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Workshop Manual.....................................................................................................2002 6-51250
Workshop Manual (TVT 195) ...................................................................................2002A 6-93080
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Functional description Injection System ...................................................................3001 6-51300
Functional description Injection System - Common Rail System (TVT 195) ............3001A 6-93150
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Functional description CAN Bus (Basics).................................................................4002 6-51350
Functional description and Troubleshooting – ADIC ................................................4003 6-91700
Function diagrams - Electrics ...................................................................................4008 6-92771
Function diagrams - Electrics (TVT 195) ..................................................................4008A 6-93221
Connectors, Wiring Harnesses, Electrical and Electronic Components ...................4009 6-92970
Connectors, Wiring Harnesses, Electrical and Electronic Components (TVT 195)..4009A 6-93290
Circuit diagram .........................................................................................................4010 6-51402
Circuit diagram (TVT 195) ........................................................................................4010A 6-93360
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Fault codes ...............................................................................................................4011 6-52632
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Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.25S.....................................................5001 6-51450
Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.29S.....................................................5002 6-51500
Workshop Manual - Front Axle - Carraro 20.25, 20.25 FR.......................................5005 6-51550
Workshop Manual - Independently Suspended Front Axle 20.25S and 20.25SI FR5006 6-51600
Workshop Manual - Independently Suspended Front Axle 20.29SI / FR .................5007 6-51651
75$160,66,21
Functional description Transmission ........................................................................6001 6-51700
Troubleshooting - System hydraulics .......................................................................6002 6-51750
Cartridge - Removing and Fitting..............................................................................6005 6-51800
Cartridge - Disassembling and Assembling..............................................................6006 6-51850
Rear Axle - Removing and Fitting.............................................................................6007 6-51900
Rear Axle - Disassembling and Assembling.............................................................6008 6-51950
Parking Interlock, 4-wheel Drive Clutch and Bevel Pinion (Rear Module)................6009 6-52000
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Functional description and troubleshooting Air Conditioning ................................... 9002 6-92840
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Fault codes .............................................................................................................. 4011 6-52632
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Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.25S.................................................... 5001 6-51450
Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.29S.................................................... 5002 6-51500
Workshop Manual - Front Axle - Carraro 20.25, 20.25 FR ...................................... 5005 6-51550
Workshop Manual - Independently Suspended Front Axle 20.25S and 20.25SI FR5006 6-51600
Workshop Manual - Independently Suspended Front Axle 20.29SI / FR ................ 5007 6-51651
75$160,66,21
Functional description Transmission ....................................................................... 6001 6-51700
Troubleshooting - System hydraulics....................................................................... 6002 6-51750
Cartridge - Removing and Fitting............................................................................. 6005 6-51800
Cartridge - Disassembling and Assembling............................................................. 6006 6-51850
Rear Axle - Removing and Fitting............................................................................ 6007 6-51900
Rear Axle - Disassembling and Assembling............................................................ 6008 6-51950
Parking Interlock, 4-wheel Drive Clutch and Bevel Pinion (Rear Module)............... 6009 6-52000
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Functional description CC-LS Hydraulic System (Closed Center-Load Sensing) ... 8001 6-52051
Functional description and troubleshooting
High Pressure Hydraulic Circuit............................................................................... 8002 6-92610
Functional description and troubleshooting
(Electronic 3-point hitch control system EDC) ......................................................... 8005 6-52100
Fault codes and fault description, EHS Auxiliary Control Units ............................... 8006 6-52150
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Functional description and troubleshooting Air Conditioning................................... 9002 6-92840
TVT 195
2002
ENGINE WORKSHOP MANUAL
CONSTRUCTION ..................................................................................................................17
General ..............................................................................................................................17
Cylinder block ....................................................................................................................17
Flywheel casing .................................................................................................................17
Cylinder head .....................................................................................................................18
Valve mechanism ..............................................................................................................18
Crankshaft drive .................................................................................................................20
Timing gears ......................................................................................................................21
Lubrication system .............................................................................................................22
Cooling system ..................................................................................................................23
Fan .....................................................................................................................................24
Intake/exhaust system .......................................................................................................25
SS00B068
SS00B064
1 x 380000005 (1TSW 523)
1 x 380000010 (1TSW 519)
Universal pin
Pressing tool for the front crankshaft
shaft sealing ring
SS00B077
1 x 1TSW 18390 M24
SS00B065
Pressing tool for valve guides
1 x 380000002 (1TSW 520)
SS00B069
1 x 380000007 (1TSW 524)
SS00B071
1 x 380000008 (1TSW 014)
SS00B067
1 x 380000004 (1TSW 522)
Sva 6-51250 EN Edition 07/2003
2002-6
Extractor Mini-measuring connection
SS98J031
1 x 380001915 M12x1,5
SS00B070
1 x 1TSW 662 (available from your dealer)
Mini-measuring line
Cylinder liner extractor
SS98J030
1 x 380001127 (1TSW 635)
SS00B072
1 x 1TSW 510 (available from your dealer)
SS00B076
Extraction plate
1 x 380001129 (1TSW 645) Connection
1 x 380001121 (1TSW 5002) Pressure gauge
SS00B073
1 x 380000011 (1TSW 508)
SS03D046
380001487
SS00B075
1 x 380000364 (1TSW 5610) Holder
1 x 380000228 (1TSW 17049-6) Dial test indicator
Engine Engine
type output
620.95 135 PS
620.96 145 PS
620.97 155 PS
620.98 170 PS
Manufacturer
620.99 190 PS
SISU Diesel Inc.
FIN-37240 Linnavuori
e17*97/68EA*97/68EA*0016*00
FINLAND
Type XXXX XXXXX 620.99
regulations large nonroad compression
Engine number
Serial nr M19858 5.05.2003
Valve
0,35 mm
(serial number)
clearance
Timing
TDC 30 degrees
Low idle 850 rpm
ignition engines
Cust.
Part nr 620.99.00.0001
EU
Family D20AEE
EPA
Family 3SIDL7.4G4A
Displacement: 6.6 l Fuel: 2-D fuel oil
Assembled by:
SC03G005
SAFETY REGULATIONS
There is always a risk of getting  Naked flames and smoking are not permitted in the
injured when performing serv- vicinity of fuel tanks or batteries. Electrical sparks
ice and repair work. Before com- should be avoided. (Particularly when charging the
mencing work, the following batteries. Explosion hazard!)
safety regulations and instruc-
tions must be read.
 Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
 Never start repair work which you do not fully electrical system.
understand.
 If the engine gets excessively hot (over 300 °C), for
 Make sure that it is possible to work safely at the example, if it catches fire, the viton seals (e.g.
location and in the vicinity. bottom O-ring on the cylinder liner or the O-ring on
 Make sure the location is clean and in a good
the oil pressure valve) release highly caustic HF
acid. Never touch viton seals, which have been
state.
subjected to unusually high temperatures, with
 Never use wrong or unsuitable tools. bare hands. Always wear neoprene gloves or thick
 Remove all rings, chains and watches before
work gloves and safety goggles when removing
these harmful substances. Wash the seals and
commencing work.
contaminated surfaces with a 10 % hydroxide
 Use state of the art safety equipment. For solution or another alkaline solution. Collect the
example, wear goggles when using compressed material in air-tight sealed plastic bags and bring
air for cleaning, grinding, hammering or similar them to an authorised collecting depot.
work.
,03257$17Viton seals may never be burned!
 Use a lifting device for lifting or transporting heavy
 Fuel, lubrication oil and coolant can cause skin
(over 20 kg) parts. Make sure the hooks and
irritations, if contact is made over a longer period.
chains are in a good condition and sit firmly.
 Never work below an engine hanging from a lifting
 Avoid running the engine in idle unnecessarily.
device or raised by a jack. Always secure the  When carrying out service work, take measures to
engine with strong supports before commencing prevent fuel or other fluids from entering the
work. ground or drains.
 Only use original CNH spare parts.  All seals are asbestos-free.
 Only start the engine from the cab, using the  Be careful when washing the engine using a
ignition key. washing facility with a high water pressure. Do not
wash, for example, the electrical and fuel systems
 Never start the engine with the protective covers
under high pressure as they can easily be
removed.
damaged.
:$51,1* It is difficult to see the radiator fan when
the engine is running! Loose fitting clothes and long
hair can get caught in rotating engine parts!
 If the engine is started in a confined space,
sufficient ventilation must be provided.
 Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
 Ear muffs must be worn when testing the engine or
working close to the engine.
 Always switch the engine OFF before carrying out
repair work.
 Avoid touching the exhaust manifold, turbocharger
and other hot engine parts.
 When the engine is hot and the coolant is
pressurised, be careful on opening the radiator
sealing cover. Coolant and lubrication oil out of the
hot engine can cause severe injuries if contact is
made with the skin.
Sva 6-51250 EN Edition 07/2003
2002-9
ENGINE DATA
Engine type 620.95 620.96 620.97 620.98 620.99
Number of cylinders 6
3
Capacity (dm ) 6,6
Bore (mm) 108
Stroke (mm) 120
Rated power in PS at 2100 rpm 135 145 155 170 190
acc. to ISO 14396
Delivery start mark on the
30
V-belt pulley (° before UDC)
Compression ratio 18,5 : 1 18,5 : 1
Method of combustion direct injection
Injection sequence 1-5-3-6-2-4
Compression pressure1 (bar) 24
2
Charge-air pressure (bar) 0,94 1,03 1,12 1,24 1,45
3
Weight (kg) 510
Direction of rotation of the Clockwise
crankshaft
1
) Minimum value at operating temperature and starter speed.
Highest permissible difference between the cylinders is 3 bar (max.)
2
) Measured behind the charge-air cooler (measuring point: see section entitled "Checking the boost pressure"
page 55), at full load, nominal engine speed and top fan speed
3
) Without flywheel and electrical equipment.
,03257$17After certain repairs to the engine, the fuel system must be bled before starting for the first time (for
details, refer to Chapter 3001, Injection system).
127( The plug-in connection on the PCU must be released and disconnected before performing any arc
welding work. Do not touch the plug-in contacts!
