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Same Diamond 2 II 230 260 service repair workshop manual
230
260
language:english
number of pages: 604 (full digital version)
Main sections:
Introduction
Safety sections
1. TRANSMISSION ................................................................. 1
INTRODUCTION.................................................................. 1
1.1 FLUID COUPLING........................................................ 2
1.2 TRANSMISSION .......................................................... 3
1.2.1 MAIN COMPONENTS .......................................3
1.2.2 TRANSMISSION HYDRAULIC SYSTEM ...........6
1.2.3 GEARBOX..........................................................7
GEARBOX COMPONENTS ........................................8
1.2.4 MAIN CLUTCH ..................................................9
1.2.5 HYDRAULIC GEARBOX AND SHUTTLE
DISTRIBUTION VALVE ....................................10
1.2.6 CLUTCH ENGAGEMENT AND SOLENOID
VALVE OPERATION SCHEMATIC...................14
1.2.7 TRANSMISSION ELECTRONIC SYSTEM
SCHEMATIC....................................................15
1.3 REAR AXLE ................................................................ 16
1.4 REAR PTO.................................................................. 18
2. BRAKING SYSTEM.......................................................... 19
2.1 BRAKE MASTER CYLINDER ..................................... 20
2.2 BRAKE ....................................................................... 20
2.3 TRAILER BRAKING SYSTEM .................................... 22
2.3.1 HYDRAULIC TRAILER BRAKING
(ITALY VERSION).............................................22
2.3.2 HYDRAULIC TRAILER BRAKING
(EXPORT VERSION) ........................................24
2.3.3 AIR TRAILER BRAKING
(ITALY VERSION).............................................26
2.3.4 AIR TRAILER BRAKING
(EXPORT VERSION) ........................................27
COMPRESSOR ........................................................28
PRESSURE LIMITING VALVE...................................29
CAB SUSPENSION FEED VALVE ............................30
BRAKE APPLY SOLENOID VALVE...........................31
TRAILER BRAKING VALVE (2-WAY) ........................32
TRAILER BRAKING VALVE (1-WAY) ........................33
3. HYDRAULIC FRONT AXLE SUSPENSION..................... 34
3.1 FRONT SUSPENSION CONTROL VALVE ................. 35
4. FRONT AXLE.................................................................... 39
4.1 HUB CARRIER AND FINAL REDUCTION UNIT......... 40
4.2 DIFFERENTIAL........................................................... 41
4.3 STEERING ANGLE SENSOR .................................... 41
5. HYDRAULIC SYSTEM..................................................... 43
DESCRIPTION................................................................... 43
HYDRAULIC SYSTEM....................................................... 44
5.1 VARIABLE DISPLACEMENT PUMP........................... 45
5.1.1 BOOST PUMP................................................. 48
5.1.2 HYDRAULIC PUMP......................................... 49
5.1.3 LOAD SENSING VALVE, PRESSURE
CUT-OFF VALVE............................................. 51
5.2 POWER STEERING.................................................... 59
5.3 PRIORITY VALVE ....................................................... 60
5.4 AUXILIARY SERVICES CONTROL VALVE................. 61
5.4.1 MAIN COMPONENTS..................................... 62
5.4.2 SERVICES CONTROL SECTION .................... 63
5.4.3 DESCRIPTIONS OF COMPONENTS .............. 64
5.4.4 LIFT CONTROL VALVE SECTION................... 66
OPERATORS MANUAL SERDIA (LEVEL III) .................... 1
1. ENTRY AND COMMUNICATION ........................................ 2
1.1 OVERVIEW........................................................................... 2
1.2 ORDERING ....................................................................... 3
1.3 SWITCH ON NOTEBOOK AND INSTALL SOFTWARE .... 4
1.4 USER LEVEL, ACCESS AUTHORIZATION....................... 5
1.5 MAKING A CONNECTION BETWEEN ECU
(ENGINE) AND NOTEBOOK ............................................. 6
1.6 PROGRAM START ........................................................... 6
1.7 OFFLINE MODE................................................................ 7
1.8 WORKING WITH THE PROGRAM.................................... 9
1.9 PRINT (OUTPUT) ............................................................ 11
1.10 PROTOCOL (PROTOKOLL)............................................ 12
1.11 END COMMUNICATION ................................................ 12
2. ECU SELECTION .............................................................. 13
2.1 GENERAL ....................................................................... 13
2.2 RECOGNITION OF ECUS............................................... 13
2.3 IDENTIFICATION DATA.................................................. 13
3. MEASURED VALUES ....................................................... 14
3.1 ACTUAL MEASURED VALUES (GENERAL) ................... 14
3.2 RAM VALUES ................................................................. 18
3.3 DATA LOGGER (ONLY EMS) ......................................... 18
3.4 INPUT/OUTPUT ASSIGNMENT ..................................... 18
