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Same Rubin 160 180 200 service repair workshop manual book
160
180
200
language:english
number of pages: 804 (full digital version)
Main sections:
HYDRAULIC SYSTEM.................................................. 1
INTRODUCTION.................................................................. 1
HYDRAULIC DIAGRAM (1/3)............................................... 4
HYDRAULIC DIAGRAM (2/3)............................................... 5
HYDRAULIC DIAGRAM (3/3)............................................... 6
A. OIL LEVEL MAINTENANCE CIRCUIT ............................ 7
B. STEERING AND POWER SHIFT
CONTROL CIRCUIT ....................................................... 7
C. AUXILIARY SERVICES AND
LUBRICATION CIRCUIT................................................ 8
OIL LEVEL MAINTENANCE CIRCUIT PUMP ............. 9
VARIABLE DISPLACEMENT PUMP......................... 10
AUXILIARY SERVICES CONTROL VALVE .............. 24
DEFINITIONS OF VALVE ELEMENTS ............................... 25
CONTROL VALVE TYPES................................................. 26
MAIN CLUTCH CONTROL VALVE ............................ 28
POWER SHIFT CONTROL VALVE............................. 29
SERVICES CONTROL VALVE.................................... 38
RANGE GEARBOX CONTROL VALVE...................... 39
POWER STEERING .................................................... 40
TRAILER BRAKING VALVE........................................ 41
ITALY VERSION ............................................................... 41
EXPORT VERSION........................................................... 43
POWER SHIFT TRANSMISSION ............................... 45
FRONT AXLE .............................................................. 63
REAR AXLE................................................................. 65
REAR PTO.................................................................. 67
REAR POWER LIFT .................................................... 72
BRAKING SYSTEM..................................................... 77
HYDRAULIC FRONT AXLE SUSPENSION ............... 83
FRONT SUSPENSION CONTROL VALVE................. 84
SYSTEM FOR TESTING AND CALIBRATION OF
ELECTRONIC COMPONENTS
System conformation .......................................................1
Connection of the Tester to the ECU ...............................2
Introductory screen ..........................................................3
ENGINE ECU TESTER
Manual ..............................................................................5
List of alarm codes .........................................................23
TRANSMISSION ECU TESTER
Manual ............................................................................27
List of alarm codes .........................................................41
LIFT ECU TESTER
Manual ............................................................................53
List of alarm codes .........................................................68
ARMREST ECU TESTER
Manual ............................................................................71
List of alarm codes .........................................................86
Alarm codes for BOSCH electro-hydraulic
control valve ....................................................................87
ELECTRICAL DIAGRAMS
Functional diagram......................................................... 89
0.011.5375.4/03 Suspended front axle wiring ............... 90
0.011.5376.4/02 Suspended front axle cab wiring (1/2) 91
0.011.5376.4/02 Suspended front axle cab wiring (2/2) 92
0.011.5445.4/00 Diagnostic wiring................................. 93
0.011.7032.4/00 Wiring for press. cab (Germany) ......... 94
0.010.8700.4/21 Cab roof wiring (1/2) ........................... 95
0.010.8700.4/21 Cab roof wiring (2/2) ........................... 96
0.011.9237.4/11 Cab FPS wiring (1/2) ........................... 97
0.011.9237.4/11 Cab FPS wiring (2/2) ........................... 98
0.011.8683.4/12 40S Front wiring (1/2).......................... 99
0.011.8683.4/12 40S Front wiring (2/2)........................ 100
0.010.8707.4/10 Draft angle sensor wiring .................. 101
0.010.8708.4/82 HS subframe wiring (1/4) .................. 102
0.010.8708.4/82 HS subframe wiring (2/4) .................. 103
0.010.8708.4/82 HS subframe wiring (3/4) .................. 104
0.010.8708.4/82 HS subframe wiring (4/4) .................. 105
0.010.8710.4/41 HS central wiring (1/2)....................... 106
0.010.8710.4/41 HS central wiring (2/2)....................... 107
0.011.8420.4/01 Link-box wiring ................................. 108
0.011.8453.4/00 Fans guard ........................................ 109
0.011.8481.4/03 40S Lights-fans wiring ...................... 110
0.010.8711.4/20 Rear light cables ............................... 111
0.010.8712.4/32 Switches wiring (1/2)......................... 112
0.010.8712.4/32 Switches wiring (2/2)......................... 113
0.010.8714.4/44 Light cables....................................... 114
0.011.8468.04/01 Battery cables ................................. 115
0.011.9245.4/00 Rear wiring (1/2) ................................ 116
0.011.9245.4/00 Rear wiring (2/2) ................................ 117
0.011.9236.4/11 FPS wiring (1/2)................................. 118
0.011.9236.4/11 FPS wiring (2/2)................................. 119
0.011.9260.4/01 Filter clogging wire............................ 120
0.010.9139.4/12 Manual climate control wiring ........... 121
0.011.8454.4/11 A/C compressor wiring ..................... 122
0.011.8747.4/01 wiring with 3 relays for steering
column lights switch...................................................... 123
0.011.9643.4/00 35S Wiper timer wiring...................... 124
0.011.9439.4/00 Air pressure switch wiring Italy. ........ 125
0.011.9430.4/11 Air pressure switch wiring Germany . 126
2.8399.146.0/50 Instrument with computer L1............ 127
ENGINE HOOD, SIDE PANELS AND GRILLE
Removal ...................................................................... 1
Adjustment.................................................................. 1
STARTER MOTOR
Removal ...................................................................... 3
Refitting....................................................................... 3
ALTERNATOR
Removal ...................................................................... 4
Refitting...................................................................... 4
TENSIONING AND RENEWAL OF THE
ALTERNATOR DRIVEBELT ........................................ 5
AIR COMPRESSOR
(for air trailer braking)
Removal ...................................................................... 7
Refitting....................................................................... 8
TRAILER AIR BRAKING UNITS AND
THE CAB SUSPENSION
(EXPORT D Version)
Removal ...................................................................... 9
Refitting..................................................................... 11
AIR CONDITIONING SYSTEM
Operation .................................................................. 13
Servicing ................................................................... 14
CONDENSER COOLING FANS
Tensioning................................................................. 14
DISCHARGING, FLUSHING AND RECHARGING
THE AIR CONDITIONING SYSTEM........................... 15
AIR CONDITIONING COMPRESSOR
Removal .................................................................... 16