SS99N013
TECHNICAL DATA
Conformance with exhaust standards
Europe: 97/68 EC Level 2
America: Tier 2
Cylinder block
Guide pin bore holes ...................................................................................................... 13.250 - 13.320 mm
Diameter of the crankshaft bearing base bore hole ....................................................... 91.000 - 91.025 mm
Diameter of the crankshaft bearing base bore hole (oversize) ...................................... 92.000 - 92.025 mm
Bore hole diameter of the cylinder liner:
– top ........................................................................................................................... 124.514 - 124.554 mm
– bottom ..................................................................................................................... 123.000 - 123.040 mm
Diameter of the camshaft bearing bush (fitted) .............................................................. 50.010 - 50.070 mm
Construction height of the cylinder block ................................................................... 428.170 - 428.430 mm
Cylinder liners
Liner height above the cylinder block................................................................................. 0.030 - 0.080 mm
Highest permissible height difference between cylinder liners......................................................... 0.02 mm
Diameter of the cylinder liner bore holes in the engine block:
– top end of liner ........................................................................................................ 124.475 - 124.500 mm
– bottom end of liner .................................................................................................. 122.961 - 122.986 mm
Cylinder liner bore hole .............................................................................................. 108.010 - 108.032 mm
Height, cylinder liner flange.................................................................................................... 9.03 - 9.05 mm
Height, cylinder liner flange, 1st oversize............................................................................... 9.08 - 9.10 mm
Height, cylinder liner flange, 2nd oversize ............................................................................. 9.13 - 9.15 mm
Height, cylinder liner flange, 3rd oversize .............................................................................. 9.23 - 9.25 mm
Outer diameter of the cylinder liner flange ................................................................. 131.700 - 131.800 mm
Cylinder head
Construction height of the cylinder head.................................................................... 104.800 - 105.000 mm
Minimum height of the cylinder head after surface grinding....................................................... 104.000 mm
Inner diameter of the valve guide (when not fitted) ............................................................ 9.000 - 9.015 mm
Outer diameter of the valve guide .................................................................................. 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head ................................ 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face................................................................... 21 mm
Depth, valve head below cylinder head surface:
– Inlet valve ................................................................................................... 0.7 ± 0.05 mm (max. 2,20 mm)
– Outlet valve ................................................................................................ 0.6 ± 0.05 mm (max. 2,20 mm)
Valve seat angle:
– Inlet valve ......................................................................................................................................... 35°+20’
– Outlet valve ...................................................................................................................................... 45°+20’
Valve seat width:
– Inlet valve ................................................................................................................................ 2.9 - 3.7 mm
– Outlet valve ............................................................................................................................. 1.3 - 2.3 mm
Diameter, outlet valve seat insert (standard).................................................................. 44.070 - 44.132 mm
Bore hole in cylinder head for outlet valve seat insert (standard) .................................. 44.000 - 44.025 mm
Diameter, outlet valve seat insert (oversize) .................................................................. 44.270 - 44.332 mm
Bore hole in cylinder head for outlet valve seat insert (oversize) ................................... 44.200 - 44.225 mm
Diameter, inlet valve seat insert (standard).................................................................... 48.570 - 48.632 mm
Bore hole in cylinder head for inlet valve seat insert (standard) .................................... 48.500 - 48.525 mm
Diameter, inlet valve seat insert (oversize) .................................................................... 48.770 - 48.832 mm
Bore hole in cylinder head for inlet valve seat insert (oversize) ..................................... 48.700 - 48.725 mm
Crankshaft
Diameter of the con-rod bearing journals:
– Standard dimension ......................................................................................................... 67.981 - 68.000 mm
– 1st. repair level 0.25 mm.................................................................................................. 67.731 - 67.750 mm
– 2nd. repair level 0.50 mm................................................................................................. 67.481 - 67.500 mm
– 3rd. repair level 1.00 mm ................................................................................................. 66.981 - 67.000 mm
– 4th. repair level 1.50 mm.................................................................................................. 66.481 - 66.500 mm
Width of the con-rod bearing journal ................................................................................... 40.000 - 40.160 mm
Diameter of the crankshaft journals:
– Standard dimension ......................................................................................................... 84.985 - 85.020 mm
– 1st. repair level 0.25 mm.................................................................................................. 84.735 - 84.770 mm
– 2nd. repair level 0.50 mm................................................................................................. 84.485 - 84.520 mm
– 3rd. repair level 1.00 mm ................................................................................................. 83.985 - 84.020 mm
– 4th. repair level 1.50 mm.................................................................................................. 83.485 - 83.520 mm
Diameter, crankshaft bearing casing................................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells
– Standard dimension ........................................................................................................ 2.955 - 2.965 mm
– 1st. repair level 0.25 mm................................................................................................. 3.080 - 3.090 mm
– 2nd. repair level 0.50 mm................................................................................................ 3.205 - 3.215 mm
– 3rd. repair level 1.00 mm ................................................................................................ 3.455 - 3.465 mm
– 4th. repair level 1.50 mm................................................................................................. 3.705 - 3.715 mm
Crankshaft bearing play ..................................................................................................... 0.050 - 0.127 mm
Width of the journal at the thrust bearing (crankshaft bearing at flywheel):
– Standard dimension (2 standard thrust washers) ....................................................... 45.000 - 45.080 mm
– 1st. repair level (one standard thrust washer and one with an oversize of 0.1 mm) ... 45.100 - 45.180 mm
– 2nd. repair level (one standard thrust washer and one with an oversize of 0.2 mm) .. 45.200 - 45.280 mm
– 3rd. repair level (one 0.1 mm thrust washer and one with an oversize of 0.2 mm)..... 45.300 - 45.380 mm
– 4th. repair level (two thrust washers with an oversize of 0.2 mm) .............................. 45.400 - 45.480 mm
Other crankshaft bearing journals must not be ground wider.
Axial play of the crankshaft ................................................................................................ 0.100 - 0.380 mm
Max. permissible out-of-true of the crankshaft or con-rod bearing journals ..................................... 0.03 mm
Max. permissible imbalance of the crankshaft .................................................................................1.0 Ncm.
Con-rods
Inner diameter, piston-pin bush
(bearing bush pressed into the con-rod) ........................................................................ 40.025 - 40.040 mm
Outer diameter of the piston-pin bush............................................................................ 44.082 - 44.120 mm
Overlap of the bearing seat (press fit) in the con-rod......................................................... 0.057 - 0.120 mm
Bore, seat for piston-pin bush ........................................................................................ 44.000 - 44.025 mm
Bore, con-rod bearing end ............................................................................................. 71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
– Standard ......................................................................................................................... 1.835 - 1.842 mm
– 1st. repair level 0.25 mm................................................................................................. 1.960 - 1.967 mm
– 2nd. repair level 0.50 mm ............................................................................................... 2.085 - 2.092 mm
– 3rd. repair level 1.00 mm ................................................................................................ 2.335 - 2.342 mm
– 4th. repair level 1.50 mm ................................................................................................ 2.585 - 2.592 mm
Con-rod bearing play ......................................................................................................... 0.046 - 0.098 mm
Con-rod bearing axial play ................................................................................................. 0.200 - 0.410 mm
Alignment of the con-rod bearing bore to the piston-pin bearing bore................................... within 0.15:100
Parallelism of the con-rod bearing bore to the piston-pin bearing bore ................................. within 0.05:100
The weight markings are punched in the bottom end of the con-rods
(on the camshaft side)
Max. permissible weight difference between con-rods in the same engine ............................................ 20 g
Lubrication system
Oil pressure at normal operating temperature:
– idling ................................................................................................................................... at least 1.0 bar
– at operational speed....................................................................................................................2.5 - 5 bar
Lubrication oil filter overflow valve opens at a differential pressure of ........................................... 2 ±0,5 bar
Oil pressure switch opens at .........................................................................................................p > 0.5 bar
Engine types 620.95 and 620.96:
Spring in oil pressure valve: length, relaxed .................................................................................... 49.5 mm
Spring length and force (with oil pressure valve fitted) ........................................................... 28.5 mm/76 N
Engine types 620.97, 620.98 and 620.99:
Spring in oil pressure valve: length, relaxed .................................................................................... 49.8 mm
Spring length and force (with oil pressure valve fitted) ......................................................... 28.5 mm/127 N
Oil pressure alarm at.....................................................................................................................p < 0.5 bar
Fault code EEM99 ............................................................................................................ Indicated on ADIC
Optical and acoustic warning, automatic
engine shutoff after ......................................................................................................................30 seconds
Overflow valves for the piston cooling nozzles: Opening pressure ...............................................3 ±0.25 bar
Thermostat
Type, version .......................................................................................................................... ∅ 54 mm/single circuit
Starts opening at................................................................................................................................ 79 °C±2
Fully open at ......................................................................................................................................... 94 °C
Max. stroke ........................................................................................................................................ 7.5 mm
Type, version .....................................................................................................................................∅ 67/dual-circuit
Starts opening at................................................................................................................................ 83 °C±2
Fully open at ......................................................................................................................................... 95 °C
Max. stroke ........................................................................................................................................... 8 mm
Coolant pump
Bearing outer diameter ....................................................................................................................... 52 mm
Bearing housing diameter .............................................................................................. 51.979 - 52.009 mm
Shaft diameter at bearing............................................................................................... 19.980 - 19.993 mm
Shaft diameter at impeller .............................................................................................. 15.907 - 15.920 mm
Diameter of impeller bore hole....................................................................................... 15.876 - 15.894 mm
Clearance between impeller and rear side of housing............................................................... 0.8 - 1.2 mm
(must be observed when pressed on)
Permissible imbalance of the fan ..................................................................... max. 0.3 Ncm max (30 pcm)
V-belt tension, when pressed in between the two pulleys,
amount of give ............................................................................................................................. 10 - 15 mm
M8 M10
±5
Cast iron 35 Nm 70±5 Nm
Aluminium 25±5 Nm 50±5 Nm
CONSTRUCTION
General
The 620 series CNH diesel engines are water-
cooled, four stroke, in-line engines with direct
injection. All models are equipped with wet,
replaceable cylinder liners, an exhaust turbocharger
and charge-air cooling (air/air). As the engines are
equipped with an electronic diesel control system in
conjunction with an electronic engine control system
(CAN network including solenoid valve-controlled
distributor injection pump VP30), all models comply
with the exhaust-gas regulations in accordance with
Tier 2.
Cylinder block
The rib-reinforced cylinder block forms the main
engine unit, onto which other engine components are
mounted.
The wet, replaceable cylinder liners are supported in
the middle, thus reducing vibration and the coolant
flow is mainly directed to the upper section of the
cylinder liners.
The bottom part of the cylinder liner and the cylinder
block are sealed by three O-rings, which are inserted
in the grooves in the cylinder liner. The upper part is
sealed by the cylinder head gasket.
The camshaft is located in the cylinder block.
All camshaft bearings are equipped with replaceable
SS00F035
cylinder liners.
Guide bearings are fitted on both sides of the rear
crankshaft bearings (crankshaft – axial bearings).
Flywheel casing
The flywheel casing is fitted at the rear end of the
cylinder block. The seal for the rear end of the
crankshaft is fitted in a bore hole in the casing. The
flange for the starter is located in the flywheel casing.
The underside of the flywheel casing is used as a
sealing surface for the oil sump seal. This means that
the underside of the cylinder block must be flush with
the flywheel casing. When the flywheel casing is
fitted, its position is determined by sprung dowel
pins.
SS99N017
Cylinder head
The engines are equipped with two interchangeable
cylinder heads. Each cylinder has its own intake and
outlet channels in the cylinder head. To compensate
for thermal stress, an inlet valve is fitted between the
outlet valves
The cylinder head bolts are high-tensile pre-
tensioned bolts, which are tightened to their
elongation limit in accordance with the angular
tightening principle. Due to the high degree of
elongation, the retaining power is kept constant
throughout the entire service life, and the bolts do not
therefore have to be check tightened.
The injection nozzle seats are integrated into the
cylinder head. The inlet and outlet valve guides are
identical and can be interchanged. Furthermore, the
in/outlet valves are fitted with replaceable valve seat
inserts.
BLANK PAGE
SS03G080
Timing gears
The engine control gear wheels are hardened in the area of contact and have a helical gearing.
The gear wheels are located in the timing gear case, which is fitted at the front of the engine.
The timing gears drive the camshaft, the fuel injection pump and the oil pump.
The intermediate wheel runs in pressure-lubricated friction bearings (like the camshaft).
The bearing journal is fixed to the front surface of the cylinder block.
7
6
5
Lubrication system
1. Lubrication oil pump
2. Oil pressure valve
3. Oil filter
4. Turbocharger
1 5. Main oil duct
6. Oil spray nozzles
7. Oil pressure switch
SS99N019
Lubrication system
The engine is equipped with a pressure lubrication The oil pressure valve regulates the lubrication oil
system, in which the oil pump (gear pump) is fixed to pressure so that a constant value is maintained
the lower part of the cylinder block. The pump sucks independent of the engine speed. Depending upon the
the oil in via an intake sieve. From the pump, the oil is grade of oil, the engine speed and temperature, the oil
fed through an oil line to the oil cooler (heat pressure lies between 2.5 - 5 bar.
exchanger) and to the oil filter. The oil pressure valve The oil pressure must be at least 1.0 bar at idling
is located parallel. The oil is then fed into the main oil speed.
duct, from which other oil bores branch off. The oil
The oil filter is a one-way main stream filter. An
flows through the oil bores to the crankshaft bearings
overflow valve, on the underside of the filter, ensures
and through the crankshaft to the con-rod bearings.
reliable engine lubrication after cold starting at
The pressure oil flows from the main oil duct to the extremely low outside temperatures and sufficient
turbocharger and to the air compressor (if fitted). In lubrication in the event of a filter blockage. A non-
addition, the intermediate gear wheel bearings, return valve prevents the filter being completely
camshaft bearings and valve mechanism are drained of oil after switching off the engine.
lubricated with pressure oil via the main oil duct. The oil pressure switch opens at a pressure of
> 0.5 bar.
In the case of engines 620.97, 620.98 and 620.99, the
piston heads are sprayed with oil from below and
cooled as long as the lubrication oil pressure is higher
than 3 bar.