3.5 CAN-Status .................................................................... 18
3.6 EXAMPLE OF A DISPLAYED ERROR INFORMATION:.. 20
4. PARAMETERS .................................................................. 21
4.1 CONFIGURATION .......................................................... 21
4.2 OVERALL PROGRAMMING ........................................... 32
4.3 CALIBRATION ................................................................ 32
5. ERROR MEMORY ............................................................ 34
5.1 GENERAL ....................................................................... 34
6. FUNCTION TEST .............................................................. 39
6.1 GENERAL ....................................................................... 39
7. EXTRAS ............................................................................ 40
7.1 MAXIMUM VEHICLE SPEED.......................................... 40
7.2 LOGISTIC DATA ............................................................. 40
7.3 LOAD SPECTRUM (ONLY EMS) .................................... 41
7.4 MAINTENANCE INTERVAL EXCEEDED (ONLY EMS).... 41
7.5 OVERRIDE MEMORY (ONLY EMS)................................ 41
8. WHAT SHOULD YOU DO IF ...? ....................................... 42
8.1 SERDIA IN GENERAL..................................................... 42
8.2 EMR................................................................................ 45
9. SERDIA UPGRADE FROM VERSION 2.5
TO VERSION 3.1 .............................................................. 57
9.1 IMPROVEMENTS AND HELP WITH PROBLEMS IN
COMMUNICATING WITH NOTEBOOKS/WIN 98........... 57
9.2 NEW ENTRY MASK WITH MEASURED VALUES AND
COLOURED-CODED INDICATION OF
CONNECTION STATUS ................................................. 58
9.3 NEW SWITCH JOBS FOR PERFORMING
SELECTED SERVICING OPERATIONS,
E.G. ADJUSTING CONTROLLER OR ADJUSTING
OFFSET...........................................................................59
9.4 IN- AND OUTPUT ASSIGNMENT IS NOW ADDITIONALLY
CONFIGURABLE USING PLAIN TEXT
(PREVIOUSLY ONLY CODE NUMBERS)........................60
9.5 UPGRADES IN "PARAMETER
SETTING/CONFIGURATION.........................................60
OPERATORS MANUAL EDS
(Electronic Diagnosis System) ........................................... 61
1. GENERAL INTRODUCTION ..............................................62
1.1 FUNCTIONAL SCOPE ....................................................62
1.2 HARDWARE REQUIREMENTS.......................................63
1.3 STARTING AND TERMINATING OF THE
EDS PROGRAM..............................................................65
2. TRANSMISSION DIAGNOSIS ...........................................67
2.1 THE MAIN MENU............................................................67
2.2 ONLINE HELP.................................................................69
3. POWER-SHUTTLE DIAGNOSISPROGRAMM DEST 45 ...71
3.1 PREPARATIONS FOR TRANSMISSION
DIAGNOSIS WITH DEST 45............................................71
3.2 DEST 45 PROGRAM DESCRIPTION .............................72
3.3 ERROR CODES POWER-SHUTTLE /DEST 45...............87
3.4 DISPLAY POWERSHUTTLE ...........................................88
3.5 ERROR CODE LIST WITH DESCRIPTION......................89
3.6 OTHER INFORMATIONS ..............................................100
3.7 SENSORS AND SOLENOID VALVES AT THE
TRANSMISSION T-7100...............................................101
3.8 ELECTRO-HYDRAULIC GEAR SHIFT T-7100..............102
3.9 SENSORS AND SOLENOID VALVES AT THE
TRANSMISSION T-7200...............................................103
3.10 ELECTRO-HYDRAULIC GEAR
SHIFT T-7200 / T-7300.................................................104
3.11 ERROR ANALYSIS........................................................105
4. PREPARATIONS FOR DIAGNOSIS OF
THE INFOCENTER ...........................................................107
4.1 PROGRAM DESCRIPTION ...........................................108
4.2 CONSTANT VALUES FOR INFOCENTER ....................118
ALL ROUND TESTER MANUAL -MK3 230-260 SERIES . 123
ELECTRONIC COMPONENTS CONTROL AND
SETTING SYSTEM ................................................................123
PRESENTATION SCREEN .....................................................124
MAIN MENU...........................................................................124
1. MONITOR...........................................................................125
2. PARAMETERS....................................................................129
3. CALIBRATIONS..................................................................131
4. ALARMS LIST.....................................................................136
ACCESSORIES
AIR COMPRESSOR
Removal.................................................................... 23
Installation ................................................................ 24
CAB AIR SPRINGS AND HYDRAULIC DAMPERS
Renewal .................................................................. 187
FLEXIBLE COUPLING OF THE FRONT PTO
Removal and installation .......................................... 52
FRONT PTO ASSEMBLY
Removal.................................................................... 94
Installation ................................................................ 95
QUICK-ACTION HYDRAULIC COUPLERS FOR
IMPLEMENTS AND LS
