
Discharging, flushing and recharging....................... 33
CLIMATE CONTROL PANEL
Removal and refitting ............................................. 179
COMPRESSOR
Removal.................................................................... 34
Refitting .................................................................... 35
COMPRESSOR DRIVEBELT
Adjusting the tension................................................ 32
CONDENSER ASSEMBLY
Removal.................................................................... 38
Refitting .................................................................... 40
CONDENSER FAN
Removal and refitting................................................ 37
HEATER MATRIX
Removal.................................................................. 182
Refitting .................................................................. 184
HEATER VALVE
Renewal .................................................................. 180
LEFT-HAND AIR CONDITIONING FAN
Removal and refitting.............................................. 188
RECEIVER-DRIER
Removal and refitting................................................ 36
RIGHT-HAND AIR CONDITIONING FAN
Removal and refitting.............................................. 187
CAB
CAB
Removal.................................................................. 194
Refitting .................................................................. 202
CAB ACCESS STEPS
Removal and refitting................................................ 12
CAB DOOR CABLE
Renewal .................................................................. 190
CENTRE CONSOLE AND SHROUD
Removal.................................................................. 149
Refitting .................................................................. 152
CONTROLS IN THE MULTIFUNCTION ARMREST
CONSOLE (OPTIONAL)
Removal.................................................................. 143
Refitting .................................................................. 144
DRIVER'S SEAT
Removal and refitting.............................................. 142
LEFT-HAND CONSOLE
Removal.................................................................. 160
Refitting .................................................................. 161
POWERSHIFT - POWERSHUTTLE STATUS DISPLAY
Removal and refitting.............................................. 193
PTO ENGAGEMENT AND SELECTION
CONTROL CABLES
Renewal .................................................................. 173
RIGHT-HAND CONSOLE
Removal ..................................................................153
Refitting ..................................................................159
STEERING COLUMN SWITCH UNIT AND
THE SHUTTLE CONTROL LEVER
Disassembly ............................................................147
Assembly.................................................................148
STEERING WHEEL, STEERING COLUMN SWITCH
UNIT AND INSTRUMENT PANEL
Removal ..................................................................145
Refitting ...................................................................146
TRAILER BRAKING AIR PRESSURE GAUGE
Removal and refitting ..............................................192
CREEPER
CREEPER ENGAGEMENT LEVER
Removal and refitting ..............................................124
ELECTRICAL AND ELECTRONIC
CONTROLS
ACCELERATOR POTENTIOMETER
Removal and refitting ..............................................107
CLUTCH PEDAL AND RELATED DEVICES ............. 167
ENGINE ECU
Removal and refitting ..............................................166
FUSE AND RELAY BOARD
Removal ..................................................................164
Refitting ...................................................................165
TRANSMISSION LIFT AND FRONT SUSPENSION
ELECTRONIC CONTROL UNITS
Removal ..................................................................162
Refitting ...................................................................163
ENGINE
AIR CLEANER
Removal ....................................................................58
Refitting .....................................................................59
AIR INLET PIPE
Removal and refitting ................................................62
ALTERNATOR
Removal and refitting ................................................17
ALTERNATOR DRIVEBELT
Renewal and tensioning ............................................18
ENGINE
Removal ..................................................................203
Refitting ...................................................................212
EXHAUST PIPE
Removal and refitting ................................................64
INTERCOOLER
Removal ....................................................................41
Refitting ....................................................................43
SILENCER
Removal and refitting ................................................63
STARTER MOTOR
Removal and refitting ................................................16
TURBOCHARGER
Removal ....................................................................60
Refitting .....................................................................61
ENGINE HOODS
ENGINE HOOD - LAMP ASSEMBLIES
Removal ..................................................................... 9
Refitting .................................................................... 11
FRAME
4WD PROPELLER SHAFT
Removal ................................................................... 65
Refitting .................................................................... 67
AIR RESERVOIR AND BATTERY SUPPORT
Removal and refitting ............................................... 15
BATTERY
Removal ................................................................... 13