5 7
7
6
SS03G023
Cooling system
1. Coolant pump 5. Expansion chamber
2. Thermostat 6. Oil cooler
3. Bypass channel 7. Engine temperature sensor
4. Radiator
Cooling system
The belt-driven coolant pump is located at the front
end of the cylinder block. The thermostat housing
is situated above the pump. The cooling system is
equipped with two thermostats, which control the
coolant flow. The thermostats have different C
opening temperatures. If the coolant temperature
lies below the opening temperature, the coolant (A)
circulates back to the coolant pump via the bypass
channel. The smaller, single-action thermostat (1)
starts to open at 79 °C and lets some of the B
coolant (B) flow into the radiator. When the engine 1
temperature increases, the dual-circuit
thermostat (2) also starts to open at 83 °C. It
closes the bypass when it opens and allows all the 2
coolant (C) to flow into the radiator. A
SS00F031
SS03G024
SC03G004
SC03G006
Intake/exhaust system
The filter system for the engine intake air comprises a The turbocharger is lubricated and cooled by oil from
pre-cyclone filter (integrated into the air filter) and a the engine lubrication system.
dry air filter with safety cartridge. The intake air is
Charge-air cooling
rotated in the pre-cyclone filter. This removes heavy
dirt particles, which are then discharged via the pre- The intake air compressed by the turbocharger can
cyclone filter’s dust discharge valve. reach a temperature of up to 150 °C under extreme
conditions. It is cooled down to 50 - 60 °C in a charge-
Ejector
air cooler (air/air version) located in front of the
The tractor can be equipped with an ejector system for radiator. The cooling of the charge-air reduces the
use in extremely dusty conditions. The exhaust pipe is thermal and mechanical strain on the engine and
fitted with an injector and there is a permanent suction reduces the discharge of nitrogen oxides and soot
effect at its hose connection when the engine is particles.
running. The dust particles separated in the pre-filter
Charge-air pressure/temperature
are continuously sucked in via a hose connection and
as engine control variables
discharged together with the exhaust gases.
A combined sensor is located in the air collector. It
Filter cartridges
continuously supplies information about the charge-air
The dirt particles in the air are collected in the main pressure/temperature to the electronic engine
cartridge, which can be cleaned as required. The management (EEM2). Fuel injection is optimised in
internal safety cartridge stops dirt particles getting into conjunction with the electronic injection control
the engine in the event of the main cartridge breaking system, thus substantially reducing the discharge of
or being fitted incorrectly. nitrogen oxides and soot particles.
Filter service indication The charge-air cooler is easy to service. It can be
folded up and can thus be effectively cleaned against
A differential pressure switch is located in the filter
the direction of the flow of outside air. By folding up
housing. This switch makes an indicator lamp on the
the charge-air cooler, the other coolers are easier to
ADIC light up when the air filter reaches a certain
access.
degree of soiling. The intake system also comprises
the air lines between the air filter and the
turbocharger, between the turbocharger and the
charge-air cooler and between the charge-air cooler
and the inlet manifold.
The exhaust manifold is fixed to the cylinder head by
means of special bolts, without a separate seal.
The special bolts do not have to be re-tightened.
6 7
3
5
8 4
10
SC03G007
11
CAN H
CAN L
MAB
DZG
Switch S6
A2
Oil pressure
Sensor B29
Charge-air pressure
Charge-air
Starting aid E10/1
temperature
(heating flange)
Sensor B22
Coolant temperature
EEM 2
M13 Fuel
Test switch B21 feed pump
Fuel delivery pressure
Switch S22
Sensor B23 Coolant level
"Water in
fuel"
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position
Limp home
A1
ADIC
Sensor B28
Man. oper.
accelerator slider
CAN H
CAN L
DISPLAY Warning
Fuel
level
too low
ARU
Warning Warning
Fuel
Coolant level feed pressure
too low
R8 sensors A4
Accelerator pedal FMGR Warning
Water in fuel
(optional extra)
Function
The EEM2 always has continuously updated values for various parameters which are important for controlling the
engine at its disposal. The EEM2 electronics evaluate this data and send corresponding control commands in the
form of CAN messages to the electronic control unit for the injection pump. Control variables such as the
maximum injection volume or start of delivery are continuously adjusted (in real-time). This ensures an optimum
engine power curve and torque increase, high economy and conformance with the more stringent emission
standards which are now valid. For Europe: 97/68 EC Level 2. For America: Tier 2.
Control variables which influence the dynamic delivery start
 Engine speed
 Engine load
 Coolant temperature
Control variables which influence the maximum injection volume
 Torque characteristics
 Coolant temperature
 Charge-air pressure
 Certain faults which occur (e.g. incorrect injection pump Serial No. in the EEM2 software, fault code 175).
Idling speed
The idling speed and final idling speed are electronically controlled and cannot be changed. Readjustment is not
necessary.
Engine protection when exceeding limit values
If limit values are exceeded, the engine control system intervenes to protect the engine. The engine power/speed
is reduced and the fuel injection is stopped as required, thus shutting down the engine.
Fault Detection
If a fault occurs, a fault warning appears on the ADIC and the corresponding EEM2 fault code is shown on the
display on the A column.
The fault can be localised and remedied by means of the CNH Service Tool. Also refer to Chapter 4011, Fault
codes.
127( Function, fitting and removing the injection pump, checking the delivery pressure, checking the injection
nozzles: see Chapter 3001 – Functional description of the injection system.
JOB INSTRUCTIONS
1. Cylinder block
A. Measuring the cylinder liner wear
1. Set the dial test indicator to zero by means of a
micrometer screw or using a new cylinder liner (initial
dimension 108.00 mm). 1TSW 510
2. Thoroughly clean the inner surface of the cylinder
liner before the measurement.
380000011
SS99N037
SS99N036
4. Measure the wear on the camshaft bearings
(compare with nominal values).
3. Measure cross-wise at the top end, bottom end 127( If the surface of the cylinder block has to be
and in the middle of the cylinder liner. re-ground, the pistons must be shortened by a
corresponding amount. Pay attention to the valve
4. Check the displayed value for max. wear and head clearance at the top surface of the piston.
ovality (compare with nominal values).
D. Replacing the camshaft bearing bush
B. Removing the cylinder liner
1. Pull the bearing bush out using an internal
1. If the cylinder liners are to be re-used, they must extractor. After removing the rear camshaft end
be marked so they can be re-fitted in the same support piece, the bearing bush can be driven out
positions. using a long drift.
2. Remove the cylinder liners using the 380000011 2. Clean the bush seating.
and 1TSW 510 extraction tools.
0.1 - 0.4 mm
SS99N038
5 4 3 2 1
SS99N039
266 mm
272 mm
134 mm
A-A 7,2...8,0 mm
A
0,1...0,4 mm
5 4 3 2 1
A SC03G008
max. 1,0 mm
111 mm
SC03G009 SS99N045
1. Clean the plug seating. 127( The position of the tube influences the
measured engine oil level.
2. Apply sealant (e.g. Loctite 572) to the contact
surface of the plug. I. Fitting the cylinder liner
3. Drive the plug in using pressing tool 380000004.
1. Clean the cylinder liner and liner recess in the
127( Do not drive the plug in too far, as it could cylinder block. Without the O-ring, it must be easy to
impair the axial play of the camshaft. turn the liner to its installation position.
2. Apply a thin coat of marking paint to the underside
G. Fitting the plug at the rear camshaft of the cylinder liner flange. Fit the cylinder liner
end after inserting an oversize bearing without O-rings and turn it back and forth. Remove
bush the cylinder liner and check whether there is paint
over the entire contact surface.
O-ring 3. Clean the contact surfaces.
0.03 - 0.08 mm
Plug
SS00F003
SS99N048
Upon completion, the rear camshaft end plug is 4. Fit the cylinder liners and secure each liner using
replaced by the plug and the O-ring. two clamps. Measure the cylinder liner height using a
dial test indicator and the holder (380000364). Set
H. Installing the oil dipstick tube the dial test indicator to zero on a flat surface, e.g.
the cylinder block. Measure each cylinder liner at four
1. Clean the tube seating.
points. The cylinder liner should protrude from the
2. Apply locking fluid (e.g. Loctite 601) to the bottom top of the cylinder block by 0.03 - 0.08 mm.
end of the tube.
3. Drive the guide tube into the cylinder block to the
dimension shown in the figure.
SS99N049
Height Marking
(H) grooves
(quantity)
9.03+0.02 (standard)
9.08+0.02 1 SS99N051
9.13+0.02 2
8. Press the cylinder liners into the cylinder block. It
9.23+0.02 3 should be easy to press them into their initial
position. Make sure the cylinder liners do not move
An oversize of the cylinder liner (higher flange) is upwards once they have been fitted.
marked as follows on the outer circumference by
means of one or more marking grooves:
1. oversize, 0.05 mm = 1 marking groove
2. oversize, 0.10 mm = 2 marking grooves
3. oversize, 0.20 mm = 3 marking grooves
6. If the height of a cylinder liner is not the same over
the entire circumference, the cylinder liner flange and
recess depth must be checked. Cylinder liners with
warped flanges must be replaced. If necessary, ream
the liner seating in the cylinder block.
BLACK
GREEN
SS99N050
SS99N054
1TSW 662
SC03G010
Drain plug
SS99N057
SS99N059
SS99N061
380000007
SS99N060
SS99N062
48,500...48,525 mm
SC03G030
3. Clean the valve seat. Cool the new valve seat ring
in dry ice of liquid nitrogen.
4. Fit the valve seat ring using a suitable pressing
SS99N063
tool. Re-work the seat.
A damaged valve seat must be machined using a
milling cutter. If the width of the seat exceeds 2.3 mm G. Grinding the valves
in the case of an outlet valve and 3.7 mm in the case In order to ensure that a sufficient sealing effect is
of an inlet valve, then it has to be reduced at the attained around the valves, there are different sealing
outer edge, in particular. surface angles. Thus, there is a particularly narrow
The valve seat angle is 45°+20’ for outlet valves and sealing surface, which ensures an effective sealing
35°+20’ for inlet valves. effect even after prolonged operation.
Outlet valve
A B C (mm)
10,1 mm -20’ +20’
INLET 35° 35° 0.7
-20’ +20’
OUTLET 45° 45° 0.6
2. Lubricate the valve stems and insert the valves in 2. Tighten by 90°.
the cylinder in the correct order. 3. Tighten by 90°.
3. Fit the valve springs, valve disks and valve spring 4. Adjust the valve clearance (see page 39).
seat retainers in the cylinder head with the aid of
lever 380000008. 5. Fit the other engine parts, add coolant and
engine oil.
4. After inserting the valves, tap the ends of the valve
stems, e.g. with a plastic hammer, to make sure the 6. Let the engine run at low load until it reaches a
valve spring seat retainers are sitting correctly. coolant temperature of 75 °C.
7. Tighten by 60°.
I. Fitting the cylinder head
8. Adjust the valve clearance.
1. Measure the length of the cylinder head bolts. The
length should lie within the limit values specified in 127( The cylinder head bolts do not have to be
tightened again after this procedure.
the figure. If this is not the case, the bolt must be
replaced.
max. 142 mm
50 Nm
max. 188.5 mm
SS99N066
SS99N067
SS99N073
SC03G014
23,000...23,021
SC03G013 B. Replacing the camshaft/camshaft gear
wheel
4. If the pressure surface of the rocker arm is worn,
grind it until it has the right shape. Do not grind off 1. Remove the suction pipe between the
more than necessary as the pressure surface is turbocharger and the intake manifold. Remove the
hardened. cover for the valve mechanism and the bleed pipe.
Remove the rocker arm mechanism.
2. Remove the cooler/radiator assembly, fan,
alternator and the V-belts.
3. Loosen the crankshaft nut. Remove the V-belt
pulley with the hub (loosen the belt pulley first).
4. Remove the control box cover.
SS99N072
0,35
SS99N075
6. Turn the crankshaft, so the positioning marks on If the valve clearance deviates from the specified
the camshaft gear wheel and intermediate gear value, loosen the locking nut and adjust it to the
wheel coincide. Pull the camshaft out. correct value via the adjusting screw. A 0.35 mm
feeler gauge must fit tightly between the rocker arm
7. Loosen the camshaft gear wheel using a suitable and the end of the valve stem.
mandrel.
8. If the used camshaft or camshaft gear wheel is
going to be re-fitted, clean them before assembly.
9. Push the feather key into the corresponding
groove in the camshaft. Heat the camshaft gear E A E A E A E A E A E A
wheel up to 200 °C and fit it in the corresponding
position.