Refitting..................................................................... 16
CONDENSER COOLING FANS
Removal .................................................................... 18
Refitting..................................................................... 18
RECEIVER-DRIER
Removal .................................................................... 19
Refitting..................................................................... 19
CONDENSER ASSEMBLY
Removal .................................................................... 20
Refitting..................................................................... 20
FANS - CONDENSER - RECEIVER/DRIE
ASSEMBLY
Removal .................................................................... 21
Refitting..................................................................... 23
AUTOCLEAN SCREEN
Removal .................................................................... 24
Refitting..................................................................... 25
INTERCOOLER
Removal .................................................................... 26
Refitting..................................................................... 27
GEARBOX OIL COOLER
Removal .................................................................... 28
Refitting..................................................................... 28
FRONT PTO OIL COOLER
Removal .................................................................... 29
Refitting..................................................................... 29
RADIATOR
Removal .................................................................... 30
Refitting..................................................................... 32
EXPANSION TANK
Removal .................................................................... 33
Refitting..................................................................... 33
THERMOSTAT VALVES
Removal .................................................................... 34
Refitting..................................................................... 34
COOLANT PUMP
Removal .................................................................... 35
Refitting..................................................................... 37
OIL PRESSURE SENSOR AND SENDER UNIT
Inspection and renewal............................................. 38
ELECTRONIC ACTUATOR
Removal .................................................................... 39
Refitting..................................................................... 39
Calibration................................................................. 40
INJECTION PUMPS
Removal .................................................................... 41
Refitting..................................................................... 42
SUCTION FILTER
Removal .................................................................... 43
Refitting..................................................................... 44
EXHAUST PIPE AND SILENCER
Removal .................................................................... 45
Refitting..................................................................... 47
TURBOCHARGER
Removal .................................................................... 48
Refitting..................................................................... 49
ROCKER COVERS
Removal.....................................................................50
Refitting .....................................................................51
ENGINE SPEED SENSOR (PICK-UP UNIT)
Removal.....................................................................52
Refitting .....................................................................52
FRONT CRANKSHAFT SEAL
Renewal .....................................................................53
Refitting .....................................................................55
BRAKE PUMPS
Removal.....................................................................57
Refitting .....................................................................57
BRAKE PEDALS AND MICROSWITCHES
Adjustment and alignment.........................................58
BRAKING SYSTEM
Bleeding.....................................................................59
POWER STEERING
Checking....................................................................60
Removal.....................................................................61
Refitting .....................................................................62
Dismantling................................................................63
Assembly ...................................................................70
FRONT WHEELS
Removal.....................................................................80
Refitting .....................................................................80
FRONT BRAKES
Overhaul ....................................................................81
Assembly ...................................................................84
EPICYLIC REDUCTION UNITS OF THE FRONT AXLE
Dismantling................................................................85
Assembly ...................................................................89
STUB AXLE HOUSINGS AND FRONT HALFSHAFTS
Dismantling................................................................90
Assembly ...................................................................96
STEERING SENSOR
Removal...................................................................101
Refitting ...................................................................101
STEERING CYLINDERS
Removal...................................................................102
Refitting ...................................................................102
FRONT LIFT CYLINDERS AND ROCKERS
Removal...................................................................103
Refitting ...................................................................104
FRONT SUSPENSION SOLENOID VALVES
Removal...................................................................105
Refitting ...................................................................105
FRONT SUSPENSION CYLINDERS (when fitted)
Removal...................................................................106
Refitting ...................................................................107
STEERING CYLINDERS AND FRONT SUSPENSION
Dismantling and assembly.......................................108
FRONT AXLE AND SUPPORT ASSEMBLY
(Version with front suspension)
Removal .................................................................. 112
Refitting................................................................... 114
FRONT SUSPENSION POSITION SENSOR
Positioning .............................................................. 115
FRONT AXLE DIFFERENTIAL
Dismantling ............................................................. 116
Assembly ................................................................ 127
FRONT AXLE SUPPORT BUSHINGS
Renewal .................................................................. 140
Assembly ................................................................ 141
ADJUSTING END FLOAT OF
FRONT AXLE MOUNTINGS..................................... 142
FRONT CARRIER
(Version with front suspension)
Removal .................................................................. 144
Refitting................................................................... 146
FRONT PTO
Removal .................................................................. 147