Removal and installation ........................................ 204
TOWING HITCH
Removal.................................................................. 202
Installation .............................................................. 203
TRAILER BRAKING VALVES AND AIR RESERVOIR
Removal................................................................... 25
Installation ................................................................ 29
TRAILER AIR BRAKES COUPLING VALVES
Removal and installation .......................................... 30
AIR CONDITIONING
AIR CONDITIONING COMPRESSOR
Removal.................................................................... 35
Installation ................................................................ 36
AIR CONDITIONING EVAPORATOR
Removal.................................................................. 169
Installation .............................................................. 170
AIR CONDITIONING SYSTEM
Functioning............................................................... 32
Maintenance............................................................. 33
Discharging, flushing and recharging ............................34
CLIMATE CONTROL PANEL
Removal and installation ........................................ 163
COMPLETE CONDENSER ASSEMBLY
Removal.................................................................... 39
Installation ................................................................ 40
COMPRESSOR DRIVEBELTS
Adjusting the tension................................................ 33
COMPRESSOR FAN
Removal.................................................................... 20
Installation ................................................................ 22
COMPRESSOR FAN DRIVEBELTS
Rimozione................................................................. 20
CONDENSER FAN
Removal and installation .......................................... 38
HEATER MATRIX
Removal.................................................................. 166
Installation .............................................................. 168
HEATER VALVE
Renewal .................................................................. 164
LEFT-HAND AIR CONDITIONING FAN
Removal and installation ........................................ 172
RECEIVER-DRIER
Removal and installation .......................................... 37
RIGHT-HAND AIR CONDITIONING FAN
Removal and installation ........................................ 171
CAB
CAB
Removal.................................................................. 177
Installation .............................................................. 186
CAB ACCESS STEPS
Removal and installation .......................................... 15
CAB DOOR CABLE
Renewal .................................................................. 173
CENTRE CONSOLE AND SHROUD
Removal.................................................................. 136
Installation .............................................................. 139
DRIVER'S SEAT
Removal and installation ........................................ 129
LEFT-HAND CONSOLE
Removal.................................................................. 147
Installation .............................................................. 148
MULTIFUNCTION ARMREST CONSOLE
Removal.................................................................. 130
Installation .............................................................. 131
RIGHT-HAND CONSOLE
Removal.................................................................. 140
Installation .............................................................. 146
STEERING WHEEL, STEERING COLUMN
SWITCH UNIT AND INSTRUMENT PANEL
Removal ..................................................................132
Installation ...............................................................133
STEERING WHEEL, STEERING COLUMN
SWITCH UNIT AND INSTRUMENT PANEL
Renewal...................................................................134
Assembly.................................................................135
TRAILER BRAKING AIR PRESSURE GAUGE
Removal and installation .........................................175
TRANSMISSION STATUS DISPLAY
Removal and installation .........................................176
CHASSIS
4WD PROPELLER SHAFT
Removal ....................................................................59
Installation .................................................................60
BATTERY
Removal and installation ...........................................14
BATTERY SUPPORT
Removal and installation ...........................................16
FRONT BEARING OF THE 4WD PROPELLER SHAFT
Removal ....................................................................61
Installation .................................................................62
FRONT FENDERS
Removal and installation ...........................................85
FRONT WHEELS
Removal and installation ...........................................84
FUEL TANKS
Removal ..................................................................111
Installation ...............................................................112
REAR WHEELS
Removal and installation ...........................................86
ELECTRICAL AND ELECTRONIC
SIDE PANELS
ACCELERATOR POTENTIOMETER
Renewal and checking ............................................109