SC03G016
10. Grease the bearing surfaces and press the shaft I = INLET
into the cylinder block, paying attention to the
position marks on the camshaft gear wheel. O = OUTLET
11. Fit the control box cover and the belt pulley with
the hub. – turn the crankshaft in the direction of rotation until
the valves of cylinder 6 overlap. (Outlet valve closes,
12. Release the push rods and fit the rocker arm inlet valve opens). Check the valves of the first
mechanism. Adjust the valves. Then screw the valve cylinder.
cover and air bleed hose onto the cylinder head. Also
fit the suction pipe between the turbocharger and – turn the crankshaft 1/3 of a revolution in the
intake manifold. direction of rotation so that the valves of the 2nd
cylinder overlap. Check the valves of the 5th cylinder.
13. Fit the alternator and V-belts. Tension the V-belts
accordingly. Fit the cooler/radiator assembly. – continue work in the sequence of injection:
Injection sequence: 1 5 3 6 2 4
Valve overlap: 6 2 4 1 5 3
1TSW 662
SS99N078
0,10...0,38 mm
B
A
SC03G018
200 Nm
SS99N085
7
tooth.
SC03G017
A
1.5 mm
SS00E039
SS99N087
1. Loosen the alternator securing bolts and remove
the V-belt. 1. If the lines (A) are misaligned by more than
1.5 mm, the vibration damper must be replaced.
2. Unscrew the bolts holding the belt pulley and
vibration damper and remove the parts. The belt OK
pulley and vibration damper are pinned together with
the crankshaft hub (injection mark on the vibration
damper).
3. Fix a new vibration damper or belt pulley onto the
crankshaft. Drive the dowel pins in and tighten the
securing bolts to a torque of 30 Nm.
127(Vibration dampers (belt pulleys) supplied as a
spare part do not have an injection marking. New
OK
vibration dampers must be marked after being fitted.
4. Turn the crankshaft until the piston of the first
cylinder is at top dead centre (TDC). Let the valve fall
against the cylinder head. Mount the dial test
indicator at the top of the valve stem and set it to zero
when the piston is at top dead centre. Then turn the
crankshaft against the direction of rotation until the OK
dial test indicator reads approx. 15 mm below TDC.
Then slowly turn the crankshaft in the direction of SS99N088
rotation until the dial test indicator shows the value
which corresponds to the injection marking (see table 2. Also check the condition of the rubber element. If
below). pieces of rubber are missing or the rubber part is
more than 3.5 mm below the surface, or if a forward
127( The setting value is 30° before TDC for all
motion of the inertial component (outer ring) is
engines.
discernible, the vibration damper must be replaced.
5. Inscribe the injection marking by means of an
electric engraving pen (do not punch it in).
127( Make sure the pointer is not loose or bent
before making the mark.
SS99N090
620.95
620.96 D
SC03G020
SS99N098
SS99N099
∅107.873 -
107.887
17 mm
SS99N101
SS99N103
SC03G021
SC03G022
200 Nm
60 Nm 35 Nm
SS99N113
SC03G023
SS99N114
SS99N115
1000 Nm
SC03G024
SS99N085
Gear wheel
25 Nm
Loctite
638
SS00B054
1. Drain the engine oil and remove the sump. 2. Mount the drive gear wheel on the pump shaft. Put
screw locking fluid Loctite 243 on the nut thread. Fit
2. Disconnect the intake and pressure lines on the oil the washer and the nut. Tighten the nut to a torque of
pump. 60 Nm.
3. Remove the oil pump and any adjusting disks
between the pump housing and the cylinder block.
4. Release the pump cover and the seal. Remove the
gear wheel fitted on the axle.
TOP
SS99N126
SS99N127
°C
40
30
20
SAE 30
10
SAE 20W-20
SAE 20W-40
SAE 15W-40
0
SAE 10W-40
SAE 10W-30
SS99N130
-10
1. Change the valve as required. Unscrew the valve
SAE 5W-30
SAE 5W-40
from the engine and remove the nozzle pipe. Insert
the new valve. -20
-30
-40
SC03G027
SS99N131
– the thermostat must be fully open after no longer 5. Remove the circlip from the pump body. Use a
than 50 seconds. Compare the measured values with hydraulic press, for example, to press the shaft with
those specified in the technical data. the bearing out of the pump body towards the fan.
Clamp the pump body so that the shaft bearing can
be taken out.
6. Remove the axial and shaft seals from the pump
body by means of a mandrel. Clean the parts and
check their condition. Replace worn or faulty parts.
127(If the pump bearings have to be replaced, it is
better to fit the pump repair kit, which also comprises
all seals required for the repair (refer to spare parts
catalogue).
SS00F032
1TSW 18390
380000005
SS99N143
SS99N138 10. Fix the back plate using a new seal. To fit the
back plate, use guide pins with a diameter of 8.5 mm
7. Use mandrel 380000005 to drive the shaft seal for the bore holes shown in the figure.
into the pump body. Mount the bearings and
intermediate sleeves on the shaft. Grease the C. Coolant quality requirements
bearings with plenty of heat-resistant ball bearing
grease. Fit the shaft and bearings in their place so – the coolant must conform with quality standard
that the forces produced by pressing do not act on ASTM D 3306 or BS 6580:1992.
the bearing balls. Fit the bearing circlip in its place. – if there are no frost resistance requirements, a
mixture ratio of 40 % is enough to ensure sufficient
corrosion protection.
– check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
0,8...1,2
years.
– the water used must be clean and soft, i.e. it must
not contain any metals and their salts.
,03257$17Never use only water as a coolant.
120 Nm
SC03G028
SS99N144
SS99N145
4
3
1 5
SS99N146
2002A
ENGINE WORKSHOP MANUAL
CONTENTS
SPECIAL TOOLS .................................................................................................................................................. 7
CONSTRUCTION ............................................................................................................................................... 19
GENERAL INFORMATION .............................................................................................................................. 19
Cylinder block .................................................................................................................................................. 19
Flywheel casing ............................................................................................................................................... 19
Cylinder head ................................................................................................................................................... 20
Valve mechanism ............................................................................................................................................. 20
Crank drive ....................................................................................................................................................... 21
Vibration absorber ............................................................................................................................................ 22
Timing gears .................................................................................................................................................... 23
Lubrication system ........................................................................................................................................... 24
Cooling system ................................................................................................................................................ 25
Fan ................................................................................................................................................................... 26
Intake / exhaust system ................................................................................................................................... 27
BLANK PAGE
SS00B077
1 x 1TSW 18390 M24
SS00B069
1 x 380000007 (1TSW 524)
SS00B071
1 x 380000008 (1TSW 014)
SS00B067
1 x 380000004 (1TSW 522) Extractor
SS00B070
1 x 1TSW 662 (available from stockists)
SS00B068
1 x 380000005 (1TSW 523)
SS05N371
1 x 380000329
Extraction plate
SS05N0372
1 x 380002658
SS05N395
1 x 380001791
SS00B075
Key for reverse fan
1 x 380000364 (1TSW 5610) Holder
1 x 380000228 (1TSW 17049-6) Dial gauge
SS05N396
1 x 380002657
TO THE USER
The purpose of this manual is to provide basic information required to service and repair CNH diesel engines.
The engines are of the same design. Differences which have an influence on repair work are therefore listed in the
technical data and repair instructions. All dimensions are specified in millimetres and apply at a temperature of +20°C,
unless otherwise specified.
Before starting repair work, make sure all necessary special tools, spare parts and accessories are available. It is not
absolutely necessary to have all the special tools mentioned in this manual. However, they do make it quicker and
easier to carry out the necessary repairs. After carrying out any repair work you must run in the engine as you would
a new engine.
Should any problems arise which are not covered in this manual, please contact the customer service team at CNH
Österreich GmbH in St. Valentin or through the relevant importer.
IMPORTANT: When making any queries, please specify the following engine data and the current operat-
ing hours count.
EEM3 = Electronic Engine Management.
Engine number
(serial number)
SS05N359
SAFETY REGULATIONS
There is always a risk of injury · Avoid touching the exhaust manifold, turbo charg-
when carrying out maintenance er and other hot engine parts.
and repair work. Read the · When the engine is hot and the coolant is pressu-
following safety regulations and rised, be careful when opening the radiator cap.
information before starting work. Coolant and lubrication oil out of the hot engine
· Never start repair work which you do not fully un- can cause severe injuries if contact is made with
derstand. the skin.
· Make sure that it is possible to work safely at the · Naked flames and smoking are not permitted in
location and in the vicinity. the vicinity of fuel tanks or batteries. Electrical
· Make sure that the repair area is clean and well- sparks should be avoided. (Particularly when
maintained. charging the batteries. Explosion hazard!)
· Never use incorrect or unsuitable tools. · Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
· Remove all rings, chains and watches before electrical system.
starting work.
· If the engine gets excessively hot (over 300°C),
· Use modern safety equipment when working. For for example if it catches fire, the viton seals (e.g.
example, protect your eyes when using com- bottom O-ring on the cylinder liner or the O-ring on
pressed air for cleaning, grinding, hammering or the oil pressure valve) release highly caustic HF
similar tasks. acid. Never touch viton seals which have been
· When lifting or transporting heavy parts (over 20 subjected to unusually high temperatures, with
kg), use lifting equipment. Make sure that hooks bare hands. Always wear neoprene gloves or thick
and chains are in good condition and are firmly at- working gloves and protective glasses when re-
tached. moving these harmful materials. Wash the seals
· Never work underneath an engine that is freely and soiled surfaces using a 10% hydroxide solu-
suspended from a lifting apparatus or has been tion or other alkaline solution. Collect the material
raised by a jack. Always secure the engine with in air-tight sealed plastic bags and take it to an au-
strong supports before starting work. thorised collecting depot.
· Only use genuine CNH spare parts. IMPORTANT: Viton seals must never be burned!
· Only start the engine from the cab using the igni- · Extended contact with the fuel, lubricant and cool-
tion key. ant can irritate the skin.
· Never start the engine when any protective covers · Avoid idling the engine unnecessarily.
are removed. · When carrying out service work, take measures to
CAUTION: The cooling fan is difficult to see when the prevent fuel or other fluids from entering the
engine is running. Loose clothing and long hair may ground or drains.
become caught in rotating engine parts. · All seals are free of asbestos.
· If starting the engine in an enclosed space, make · Be careful when washing the engine using a
sure there is sufficient ventilation. washing facility with a high water pressure. For
· Never use aerosol-based starting fuels while the example, the electrical systems, fuel system and
thermal auxiliary ignition system is operating (risk cooler must not be washed at high pressure be-
of explosion). cause this could easily cause damage.
ENGINE DATA
Engine type 620.64
Number of cylinders 6
3
Cubic capacity (dm ) 6.6
Bore (mm) 108
Height of stroke (mm) 120
Nominal power output in kW at 2100 144
rpm in line with ISO 14396
Marker for start of fuel delivery on
set automatically
V-belt disc (° before TDC)
Compression ratio 18.5 : 1
Combustion process direct injection
Injection sequence 1-5-3-6-2-4
1
Compression pressure (bar) 24
Charge-air pressure 2 (bar) 1.45
3
Weight (kg) 515
Direction of rotation of the crank- Clockwise
shaft
1)
Minimum values at operating temperature and starter speed.
Maximum permissible difference between cylinders max. 3 bar.
2)
measured using Service Tool at full load, rated engine speed and maximum fan speed
3)
Without flywheel and electrical equipment.
A A
SS05N281
TECHNICAL DATA
Compliance with exhaust standards
The engine complies with emissions requirement EU97/68/EC Level 3A.