Refitting................................................................... 149
Dismantling ............................................................. 150
Assembly ............................................................... 162
ANTISHOCK VALVE AND ACCUMULATORS
OF THE FRONT LIFT
Removal .................................................................. 172
Refitting................................................................... 172
BATTERY SUPPORT
Removal .................................................................. 173
Refitting................................................................... 174
FUEL TANKS
(Normal and supplementary)
Removal .................................................................. 175
Refitting................................................................... 177
PROPELLER SHAFTS
Removal .................................................................. 178
Refitting................................................................... 178
RENEWAL OF THE FRONT AXLE PINION OIL SEAL
Renewal .................................................................. 179
CLUTCH CONTROL UNIT
Removal .................................................................. 180
Refitting................................................................... 181
Dismantling ............................................................. 182
Assembly ................................................................ 183
REAR WHEELS
Removal .................................................................. 184
Refitting................................................................... 184
COMPLETE PUMP ASSEMBLY
Removal .................................................................. 185
Refitting................................................................... 185
TESTING THE AUXILIARY SERVICES PUMP ........ 186
30-iii
PUMPS
Removal .................................................................. 187
Refitting................................................................... 190
PUMP DRIVE
Dismantling ............................................................. 191
Assembly ................................................................ 193
POWER SHIFT CONTROL VALVE
Removal .................................................................. 194
Refitting................................................................... 194
Dismantling ............................................................. 195
Assembly ................................................................ 199
SHUTTLE ASSEMBLY
Removal and dismantling ....................................... 200
Assembly and refitting ............................................ 202
Dismantling and adjustment ................................... 203
Assembly ................................................................ 208
RANGE GEARBOX CONTROL UNIT
Removal .................................................................. 209
Refitting................................................................... 209
Dismantling ............................................................. 210
Assembly ................................................................ 213
AUXILIARY CONTROL VALVE ASSEMBLY
Removal .................................................................. 214
Refitting................................................................... 216
Dismantling ............................................................. 217
Assembly ................................................................ 221
SUPPLEMENTARY LIFT CYLINDERS
Dismantling and assembly...................................... 222
LIFT DRAFT SENSOR
Removal .................................................................. 223
Refitting................................................................... 223
LIFT
Removal .................................................................. 224
Refitting................................................................... 227
Dismantling ............................................................. 228
Assembly ............................................................... 233
ARM-REST CONTROLS
Removal .................................................................. 234
Refitting................................................................... 234
STEERING WHEEL, STEERING COLUMN
SWITCH UNIT, INSTRUMENT PANEL
Removal .................................................................. 235
Refitting................................................................... 236
INSTRUMENT PANEL SHROUD
Removal .................................................................. 237
Refitting................................................................... 238
RIGHT-HAND CONSOLE
Removal .................................................................. 239
Refitting................................................................... 242
LEFT-HAND CONSOLE
Removal .................................................................. 243
Refitting................................................................... 244
ELECTRONIC CONTROL UNITS
Removal .................................................................. 245
Refitting................................................................... 245
FUSE BLOCK
Removal .................................................................. 246
Refitting................................................................... 246
ACCELERATOR POTENTIOMETER
Renewal .................................................................. 247
Refitting................................................................... 247
CLUTCH PEDAL AND CONNECTED DEVICES...... 248
CONTROL CABLES OF THE AUXILIARY
SERVICE VALVES
Renewal .................................................................. 249
Refitting................................................................... 250
STANDARD CONTROL LEVERS AND PUSHBUTTON
PANEL FOR THE AUXILIARY SERVICE VALVES
Removal .................................................................. 251
Refitting................................................................... 252
CROSS-GATE CONTROL LEVER AND PUSHBUTTON
PANEL FOR THE AUXILIARY SERVICE VALVES
Removal .................................................................. 253
Refitting................................................................... 254
HEATER VALVE
Removal .................................................................. 255
Refitting................................................................... 255
HEATER MATRIX
Removal .................................................................. 256
Refitting................................................................... 258
AIR CONDITIONING EVAPORATOR
Removal .................................................................. 259
Refitting................................................................... 260
RIGHT-HAND BLOWER OF THE
AIR CONDITIONING SYSTEM
Removal .................................................................. 261
Refitting................................................................... 261
LEFT-HAND BLOWER OF THE
AIR CONDITIONING SYSTEM
Removal .................................................................. 262
Refitting................................................................... 262
WINDSCREEN WIPERS
Removal .................................................................. 263
Refitting................................................................... 263
Section 40 about engine transmission and another thing
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