CLUTCH PEDAL AND RELATED DEVICES ............. 154
ENGINE ECU
Removal and installation .........................................153
FUSE AND RELAY BOARD
Removal ..................................................................151
Installation ...............................................................152
TRANSMISSION LIFT AND FRONT SUSPENSION
ELECTRONIC CONTROL UNITS
Removal ..................................................................149
Installation ...............................................................150
ENGINE
AIR INTAKE PIPE
Removal and installation ...........................................54
ALTERNATOR
Removal ....................................................................18
Installation .................................................................19
ALTERNATOR BELT
Renewal and adjusting the tension ...........................21
COMPLETE AIR CLEANER ASSEMBLY
Removal and installation .......................................... 55
ENGINE
Removal ................................................................. 189
Installation .............................................................. 192
EXHAUST PIPE
Removal and installation .......................................... 56
FLUID COUPLING AND THE FLYWHEEL
Removal ................................................................. 193
Installation .............................................................. 199
FUEL PUMP BELT
Renewal and adjusting the tension .......................... 21
INTERCOOLER
Removal ................................................................... 46
Installation ................................................................ 47
SILENCER
Removal ................................................................... 57
Installation ................................................................ 58
STARTER MOTOR
Removal and installation .......................................... 17
TURBOCHARGER
Removal and installation .......................................... 53
ENGINE HOODS
Adjustments .................................................................. 11
FRONT AXLE
FRONT AXLE AND SWINGING SUPPORT
Removal ................................................................. 101
Installation .............................................................. 104
FRONT CARRIER
Removal and installation ........................................ 105
FRONT SUSPENSION SOLENOID VALVES
Removal ................................................................. 106
Installation .............................................................. 108
Disassembly and assembly.................................... 109
FRONT SUSPENSION SOLENOID VALVES
Removal ................................................................. 106
Installation .............................................................. 107
FRONT SUSPENSION POSITION SENSOR
Removal and calibration......................................... 108
FRONT LIFT
FRONT LIFT ASSEMBLY
Removal ................................................................... 91
Installation ................................................................ 93
FRONT LIFT CYLINDERS
Removal ................................................................... 88
Installation ................................................................ 90
FRONT LIFT VALVE BLOCK
Removal and installation .......................................... 87
HYDRAULIC BRAKES
ADJUSTMENT OF THE BRAKE LIGHT SWITCHES .. 68
BRAKE MASTER CYLINDERS
Removal ................................................................... 63
Installation ................................................................ 65
BLEEDING THE BRAKING SYSTEM...........................66
PARKING BRAKES
Adjustment ............................................................. 162
PARKING BRAKE SWITCH
Adjustment ............................................................. 161
HYDRAULIC SYSTEM
AUXILIARY SERVICES CONTROL VALVES
Removal.................................................................. 118
Installation .............................................................. 119
AUXILIARY SERVICES PUMPS
Checking ................................................................ 113
Removal.................................................................. 114
Installation ............................................................. 116
AUXILIARY SERVICE VALVE CONTROL CABLES
Removal.................................................................. 159
Installation .............................................................. 160
CONTROL PANELS AND LEVERS OF THE
AUXILIARY SERVICE VALVES
Removal.................................................................. 156
Installation .............................................................. 158
PRIORITY VALVE
Removal and installation ........................................ 117
LIFT
LIFT CYLINDERS
Removal.................................................................. 120
Installation ............................................................. 121
Disassembly and assembly.................................... 122
LIFT DRAFT SENSOR
Removal and installation ........................................ 128
LIFT POSITION SENSOR
Checking ................................................................ 123
Removal and adjustment........................................ 124