Cylinder block
Guide pin bores ................................................................................................................. 13.250 - 13.320 mm
Diameter of crankshaft bearing ground bore ...................................................................... 91.000 - 91.025 mm
Diameter of crankshaft bearing ground bore (oversize) ...................................................... 92.000 - 92.025 mm
Bore diameter of cylinder liner:
- top ............................................................................................................................... 124.514 - 124.554 mm
- bottom ......................................................................................................................... 123.000 - 123.040 mm
Diameter of camshaft bearing bush, no. 1 (assembled) ...................................................... 50.040 - 50.060 mm
Diameter of camshaft bearing bush, nos. 2 - 5 (assembled) ............................................... 50.010 - 50.070 mm
Height of cylinder block .................................................................................................. 428.170 - 428.430 mm
Cylinder liners
Height of liners above cylinder block ...................................................................................... 0.030 - 0.080 mm
Max. permissible height difference between cylinder liners (below same head) ................................... 0.02 mm
Diameter of cylinder liner bores in engine block:
- top end of liner ............................................................................................................ 124.475 - 124.500 mm
- bottom end of liner ....................................................................................................... 122.961 - 122.986 mm
Cylinder liner bore ......................................................................................................... 108.010 - 108.032 mm
Height, cylinder liner flange (standard) ....................................................................................... 9.03 - 9.05 mm
Height, cylinder liner flange, oversize 1 ...................................................................................... 9.08 - 9.10 mm
Height, cylinder liner flange, oversize 2 ...................................................................................... 9.13 - 9.15 mm
Height, cylinder liner flange, oversize 3 ...................................................................................... 9.23 - 9.25 mm
Outer diameter of cylinder liner flange ........................................................................... 131.700 - 131.800 mm
Cylinder head
Height of cylinder head .................................................................................................. 104.800 - 105.000 mm
Minimum height of cylinder head after surface grinding (minimum) ................................................ 104.000 mm
Inner diameter of valve guide (not fitted) ................................................................................ 9.000 - 9.015 mm
Outer diameter of valve guide ............................................................................................ 16.028 - 16.039 mm
Diameter of bore for valve guide in cylinder head .............................................................. 16.000 - 16.018 mm
Projection of valve guide above cylinder head surface ............................................................................21 mm
Depth, valve head below cylinder head surface:
- Inlet valve ........................................................................................................0.7 ± 0.05 mm (max. 2.20 mm)
- Outlet valve .....................................................................................................0.6 ± 0.05 mm (max. 2.20 mm)
Valve seat angle:
- Inlet valve ............................................................................................................................................ 35° +20'
- Outlet valve .........................................................................................................................................45° +20'
Valve seat width:
- Inlet valve ....................................................................................................................................2.9 - 3.7 mm
- Outlet valve .................................................................................................................................1.3 - 2.3 mm
Diameter, outlet valve seat ring (standard) ......................................................................... 44.070 - 44.132 mm
Bore in cylinder head for outlet valve seat ring (standard) .................................................. 44.000 - 44.025 mm
Diameter, outlet valve seat ring (oversize) ......................................................................... 44.270 - 44.332 mm
Bore in cylinder head for outlet valve seat ring (oversize) .................................................. 44.200 - 44.225 mm
Diameter, inlet valve seat ring (standard) ........................................................................... 48.570 - 48.632 mm
Bore in cylinder head for inlet valve seat ring (standard) .................................................... 48.500 - 48.525 mm
Diameter, inlet valve seat ring (oversize) ........................................................................... 48.770 - 48.832 mm
Bore in cylinder head for inlet valve seat ring (oversize) .................................................... 48.700 - 48.725 mm
Camshaft
Diameter, camshaft bearing journal no. 1 (front) ................................................................ 49.875 - 49.900 mm
Diameter, camshaft bearing journals nos. 2, 3 and 4 .......................................................... 49.865 - 49.890 mm
Diameter, camshaft bearing journal no. 5 ........................................................................... 49.885 - 49.910 mm
Clearance, camshaft bearing no. 1 ........................................................................................ 0.140 - 0.185 mm
Clearance of camshaft bearings nos. 2, 3 and 4 .................................................................... 0.110 - 0.160 mm
Clearance, camshaft bearing no. 5 ........................................................................................ 0.100 - 0.185 mm
Axial play of camshaft (seal 0.5 mm - between cylinder block and
steering housing and between steering housing and cover ............................................................0.5 - 1.0 mm
Cam height (distance between base circle and elevation of cam):
- Inlet valve ........................................................................................................................ 41.987 - 41.487 mm
- Outlet valve ..................................................................................................................... 39.883 - 40.383 mm
Cam stroke:
- Inlet valve .......................................................................................................................................... 7.38 mm
- Outlet valve ....................................................................................................................................... 8.28 mm
Max. permissible radial runout of camshaft .......................................................................................... 0.03 mm
Crankshaft
Diameter of the con-rod bearing journals:
- Standard dimension ......................................................................................................... 67.981 - 68.000 mm
- 1st repair level 0.25 mm .................................................................................................. 67.731 - 67.750 mm
- 2nd repair level 0.50 mm ................................................................................................. 67.481 - 67.500 mm
- 3rd repair level 1.00 mm .................................................................................................. 66.981 - 67.000 mm
- 4th repair level 1.50 mm .................................................................................................. 66.481 - 66.500 mm
Width of con-rod bearing journal ........................................................................................ 40.000 - 40.160 mm
Diameter of the main bearing journals:
- Standard dimension ......................................................................................................... 84.985 - 85.020 mm
- 1st repair level 0.25 mm .................................................................................................. 84.735 - 84.770 mm
- 2nd repair level 0.50 mm ................................................................................................. 84.485 - 84.520 mm
- 3rd repair level 1.00 mm .................................................................................................. 83.985 - 84.020 mm
- 4th repair level 1.50 mm .................................................................................................. 83.485 - 83.520 mm
Diameter, main bearing housing ......................................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells:
- Standard dimension ............................................................................................................. 2.955 - 2.965 mm
- 1st repair level 0.25 mm ...................................................................................................... 3.080 - 3.090 mm
- 2nd repair level 0.50 mm ..................................................................................................... 3.205 - 3.215 mm
- 3rd repair level 1.00 mm ...................................................................................................... 3.455 - 3.465 mm
- 4th repair level 1.50 mm ...................................................................................................... 3.705 - 3.715 mm
Clearance of main bearings ................................................................................................... 0.050 - 0.127 mm
Width of the journal at the thrust bearing (main bearing at flywheel):
- Standard dimension (2 standard thrust washers) ............................................................. 45.000 - 45.080 mm
- 1st repair level(one standard thrust washer and one with 0.1 mm oversize) ..................... 45.100 - 45.180 mm
- 2nd repair level (one standard thrust washer and one with 0.2 mm oversize) ................... 45.200 - 45.280 mm
- 3rd repair level (one thrust washer of 0.1 mm and one of 0.2 mm oversize) ..................... 45.300 - 45.380 mm
- 4th repair level (two thrust washers with 0.2 mm oversize) .............................................. 45.400 - 45.480 mm
Other crankshaft bearing journals may not be ground wider.
Crankshaft axial play ............................................................................................................. 0.100 - 0.380 mm
Max. permissible ovality of main bearing or con-rod bearing journals ................................................... 0.03 mm
Max. permissible imbalance of crankshaft .................................................................................... 1.0 Ncm max.
Flywheel
Cover, starter gear ring on flywheel ....................................................................................... 0.425 - 0.600 mm
Before pressing the starter gear ring on the flywheel, heat up the
gear ring to a temperature of .......................................................................................................... 150 - 200°C
Max. permissible imbalance on flywheel ...................................................................................... 1.0 Ncm max.
max. permissible runout of coupling face, measured on inner edge
of coupling face (diameter 200mm) ..................................................................................................... 0.06 mm
Con-rods
Inner diameter, piston pin bearing bush
(bearing bush pressed into con-rod) ...................................................................................40.025 - 40.040 mm
Outer diameter of piston pin bearing bush (standard) .........................................................44.080 - 44.120 mm
Outer diameter of piston pin bearing bush (oversize) ..........................................................44.580 - 44.620 mm
Cover for bearing seat (press fit) in the con-rod ..................................................................... 0.057 - 0.120 mm
Bore, seat for piston pin bearing bush ................................................................................44.000 - 44.025 mm
Bore, seat for piston pin bearing bush (oversize bush) .......................................................44.500 - 44.525 mm
Bore, con-rod side ..............................................................................................................71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
- Standard ............................................................................................................................. 1.835 - 1.842 mm
- 1st repair level 0.25 mm ...................................................................................................... 1.960 - 1.967 mm
- 2nd repair level 0.50 mm ..................................................................................................... 2.085 - 2.092 mm
- 3rd repair level 1.00 mm ..................................................................................................... 2.335 - 2.342 mm
- 4th repair level 1.50 mm ...................................................................................................... 2.585 - 2.592 mm
Clearance of con-rod bearing ................................................................................................ 0.046 - 0.098 mm
Axial play of con-rod bearing ................................................................................................. 0.200 - 0.410 mm
Alignment of con-rod bearing to bore piston pin bearing ............................................................ within 0.15:100
Parallelism of con-rod bearing bore to bore piston pin bearing .................................................. within 0.05:100
The weight markers are engraved on the lower end of the con-rods
(on the camshaft side)
Max. permissible weight difference between con-rods in same engine ....................................................... 20 g
Lubrication system
Oil pressure at normal operating temperature:
- when idling ................................................................................................................................... min. 1.0 bar
- at operating speed ....................................................................................................................... 2.5 - 5.0 bar
Lubricating oil filter - overflow valve opens at pressure difference of .................................................. 2 ±0.5 bar
Oil pressure monitoring .............................................................................................. using oil pressure sensor
Switching pressures for oil pressure sensor .......................................... Speed-dependent from 900 - 2300 rpm
at 900 rpm ........................................................................................................................................... 1.15 bar
at 2300 rpm ......................................................................................................................................... 1.92 bar
Spring in oil pressure valve: free length (identification = yellow point) ........................................ 49.3 - 50.8 mm
Spring length and spring force (with fitted oil pressure valve) ................................................... 28.5 mm / 127 N
±0.25
Overflow valves for the piston cooling nozzles: Opening pressure .................................................... 3 bar
Thermostat
Type, version ............................................................................................................................ ∅ 54 mm / single-circuit
Starts opening at ................................................................................................................................... 79°C ±2
Fully open at ............................................................................................................................................. 94°C
Max stroke ............................................................................................................................................. 7.5 mm
Type, version ....................................................................................................................................... ∅ 67 / two-circuit
Starts opening at ................................................................................................................................... 83°C ±2
Fully open at ............................................................................................................................................. 95°C
Max stroke ................................................................................................................................................ 8 mm
Coolant pump
Outer diameter of bearing ...................................................................................................................... 72 mm
Diameter of bearing housing ..............................................................................................71.961 - 71.991 mm
Diameter for insertion of seal in housing .............................................................................39.981 - 40.019 mm
Diameter of shaft with bearing ............................................................................................30.002 - 30.015 mm
Diameter of shaft with impeller ...........................................................................................15.907 - 15.920 mm
Diameter of impeller bore ...................................................................................................15.876 - 15.894 mm
Gap between impeller and rear face of housing ..................................................................................... 0.7 mm
(must be complied with even when pressing)
Permissible imbalance of fan................................................................................. max. 0.3 Ncm max (30 pcm)
Tightening torques
Cylinder head screws and nuts .................................................................................................80 Nm+90°+90°
Cylinder head pins in the cylinder block .................................................................................................. 30 Nm
Crankshaft bearing screws .................................................................................................................... 200 Nm
Connecting rod bolts (Torx E18) ..................................................................................................... 40 Nm + 90°
Nuts on crankshaft (front face) ............................................................................................................ 1000 Nm
Pulley screws .......................................................................................................................................... 30 Nm
Retaining bolts for flywheel ................................................................................................................... 150 Nm
Retaining bolts for flywheel casing:
- inner bolts M10 ..................................................................................................................................... 80 Nm
- outer bolts M12 ................................................................................................................................... 150 Nm
Retaining screws for intermediate gear (with plain bearing):
- M10 ...................................................................................................................................................... 60 Nm
- M14 .................................................................................................................................................... 200 Nm
Overflow valve - piston cooling nozzle .................................................................................................... 30 Nm
Nuts for lubricating oil pump gear ........................................................................................................... 60 Nm
Retaining screws for lubricating oil pump ................................................................................................ 60 Nm
Connecting part to engine oil cooler ........................................................................................................ 60 Nm
Nuts for coolant pump pulley ................................................................................................................. 120 Nm
Attachment - Visco fan to Visco hub ........................................................................................................ 30 Nm
Screws/nuts on exhaust manifold ............................................................................................................ 50 Nm
Screws on air intake port ........................................................................................................................ 30 Nm
Nuts - Drive gear, high-pressure pump .................................................................................................... 90 Nm
Retaining bolt, injector ............................................................................................................................ 40 Nm
High-pressure line from high-pressure pump to rail ................................................................................. 30 Nm
High-pressure line from rail to injectors ................................................................................................... 25 Nm
Low-pressure line to high-pressure pump ............................................................................................... 25 Nm
Tightness
Thread size
8.8 10.9
M8 25 Nm 35 Nm
M10 50 Nm 75 Nm
CONSTRUCTION
GENERAL INFORMATION
The 620-series diesel engines described in this manual
are water-cooled four-stroke in-line engines with a
common rail fuel injection system. All models are
equipped with wet, replaceable cylinder liners, an ex-
haust turbocharger and charge-air cooling (air/air). The
engine is controlled by the EEM3 control unit. The en-
gine meets the requirements of the Level 3A exhaust
regulations.