Refitting .................................................................... 14
FRONT FENDERS
Removal and refitting ............................................... 85
FRONT WHEELS
Removal and refitting ............................................... 84
FUEL TANK AND RELATIVE MOUNTINGS
Removal and refitting ............................................. 109
REAR WHEELS
Removal and refitting ............................................... 86
FRONT AXLE
FRONT AXLE AND SWINGING SUPPORT
Removal ................................................................... 99
Refitting .................................................................. 101
FRONT CARRIER
Removal and refitting ............................................. 106
FRONT SUSPENSION CYLINDERS
Removal ................................................................... 94
Refitting ................................................................... 96
Disassembly and assembly...................................... 97
FRONT SUSPENSION POSITION SENSOR
Removal and refitting ............................................. 103
FRONT SUSPENSION VALVES
Removal and refitting ............................................. 102
FRONT LIFT
FRONT LIFT CYLINDERS
Removal ................................................................... 88
Refitting .................................................................... 89
FRONT LIFT ASSEMBLY
Removal ................................................................... 90
Refitting .................................................................... 92
LIFT VALVE BLOCK
Removal and refitting ............................................... 87
HYDRAULIC BRAKES AND
PARKING BRAKES
BLEEDING THE BRAKING SYSTEM .......................... 71
BRAKE LIGHT SWITCHES
Adjustment ............................................................... 73
BRAKE MASTER CYLINDERS
Removal ................................................................... 68
Refitting ................................................................... 70
PARKING BRAKES
Adjustment ............................................................. 189
PARKING BRAKE SWITCH
Adjustment ............................................................. 178
HYDRAULIC SYSTEM
AUXILIARY CONTROL VALVE BLOCKS
Disassembly ........................................................... 132
Assembly ................................................................ 133
AUXILIARY SERVICES PUMPS
Testing.................................................................... 114
AUXILIARY SERVICE VALVE CONTROL CABLES
Removal.................................................................. 176
Refitting .................................................................. 177
CONTROL PANELS AND LEVERS OF
THE AUXILIARY SERVICE VALVES AND THE PTO
Removal.................................................................. 169
Refitting .................................................................. 172
CONTROL VALVE ASSEMBLIES (Version CC)
Removal.................................................................. 125
Refitting .................................................................. 128
CONTROL VALVE ASSEMBLIES (LS version)
Removal.................................................................. 129
Refitting .................................................................. 131
GEAR PUMP
Removal.................................................................. 112
Refitting ................................................................. 113
POWER STEERING PUMP (CC version)
Removal and refitting ............................................. 119
PRIORITY VALVE
Removal and refitting ............................................. 122
PRIORITY VALVE
(For versions with variable displacement pump)
Removal and refitting ............................................. 123
VARIABLE DISPLACEMENT PUMP (Version LS)
Removal.................................................................. 116
Refitting .................................................................. 118
LIFT
LIFT CYLINDERS
Removal.................................................................. 134
Refitting .................................................................. 135
Disassembly and assembly .................................... 136
LIFT DRAFT SENSOR
Removal and refitting.............................................. 141
LIFT POSITION SENSOR
Testing .................................................................... 137
Renewal .................................................................. 138
RADIATORS - COOLERS
COMPLETE RADIATOR/COOLERS ASSEMBLY
Removal.................................................................... 50
Refitting ................................................................... 54
EXPANSION TANK
Removal and refitting................................................ 49
FAN
Removal and refitting................................................ 55
GEARBOX OIL/FUEL COOLERS
Removal.................................................................... 44
Refitting .................................................................... 45
RADIATOR
Removal.................................................................... 46
Refitting ................................................................... 48
STEERING SYSTEM
POWER STEERING UNIT
Removal.................................................................... 74
Refitting .................................................................... 75
Disassembly and assembly ...................................... 76
THE STRUCTURE OF THE UNIT ................................ 1
HOW TO CONSULT THE UNIT ................................... 2
1. INTRODUCTION ...................................................... 3