LOWER LINKS OF THE HYDRAULIC LINKAGE
Removal.................................................................. 200
Installation .............................................................. 201
RADIATORS - COOLERS
COMPLETE RADIATOR-COOLERS ASSEMBLY
Removal.................................................................... 48
Installation ................................................................ 51
EXPANSION TANK
Removal and installation .......................................... 45
GEARBOX OIL AND FUEL COOLERS
Removal and installation .......................................... 41
RADIATOR
Removal.................................................................... 42
Installation ................................................................ 44
STEERING SYSTEM
POWER STEERING UNIT
Removal.................................................................... 69
Installation ................................................................ 70
Disassembly ............................................................. 71
Assembly .................................................................. 77
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....................................................... 16
3. COMPONENTS ..................................................... 23
3.1 CONNECTOR LAYOUTS................................................. 23
3.2 COMPONENT TECHNICAL DATA................................... 28
3.3 PINOUTS AND DESCRIPTIONS OF
ELECTRONIC CONTROL UNITS..................................... 36
4. SYSTEMS .............................................................. 45
4.1 EARTHING POINTS......................................................... 45
4.2 STARTING ....................................................................... 46
4.3 PREHEATING .................................................................. 47
4.4 ELECTRICAL ENGINE CONTROL ................................... 48
4.5 LIGHTS - STEERING COLUMN SWITCH UNIT............... 49
4.6 CAB ACCESSORIES ....................................................... 50
4.7 WORKLIGHTS ................................................................. 51
4.8 WINDSCREEN WIPERS................................................... 52
4.9 INFOCENTER .................................................................. 53
4.10 POWER OUTLET SOCKETS............................................ 54
4.11 RADIO - CB ..................................................................... 55
4.12 AIR CONDITIONING - HEATER FANS............................. 56
4.13 BRAKING SYSTEM.......................................................... 57
4.14 TRAILER BRAKES ........................................................... 58
4.15 FRONT AXLE SUSPENSION ........................................... 59
4.16 TRANSMISSION.............................................................. 60
4.17 ASM - 4WD DIFFERENTIAL.......................................... 61
4.18 ELECTRONIC LIFT .......................................................... 62
4.19 FRONT AND REAR PTO.................................................. 63
5. LAYOUTS, ELECTRICAL WIRING DIAGRAMS,
CONNECTOR POSITIONS .................................... 65
ENGINE WIRING (KHD) (1/2).....................................................67
ENGINE WIRING (KHD) (2/2).....................................................68
ENGINE WIRING (1/2) ...............................................................73
ENGINE WIRING (2/2) ...............................................................74
FRONT LIGHTS WIRING...........................................................75
FRONT PTO WIRING ................................................................76
TRANSMISSION WIRING (1/2) .................................................87
TRANSMISSION WIRING (2/2) .................................................88
TRAILER BRAKING WIRING (ITALY) ........................................99
TRAILER BRAKING WIRING (EXPORT) ..................................100
FRONT AXLE SUSPENSION WIRING (CAB LINE)..................103
CAB POWER SUPPLY WIRING..............................................107
FRONT AXLE SUSPENSION WIRING.....................................113
FENDER WIRING ....................................................................117
NUMBER PLATE LIGHT WIRING............................................118
FRONT CONSOLE WIRING (1/2) ............................................123
FRONT CONSOLE WIRING (2/2) ............................................124
SIDE CONSOLE WIRING (1/3) ................................................129
SIDE CONSOLE WIRING (2/3) ................................................130
SIDE CONSOLE WIRING (3/3) ................................................131
AIR CONDITIONING SYSTEM WIRING ..................................141
DISPLAY WIRING....................................................................147
ROOF WIRING (1/2) ................................................................151
ROOF WIRING (2/2) ................................................................152
ARMREST WIRING .................................................................161
CONTROL UNIT - FUSES - RELAYS (1/2)..............................163
CONTROL UNIT - FUSES - RELAYS (2/2)..............................164
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