Cylinder block
The rib-reinforced cylinder block forms the main engine
unit, onto which other engine components are mount-
ed.
The wet and interchangeable cylinder liners are sup-
ported in the middle, which has the effect of reducing vi-
bration and making sure that most of the coolant flows
to the upper part of the cylinder liners.
The seal between the lower part of the cylinder liner
and the cylinder block is provided by three O-rings fitted
into the grooves in the cylinder liner. The upper part is
sealed by the cylinder head gasket.
The camshaft is located in the cylinder block. All cam-
shaft bearings are fitted with interchangeable bearing
bushes.
Guide bearings are fitted on both sides of the rear main
bearing of the crankshaft
(crankshaft axial bearings).
Flywheel casing
The flywheel casing is fitted at the rear end of the cylin-
SS05N374
der block. The seal for the rear end of the crankshaft is
inserted in a bore in the casing. The attachment for the
starter is housed in the flywheel casing.
The underside of the flywheel casing serves as a seal-
ing face for the oil sump seal. This means that the lower
face of the cylinder block must stop flush with the fly-
wheel casing. When the flywheel casing is fitted, its po-
sition is determined by sprung dowel pins.
SS05N284
Cylinder head
The engines have two interchangeable cylinder heads.
Each cylinder has its own intake and outlet duct in the
cylinder head. Between the outlet valves is an inlet
valve to balance out the thermal load.
The cylinder head bolts are high-strength pre-loaded
bolts that are tightened to yield point in line with the
principle of tightening by angle. Due to the high degree
of elongation, the retaining power is kept constant
throughout the entire service life, and the bolts do not
therefore have to be re-tightened.
The injector seats are integrated into the cylinder head
itself. The inlet and outlet valve guides are identical and
can be interchanged. Furthermore, the inlet/outlet
valves are fitted with replaceable valve seat inserts.
1 SS05N324
SS03G080
Timing gears
1. Camshaft gear 4. Double intermediate gear
2. Intermediate gear 5. Crankshaft drive gear
3. High-pressure fuel pump drive gear
Timing gears
The gears of the engine control unit are hardened and bevel-toothed when engaged. The gears are located in the
timing gear housing, which is fitted on the front face of the engine.
The timing gears drive the camshaft, high-pressure fuel pump and the oil pump. The high-pressure fuel pump is driven
by the double intermediate gear (4). Like the camshaft, the intermediate gear (2) operates in pressure-lubricated plain
bearings. The bearing journal is attached to the front face of the cylinder block. The double intermediate gear is
mounted with two inclined ball bearings.
Lubrication system
7 1. Lubricating oil pump
2. Oil pressure valve
3. Oil filter
1 4. Turbocharger
5. Main oil duct
6. Oil spray nozzles
7. Oil pressure sensor
SS05N286
Lubrication system
The engine features a lubrication system for which the sure so that a constant value is maintained regardless of
oil pump (gear pump) is fitted on the lower face of the engine speed. Depending on speed, oil type and tem-
cylinder block. Oil is drawn in by the pump through a perature, the oil pressure will be between 2.5 - 5bar.
suction filter. From the pump, the oil is conveyed through When the engine is at idling speed, the oil pressure must
an oil line to the oil cooler (heat exchanger) and to the oil be at least 1.0 bar.
filter. The oil pressure valve is fitted in parallel to this. The oil filter is a one-way main stream filter. An overflow
The oil is then conveyed into the main oil duct, from valve located on the underside of the filter ensures lubri-
which other oil bores branch off. The oil is conveyed cation of the engine after a cold start at extremely low
through these bores to the main bearings and through outside temperatures and also ensures appropriate lu-
the crankshaft to the connecting rods. brication should the filter become blocked. A non-return
From the main oil duct, the compressed oil is then chan- valve prevents the filter being completely drained of oil
nelled to the turbocharger and the air compressor (if fit- when the engine is switched off.
ted). The bearing of the intermediate gear, the camshaft
bearings and the valve mechanism are also lubricated
with compressed oil.
The piston bases are sprayed and cooled with oil from
below for as long as the lubricating oil pressure is above
3 bar.
The oil pressure valve regulates the lubrication oil pres-
4 1
Cooling system
1. Coolant pump 5. Expansion tank
2. Thermostats 6. Oil cooler
3. Bypass duct 7. Engine temperature sensor
4. Cooler 05N373
Cooling system
The coolant pump, which is driven by the belt, is fit-
ted at the front end of the cylinder block. The ther-
mostat casing is located above the pump. The
cooling system features two thermostats which reg-
ulate the flow of coolant. The thermostats have dif- C
ferent opening temperatures. If the coolant
temperature is below the opening temperature, the
coolant (A) will circulate back to the coolant pump
via the bypass duct. The smaller, single-action ther-
mostat (1) starts opening at 79°C and allows a quan-
tity of the coolant (B) to flow into the cooler. When B
the temperature inside the engine rises and reaches 1
83°C, the two-circuit thermostat (2) also starts to
open. This closes when the bypass is opened and
conducts the entire flow of coolant (C) into the cool- 2
er.
A
SS05N287
Fan
SS03G024 SS05N282
SS05N357
Charge-air cooling
The intake air compressed by the turbocharger can The charge-air cooler is designed for straightforward
reach temperatures of up to 150°C during high utilisa- servicing. It can be folded upwards for effective clean-
tion. It is cooled to 50 - 60°C in a charge-air cooler (air/ ing against the direction of incoming outside air. By
air design) located upstream of the engine cooler. folding up the charge-air cooler, the other coolers are
Cooling of the charge air reduces the thermal and me- easier to access.
chanical stress on the engine and reduces emissions
of nitrogen oxides and soot particles.
Charge-air and charge-air temperature as pa-
rameters for engine control
There is a combined sensor in the air accumulator. It
continually sends information on charge-air pressure
and temperature to the Electronic Engine Management
unit (EEM3). In conjunction with the common rail fuel
injection system, fuel injection is optimised and the dis-
charge of nitrogen oxides and soot particles is signifi-
cantly reduced.
6 11
12
14
10
7
5
15
8 3
16
13
1
2
SS05N290
Layout
A7 ID MODULE
CAN H CAN L
Sensor B29
Charge-air pressure A3 Y21 - Injector 1
Charge-air
temperature Y22 - Injector 2
Y26 - Injector 6
Sensor B36
Fuel temperature
Heating flange E10/1
EEM3 (Jumper lead starting)
Sensor B38
Rail pressure
M13 Fuel
Sensor B23 delivery pump
'Water in
fuel' Solenoid valve Y20
High-pressure pump
Sensor B37
Oil pressure Switch S22
Coolant level
Sensor B22
Coolant temperature Sensor B2/1
Fuel level
Sensor B20
Engine speed
A1
ADIC
Limp home
Warning
Sensor B28 Fuel level
Manual accelerator too low
CAN H
CAN L
ICU Warning
Water in fuel
(optional feature)
ARU
Warning
Coolant level
Indicator
Oil pressure
Potentiometer R8 A4
Accelerator pedal FMGR
Indicator
Cold start aid
Function
The basic function of the EEM3 engine management system is to continually record and control the engine speed
and fuel injection volume. These two parameters are used to continually calculate the load on the engine.
The central unit of the engine management system receives continuous information (as electronic signals) from var-
ious sensors on physical parameters such as engine speed, coolant temperature, intake air and fuel, charge-air pres-
sure, fuel delivery pressure and engine lubricating oil pressure. The central unit of the engine management system
receives continuous information on the power and speed requirements of the FMGR via the CAN bus (depending on
the position of certain controls in the driver's cab).
The central unit of the engine management system receives the engine identification from the ID module. The EEM3
has an important diagnostic capacity. Errors in the EEM3 system are displayed using codes.
Signals
The EEM3 also receives data in different ways about various parameters which are important to the management of
the engine.
Idling speed
The idling speed and final idling speed are electronically regulated and cannot be changed. There is no need to re-
adjust.
Engine protection when limit values are exceeded
If any limit values are exceeded, the engine control system will be activated as a protective measure. The engine pow-
er and/or speed are reduced and if necessary fuel injection is stopped, shutting off the engine.
Fault detection
If an error occurs, an error warning message appears on the ADIC and the corresponding EEM3 error code is shown
on the A-column display.
The error can be pinpointed using the EST (Service Tool) and then remedied. (See Error codes Page 32)
NOTE: Function, removing and fitting the high-pressure pump, checking the delivery pressure: see Chap-
ter 3001A - Mode of operation: Fuel injection system.
Error codes
Fuel / speed
Error codes
reduction
Error description
Engine sensors
110 FL1 Coolant temperature sensor, signal voltage too low
111 FL1 Coolant temperature sensor, signal voltage too high
112 FLm Coolant temperature too high
113 FLm Coolant temperature alarm
109 FL1 Coolant temperature sensor, no signal
251 FL1 Fuel temperature sensor signal voltage too low
252 FL1 Fuel temperature sensor signal voltage too high
253 FL1 Fuel temperature too high
261 FL1 Fuel temperature sensor, no signal
114 FL1 Charge air temperature sensor, signal voltage too low
115 FL1 Charge air temperature sensor, signal voltage too high
116 FL1 Charge air temperature, value too high
117 FL1 Charge air temperature sensor, no signal
96 FL1 Oil pressure sensor, signal voltage too low
97 FL1 Oil pressure sensor, signal voltage too high
92 FL1/SL1 Oil pressure too high
98 Oil pressure too low
99 Oil pressure too low, alarm
95 FL1 Oil pressure sensor is faulty
93 FL1 Oil pressure sensor, no signal
100 FL1 Boost pressure sensor, signal voltage too low
101 FL1 Boost pressure sensor signal voltage too high
102 FL1/SL1 Charge presure too low
276 Pressure drop in intake system too high during engine start-up
103 FL1/SL1 Boost pressure too high
104 FL1 Boost pressure, no signal
263 FL2/SL2 Rail pressure sensor - signal voltage too low
264 FL2/SL2 Rail pressure sensor - signal voltage too high
265 FL2/SL2 Rail pressure too high
Abbreviations:
FL1 ..................................................................... Fuel injection limit 1 (75% of volume at nominal output)
FL2 ..................................................................... Fuel injection limit 2 (50% of volume at nominal output)
FLm .................................................................... Fuel injection limit through parameters in ignition map
FLf ...................................................................... Fuel injection limit fixed at 50 mg
FC ...................................................................... Fuel injection set to zero
SL1 ..................................................................... Speed limit 1 (max. 1800 rpm)
SL2, SLf ............................................................. Speed limit 2 (max. 1500 rpm)
SLp ..................................................................... Speed limit through parameters in ignition map
A ......................................................................... Analogue speed query is active
SDd .................................................................... Delayed engine shut-off
SDi ..................................................................... Immediate engine shut-off
SNA .................................................................... Starting is not possible
SS05N362
WORK INSTRUCTIONS
1. Cylinder block
A. Measuring wear on cylinder liners B. Removing the cylinder liners
1. Set the dial gauge to zero using a micrometer 1. If the cylinder liners are to be re-used, they must be
screw or a new cylinder liner, (initial dimension marked so they can be re-fitted in the same posi-
108.00 mm). tions.
2. Thoroughly clean the inner surface of the cylinder 2. Remove the cylinder liners using the 380000011
liner before the measurement. and 1TSW 510 extraction tools.