1.1 LIST OF WIRING HARNESSES ......................................... 3
1.2 DEFINITION OF COMPONENTS AND SYMBOLS ............ 4
1.3 GENERAL RULES.............................................................. 4
1.4 DIAGNOSTIC INSTRUMENTS........................................... 6
1.5 WIRE COLOUR CODES .................................................... 6
2. INDICES ................................................................... 7
2.1 COMPONENT DESCRIPTION INDEX................................ 7
2.2 COMPONENT CODE INDEX ........................................... 12
2.3 CONNECTOR INDEX....................................................... 17
3. COMPONENTS ...................................................... 26
3.1 CONNECTOR LAYOUTS................................................. 26
3.2 COMPONENT TECHNICAL DATA................................... 31
3.3 PINOUTS AND DESCRIPTIONS OF ELECTRONIC
CONTROL UNITS ............................................................ 40
4. SYSTEMS ............................................................... 49
4.1 GROUND POINTS ........................................................... 49
4.2 ENGINE START ............................................................... 50
4.3 PREHEATING .................................................................. 51
4.4 ELECTRICAL ENGINE CONTROL ................................... 52
4.5 LIGHTS - LIGHT SELECTOR SWITCH
(MACHINE WITHOUT FRONT LIFT) ................................ 53
4.6 LIGHTS - LIGHT SELECTOR SWITCH
(MACHINE WITH FRONT LIFT)........................................ 54
4.7 CAB ACCESSORY........................................................... 55
4.8 WORKING LIGHTS (MACHINE WITHOUT FRONT LIFT). 56
4.9 WORKING LIGHTS (MACHINE WITH FRONT LIFT) ........ 57
4.10 WINDSCREEN WIPER..................................................... 58
4.11 INFOCENTER .................................................................. 59
4.12 ELECTRICAL POWER SUPPLY....................................... 60
4.13 AUTORADIO - CB............................................................ 61
4.14 AIR CONDITIONING - HEATING FAN ............................. 62
4.15 BRAKES........................................................................... 63
4.16 TRAILER BRAKES ........................................................... 64
4.17 FRONT AXLE SUSPENSION ........................................... 65
4.18 TRANSMISSION.............................................................. 66
4.19 ASM - 4WD - DIFFERENTIAL .......................................... 67
4.20 REAR LIFTER................................................................... 68
4.21 FRONT AND REAR PTO.................................................. 69
5. WIRING ................................................................... 71
ENGINE WIRING (1/2) ...............................................................71
ENGINE WIRING (2/2) ...............................................................72
ENGINE WIRING (1/2) ...............................................................77
ENGINE WIRING (2/2) ...............................................................78
ENGINE HOOD WIRING (1/2) ...................................................87
ENGINE HOOD WIRING (2/2) ...................................................88
TRANSMISSION WIRING (1/2) .................................................91
TRANSMISSION WIRING (2/2) .................................................92
TRAILER BRAKE WIRING (ITALY) ..........................................103
TRAILER BRAKE WIRING.......................................................104
FRONT AXLE SUSPENSION WIRING (ROPS) ........................107
CAB POWER SUPPLY WIRING..............................................111
FRONT AXLE SUSPENSION WIRING.....................................117
FENDER WIRING - WIDE........................................................121
NUMBER PLATE LIGHT WIRING (WIDE FENDERS) ..............122
FENDER WIRING - NARROW.................................................127
NUMBER PLATE LIGHT WIRING (NARROW FENDERS) .......128
FENDERS................................................................................131
FRONT CONSOLE WIRING (1/2) ............................................133
FRONT CONSOLE WIRING (2/2) ............................................134
SIDE CONSOLE WIRING (1/3) ................................................139
SIDE CONSOLE WIRING (2/3) ................................................140
SIDE CONSOLE WIRING (3/3) ................................................141
AIR CONDITIONING WIRING (CAB) .......................................151
DISPLAY WIRING....................................................................157
ROOF WIRING (1/2) ................................................................161
ROOF WIRING (2/2) ................................................................162
ROOF WIRING ........................................................................167
CAB LOWER HEADLIGHTS WIRING......................................169
WINDSCREEN WIPER MOTOR WIRING................................169
CAB LOWER FRONT WORKLIGHTS WIRING
(MACHINE WITHOUT FRONT LIFT)........................................170
CAB FULL AND DIPPED BEAM HEADLIGHTS
(WITH FRONT LIFT).................................................................170
CAB ROOF FRONT AND REAR WORKLIGHTS WIRING .......171
LIGHTS SELECTOR SWITCH WIRING...................................177
ARMREST WIRING .................................................................181
FUSES AND RELAYS CONTROL UNIT (1/2) ..........................183
FUSES AND RELAYS CONTROL UNIT (2/2) ..........................184
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