1TSW 510
380000011
SS99N037
NOTE: All camshaft bearing points have a separate bearing bush. Observe the various outer diameters when re-
moving and adjusting bearing bushes.
SS05N292
SS05N293
0.03 - 0.08 mm
SS05N295
Plug
SS00F003
BLACK
GREEN
SS05N294
SS99N050
9.13+0.02 2
9.23+0.02 3
The oversize of the cylinder liner (higher flange) is indi-
cated on the outer circumference by one or more mark-
er grooves as follows:
SS05N291
SS05N297
1TSW 662
SS05N296
SS99N057
Drain plug
1. Screw a nut on to a stud bolt for the rocker arm
mechanism. There is no stud bolt for the valves on
the central cylinder. Instead, use a bolt of the ap-
SS05N360
propriate length.
2. Press together the valve springs with lever
Drain off the coolant at the engine drain plug and the 380000008. Remove the valve spring seat retain-
drain cock on the lower side of the cooler. Disconnect ers, the spring guide and the spring. Remove the
the coolant hoses from the cylinder head and the ther- valves.
mostat housing.
2. Remove the intake lines between the exhaust tur- C. Checking the cylinder head
bocharger and the air filter and the charge-air lines 1. Remove carbon deposits from the outlet ducts,
from the turbocharger and the intake manifold. clean the seal surfaces and wash the cylinder
3. Remove the oil lines from the exhaust turbocharg- head.
er. 2. Check the cylinder head for cracks and any other
4. Unscrew the screw connections on the electrical damage.
wires from the injectors.
5. Remove the high-pressure lines and oil leakage
lines. Remove the injectors. Fit seal caps on all
open connections.
6. Remove the intake and exhaust manifolds and the
thermostat housing.
7. Remove the valve cover and the vent hose.
8. Remove the rocker arm mechanism and the push
rods.
9. First loosen all the cylinder head screws by a quar-
ter-turn and then unscrew them. Remove the cylin-
der head.
SS05N299
SS99N061
SS05N300
1. Press or force out the old guides using a mandrel.
Clean the valve guide seats.
4. If necessary, clean the bearing surface of the injec-
2. Fit the new guides using pressing tool 380000007,
tor in the cylinder head using a reamer.
which is used to ensure the right installation height
(21 mm above the plane face of the spring).
380000007
SS05N304
SS05N301
3. The same guides are used for both inlet and outlet
valves. Ensure that the steepest chamfer on the
5. Measure the amount of play between the valve
guide points towards the valve spring. Ensure that
stem and the valve guide with a dial gauge. Lift the
the valves do not jam in the guides.
valve so that the valve disk juts out of the surface
of the cylinder head by 15 mm and measure the
clearance. For the inlet valves, this must not ex-
ceed 0.30 mm and for the outlet valves, must not
exceed 0.35 mm. To determine whether the valve
guide is worn, a new valve must be used for the
measurement.
SS05N306
3. Clean the valve seat. Cool the new valve seat ring
in dry ice or liquid nitrogen.
4. Fit the valve seat ring with a suitable pressing tool.
Machine the seat.
NOTE: If required, the valve seat rings can be re-
SS05N302
placed by oversize valve seat rings. If this is the case,
A damaged valve seat must be machined using a mill- the cylinder head will need to be reworked. (see Tech-
ing cutter. If the width of the seat exceeds 2.3 mm at the nical Data Page 12)
outlet valve or
3.7 mm at the inlet valve, it must be reduced, particu- G. Grinding the valves
larly at the outer edge. To ensure there is an adequate seal around the valves,
The angle of the valve seat is 45° +20' at the outlet there is a difference between the angles of the sealing
valve and 35°+20'at the inlet valve. faces. There is an especially narrow sealing face that
guarantees an effective seal even after extended peri-
ods of use.
F. Replacing the valve seat rings
The outlet valves have separate valve seat rings. If the
sealing face is so heavily soiled that it cannot be re-
paired by machining, the valve seat rings must be re-
placed.
1. Grind the valve disk on a discarded valve so that it
fits snugly in the valve seat. Fit the valve and weld
correctly on to its seat. Cool with water.
2. Rotate the cylinder head and knock out the valve
together with the seat.
Outlet valve
SS05N307
A B C [mm]
INLET 35° -20'
35° 0.7 ±0.05
+20'
(max. 2.20)
OUTLET 45° -20'
45° 0.6 ±0.05
+20'
(max. 2.20)
1. Machine the damaged valve disk with a valve
SS05N305 grinder. Adjust the angle for the outlet valves to 45°-
20'
and for the inlet valves to 35°-20'.
2. If the height of the edge of the valve disk is less
than 1.5 mm after grinding, or if the valve stem is
bent, the valve will need to be replaced.
3. Grind the valves using a grinding paste and exam-
ine the contact surface using marker paint.
SS05N310
SS05N308
SS05N309
SS05N313
SS05N312
SS99N072
SS05N315
SS05N314
6. Lock the valve tappets so that they do not come off
when the camshaft is removed and do not hinder The clearance of the inlet and outlet valves is 0.35
installation of the camshaft. Raise the valve tappet mm. You can carry out this check when the engine is
push rods by bending two at a time slightly to- hot or cold. Check and adjust the the valve clearance
wards each other, working with pairs positioned of one cylinder while the piston is positioned at the up-
alongside each other. Clamp the push rods to- per dead point of the compression stroke. Proceed fol-
gether (e.g. with an O-ring), working with pairs po- lowing the engine's fuel injection sequence.
sitioned alongside each other, so that they are
If the valve clearance deviates from the specified val-
slightly tensioned, keeping the tappets in the up-
ue, loosen the lock nut and adjust the valve clearance
per position.
using the adjustment screw. The 0.35 mm thickness
CAUTION: Applying too much tension to the push gauge must fit snugly between the rocker arm and
rods will cause them to distort. the end of the valve stem.
7. Rotate the crankshaft until the position markers on
the camshaft gear and intermediate gear are
aligned with each other. Pull out the camshaft.
8. Remove the camshaft gear wheel from the cam-
shaft.
9. If you will be refitting the used camshaft or cam- E A E A E A E A E A
E A
shaft gear later, clean the parts before assembling
them.
10. Slide the feather key into the appropriate groove
on the camshaft and fit the camshaft gear wheel. I = INLET
Tighten the nut to 200 Nm. O = OUTLET SS05N317
11. Lubricate the bearing faces and slide the shaft into
the cylinder block, noting the position marks on - Turn the crankshaft in running direction until the
the camshaft gear. valves of the 6th cylinder overlap. (Outlet valve is
12. Fit the cover of the timing gear case and the pulley closed, inlet valve is opened). Check the valves on the
with the hub. (see Page 49) first cylinder.
13. Lower the push rods and fit the rocker arm mech- - Rotate the crankshaft by 1/3 of a turn in running di-
anism. Adjust the valves. Then screw the valve rection until the valves of the 2nd cylinder overlap.
cover and venting hose on to the cylinder head. Check the valves on the 5th cylinder.
Also fit the intake pipe that goes between the tur- - Continue working, following the fuel injection se-
bocharger and intake manifold. quence:
14. Fit the generator and the belt. Tension the belt to
the correct level of tension. Fit the cooler unit.
Fuel injection sequence: 153624
380000329
SS05N318
SS05N320
SS05N319
SS05N323
SS05N325
SS99N090
SS05N331
SS05N329
SS05N330
∅ 107.883 -
107.897
17 mm
SS05N332
SS05N334
SS05N333
SS05N335
SS05N337
SS05N339
SS05N364
SS99N114
4. Pre-fit the angled ball bearings in the double inter- 7. Insert the protective ring correctly into the seal seat
mediate gear. Fit the intermediate gear in the timing (see sectional drawing) and use special tool
gear case using the retaining bolt. 380000002 to insert the front crankshaft sealing
NOTE: Use new O-rings! ring fully home.
SS05N340 SS05N325
8. Oil the sealing faces on the sealing ring and crank- 10. Slide the hub on to the crankshaft profile.
shaft and the profile for holding the hub. 11. Apply a thin coat of oil to the thread of the crank-
9. Line up the marker on the hub with the marker on shaft nut. Fit the nuts and tighten with key
the crankshaft (see diagram). 380002658.
Tightening torque .......................................... 1000 Nm
12. Fit the vibration damper and the V-belt pulley on the
hub. Tighten the bolts to the correct tightening
torque.
13. Refit the other dismantled parts.
25 Nm
Loctite 638
SS05N341
SS05N343
SS05N344
ACEA E7
SS05N347
SS05N349
SS05N347
SS05N350
380000005
SS05N353
10. Attach the rear plate using a new seal. To fit the
SS05N351 rear plate for the bores shown in the diagram, use
guide lugs with a diameter of 8.5 mm.
7. Use mandrel 380000005 to tap the shaft seal into
the pump body. Fit the bearings and the intermedi- C. Coolant quality requirements
ate sleeves on the shaft. Lubricate the bearings · The coolant must fulfil quality standard
with plenty of heat-resistant ball bearing grease. ASTM D 3306 or BS 6580:1992.
Mount the shaft and bearing in position such that
the force created when they are pressed does not · If no frost resistance requirements are specified, a
affect the bearing balls. Fit the bearing circlip in its mixture ratio of 40% is sufficient to protect against
place. corrosion.
· Check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
years.
· The water used must be clean and soft, i.e. it must
contain no metals or their salts.
IMPORTANT: Never use water on its own as a
coolant.
SS05N352
SS05N355
SS99N146
TABEL OF CONTENS
EMPTY PAGE
SPECIAL TOOLS
SS03D046 SS98J030
SS00B076 SS98J031
1 off 380001129 (1TSW 645) Connection 1 off 380001486 (1TSW 641) M14x1,5
1 off 380001121 (1TSW 5002) Pressure gauge
EMPTY PAGE
GENERAL INFORMATION
This manual only contains general instructions for repairing and servicing the injection system. This applies to the
injection pump in particular, as specially trained personnel with special tools and measuring instruments are required
to repair it. All service and repair work on the injection system requires particular care and cleanliness.
Boost start and arc-welding
• Only 12V Batteries must be connected in parallel. As soon as the supply voltage will raise > 17V, the EEM
will interrupt the electrical supply to the PCU. The engine will not start (zero delivery).
• Prior to arc-welding turn the starter key to position "0". At the PCU, the connector must get unlocked and
disconnected. Do not touch the pins of either side.
IMPORTANT: In the case of fuel systems with Bosch VP 30 injection pump, it is important that the fuel system is
bled of air before starting the engine for the first time (see page 19 , bleeding the fuel system).
ATTENTION: Never wash the area of the injection pump with high pressure (electrical connection)
SAFETY REGULATIONS
There is always a risk of getting injured working close to the engine.
when performing service and repair
•) Always switch the engine OFF before carrying out
work. Before commencing work,
repair work.
the following safety regulations
and instructions must be read. •) Naked flames and smoking are not permitted in the
vicinity of fuel tanks or batteries. Electric sparks
•) Never start repair work which you do not fully
should be avoided.
understand.
•) Disconnect the cable at the negative battery pole
•) Make sure that it is possible to work safely at the (–) before carrying out service or repair work on the
location and in the vicinity. electrical system.
•) Make sure the location is clean and in a good state.
•) When checking the injection nozzles, never touch
•) Never use wrong or unsuitable tools. the fuel, which is ejected under high pressure. The
jet will penetrate the skin and cause serious
•) Remove all rings, chains and watches before
poisoning. If contact is made with the skin, consult
commencing work.
a doctor without delay!
•) Use state of the art safety equipment. For example,
wear goggles when using compressed air for •) Fuel and lubrication oil can cause skin irritations if
cleaning. contact is made over a longer period.
•) Avoid running the engine in idle unnecessarily.
•) Only use original CNH spare parts.
•) When carrying out service work, take measures to
•) Only start the engine from the cab, using the
prevent fuel or other fluids from entering the ground
ignition key.
or drains.
•) Never start the engine with the protective covers
removed. •) Be careful when washing the engine using a
washing facility with a high water pressure. Do not
•) It is difficult to see the radiator fan when the engine wash, for example, the electrical and fuel systems
is running! Baggy clothes and long hair can get under high pressure as they can easily be
caught in rotating engine parts! damaged.
•) If the engine is started in a confined space, •) Never wash the area around the injection pump
sufficient ventilation must be provided. when the engine is running.
•) Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
•) Ear muffs must be worn when testing the engine or
TECHNICAL DATA
Injection pump
Manufacturer and series.......................................................................................................................Bosch VP 30
Design ..............................................................................Solenoid-valve-Controlled Axial Piston Distributor Pump
Pump control ..................................................................................electronically by PCU (in connection with EEM)
Control of fuel quantity ........................................................................................... solenoid valve (PCU controlled)
Injection timing (dynamic)...............................................................................electronic/hydraulic/mechanic control
Speed control ............................................................................................electronically by the EEM (via CAN bus)
Electrical supply to PCU (from EEM) ..................................................................................................12V (min. 7V)
Current draw of the PCU (constant) ............................................................................................................ max. 8A
Direction of rotation (to be seen from pump drive) .................................................................................... clockwise
Pump setting (static)...........................................................................................................................with timing pin
Sequence of injection
620.95 to 620.99 ...........................................................................................................................1 - 5 - 3 - 6 - 2 - 4
Fuel supply
Fuel feed by.............................................................................................................................. electrical feed pump
Position of fuel feed pump..................................................... in the head of the sedimenter/primary filter assembly
Electrical supply (Fuse F29, 7,5A, +15/2) .......................................................................................................... 12V
Current draw................................................................................................................................................ max. 6A
Feed pressure - at low idle speed (past the fuel filter) ........................................................................ 1,0 to 1,3 bar
Feed pressure - at rated power (past the fuel filter) ............................................................................ 1,0 to 1,1 bar
Control of feed pressure (past the fuel filter) ................................................... pressure control switch and warning
Feed pressure warning activated when pressure......................................................................... < 0,05 bis 0,2 bar
Fuel filters
Sedimenter/primary filter (with water drain plug)................................................................................................ 30µ
Fuel filter (with water drain plug) .......................................................................................................................... 5µ
Indicator „water in fuel“ (standard) ................................................................................ sedimenter on primary filter
Indicator „water in fuel“ (option)............................................................ sensor in sedimenter and warning on ADIC
Tightening torques
Pump retaining nuts (M8) ............................................................................................................................... 30 Nm
Pump drive gear retaining screws .................................................................................................................. 40 Nm
Banjo bolt with overflow orifice (pump-fuel return line)................................................................................... 27 Nm
Injection pipe union nut .................................................................................................................................. 25 Nm
Bracket for retaining the injector (retaining nut) ............................................................................................. 15 Nm
Injector nozzle sleeve..................................................................................................................................... 60 Nm
FUEL SYSTEM
19
18
17
7
17
13 3
14
15
5
12 9
10 8
4
6
11
16
17
SS03D002
SS03D002
Function
The electrical fuel feed pump (7) draws fuel from the tank (1) through the sedimenter/primary filter assembly (5) and
passes fuel through the fuel filter (8) to the injection pump (11).
NOTE: The electrical fuel feed pump starts operating at the moment the starter key is turned to position "1". If the
engine is not started within one minute, the EEM will cut out the feed pump. As soon as the engine will be started,
the EEM will cut in the feed pump.
The injection pump forces the fuel into the injector (14) that feeds the fuel into the combustion space via the nozzle
in a fine spray. An overflow line (17) leads from the fuel filter to the tank, passing-by the injectors (14) and the injection
pump (11). At the fuel filter (8), an overflow valve with a throttle (15), located in the filter housing, allows a constant
bleed of the filters. At the injectors, the leak-off will join the overflow line (17) and finally, the overflow valve (16) allows
a certain overflow for the purpose of pump bleeding and pump cooling. The injection pump is lubricated by the fuel
only. As an option, the prefilter (5) can carry a transparent sedimenter equipped with a sensor (6) that triggers an
alarm on the ADIC (19) if a certain amount of water has collected in the bowl.
The quantity of fuel to be injected is controlled by the PCU (12) and metered by the fuel-quantity solenoid valve inside
the injection pump (11). When the engine is in operation, a number of parameters are fed continuously to the EEM
(Electronic Engine Management) (18) from different sensors. Concerning the quantity of fuel to be injected and the
timing advance, the EEM (18) constantly gives the needed information to the PCU (12) via CAN Bus.
Safety measures
Fuel level in the tank below minimum
If the fuel level in the tank is going below a certain limit, an alarm will be activated on the ADIC (19).
Fuel feed pressure to low
If the fuel feed pressure will drop below 0,05 to 0,2 bar between fuel filter and injection pump, the control switch (9)
will trigger an alarm on the ADIC (19). Additionally, fault code EEM 122 will be stored and displayed. Possible causes
for low feed pressure see page 20, „testing the fuel feed pressure“.
NOTE: When the fault code 122 is active, the EEM does not apply any active restrictions on engine operation.
Solenoid valve
IAT Sensor A2/2
Fuel quantity
Timing advance PCU
Commencement
Solenoid valve
of delivery
Timing device
Pump speed
(proportional)
CAN H
CAN L
DZG
Signal
Engine
emergency stop
Switch S6
A2
Engine oil pressure
DZG = Signal, crankshaft position
(top dead centre)
Sensor B29
Boost pressure
Sensor B29
Starting aid E10/1
Boost air-temperature
(Grid heater)
Sensor B22
Coolant temperature
EEM M13
Control switch B21 Fuel feed pump
Fuel feed pressure
Sensor B23
"Water
in fuel"
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position
Limp home
A1
(engine speed)
ADIC
Sensor B28
Hand throttle
CAN H
CAN L
Warning
Fuel
level
too low
ARU
P8
Warning
DISPLAY Fuel feed
pressure
too low
Sensors R8 A4
Drive pedal FMGR Warning
Water
in fuel
10
17
11
16
13
SS03D037
12
15 5 6 7 14 8 9
General
The injection system consist of a mechanical distributor pump with electro-hydraulic actuators. Further an electronic
Pump Control Unit (PCU) (10), which communicates with the Electronic Engine Management (EEM) via CAN Bus.
The fuel supply is done by an electrical feed pump. A warning is activated on the ADIC if the feed pressure drops
below 0,05 - 0,2 bar, or the feed pump ceases.
• The EEM gets supplied with 12V (Fuse F30, 5A, +15/2) and ground. The PCU gets supply (12V and ground)
by the EEM only.
• The PCU (10) controls the actuators responsible for commencement of delivery and quantity of fuel injected.
• High pressure and delivery is performed by a mechanical pump with a concentrically arranged piston (7).
The piston simultaneously moves axialy to deliver fuel with high pressure and rotates to distribute the fuel to
the delivery valves (8) and delivery ports (9) of the very cylinders.
• To control the timing advance dynamically, a hydraulically controlled piston in the timing device (15) positi-
ons the bearing ring (4) together with the roller ring (5). The required pressure is delivered by an internal
vane pump (3) and gets controlled by means of a proportional pressure control valve (14).
• Engine-related parameters get changed into electrical signals by sensors. The signals are fed to the EEM.
The electronic makes use of the value of the signals.
• The IAT sensor (11) (Incremental Advance Time System), which is fixed to the bearing ring (4) inside the
injection pump, delivers the "incremental angle/time" signal to the PCU (10) by means of the conductive foil
(17). The electronic is drawing three different informations out of this signal. Details see page 14 (Electronic
control).
Idle speed
The low idle speed as well as the high idle speed are controlled electronically and cannot be altered.
There is no re-adjustment necessary.
Electronic control
• No mechanical connection (rod or cable) exists between the engine and the controls in the cabine. The para-
meters supplied by the electronic drive pedal or the electronic hand throttle are conducted as electrical
signals to control units like FMGR (Vehicle Control Unit) and ARU (Arm Rest Unit). There, these signals get
converted into CAN messages, thus being transmitted to the EEM too.
• Messages related to engine and fuel injection are transmitted between EEM and PCU by CAN Bus.
• Taking in account the coming-in parameters and the momentary engine requirements, the EEM determines
CAN messages to control injection timing and the quantity of fuel to be injected.
• The PCU (10) controls the proportional solenoid valve (14) of the hydraulic-mechanically controlled timing
device (15) by means of PCC (Pulsed Current Control).
• In the injection pump, at the circumference of the rotating incremental wheel (12), there are six notches (18)
arranged by symetrical division (see page 17). At the moment a notch will pass the IAT sensor (11), the
signal generated will trigger the PCU (10) to energise the solenoid of the fuel-quantity solenoid valve (13).
Thus the valve needle will close a port leading to the barrel. Pressure will build up and fuel, displaced by the
piston(7), gets delivered to the injector (21) via delivery valve (8) and delivery port (9) to the injector.
• By CAN message, the PCU (10) gets informed for how many degrees of rotation of the incremental wheel
(12) and rotating pump drive shaft (1) the pump should deliver to the very injector (this will represent a cer-
tain distance of the effective lift of the pump piston (7). After completing the desired angle, the PCU (10) will
de-energise the fuel-quantity solenoid valve (13). The valve needle will open the port, as a result delivery
will be stopped. The angle run through between closing and opening the valve needle will determine the
quantity of fuel injected.
• The incremental wheel rotating with the crankshaft of the engine is provided with a notch too. The signal
generated at this point by the engine speed sensor serves as an electronic (virtual) reference marking (e.g.
Top Dead Center). In connection with the signal of the IAT sensor (11) in the injection pump, the electronic
will calculate the real timing advance. Additionally, the signal of the PCC (Pulsed Current Control) to control
the solenoid valve of the timing device will be altered if required.
Cam angle
Cam lift of delivery
Effective lift
Control pulse
Lift of valve
needle
IAT-Signal
SS03D036
27
28 26
10
23 25
2 17 22
11
3 12 6
24
5
1
13
20
18 7 8 9
15
21
14
SS03D035
Operating Principle
Latest technology used with the injection pump VP30 results in a compact construction, fulfilling the emission stan-
dards, developing the whole potential of engine power, at the same time ensuring low fuel consumption.
An electrical feed pump (26) supplies fuel to the injection pump. An overflow valve (22) ensures permanent bleeding
and cooling of the injection pump.
High pressure delivery is produced mechanically by means of the cam lobes of the roller ring (5), the lift disc (6) in
connection with the axial piston (7). An integrated vane pump (3) creates a pressure, which, on the one hand ensures
proper feeding of the high pressure element and, on the other hand serves as a control pressure for the hydraulic/
mechanically controlled timing device (15). The injection pump as a whole is lubricated by the fuel only. In connection
with fitting the injection pump to the engine, static timing is part of the procedure (see page 22).
The electronic Pump Control Unit (PCU) (10) is attached to the upper side of the pump. The electrical supply to the
PCU comes from the Electronic Engine Management (EEM). With the exception of an extra line for „emergency en-
gine stop“, all signals and parameters are sent by a series of numeric values by means of CAN communication (Con-
troller Area Network) between the EEM and PCU.
The PCU (10) controls the proportional solenoid valve (14) by means of PCC (Pulsed Current Control). Valve (14)
vary a control pressure. This control pressure moves a piston in the timing device (15), positioning the bearing ring
(4) together with the roller ring (5) dynamically.
The IAT sensor (11), attached to the bearing ring (4) signals the real angle of timing advance as well as the pump
speed and triggers the commencement of delivery. Taking in account various parameters, the EEM determines the
timing advance, transmitting the message to the PCU (10) by CAN Bus. In case the signal of the engine speed sensor
is faulty, the EEM makes use of the pump speed signal to calculate the engine speed.
The fuel-quantity solenoid valve (13) is positioned concentrically around the distributor body. When the PCU (10) en-
ergises the valve, it‘s needle will close a port and delivery commences. As the valve get‘s de-energised, delivery cea-
ses. Within the periode the fuel-quantity solenoid valve (13) is energised the piston (7) moves a certain distance of
its total stroke. This again determines the quantity of fuel delivered to the injector (21). During one revolution of the
pump drive shaft (1), the fuel-quantity solenoid valve (13) runs through six cycles of closing and opening the needle.
17
17 11
2 11 5
12
6
3
7
12
19
18 4
SS03D033
15
SS03D034
• The incremental wheel (12) rotates together with the pump drive shaft (1). The IAT sensor (11) moves toge-
ther with the bearing ring(4) and the roller ring (5).
• When in the timing device (15) the timing advance is altered by the proportional solenoid valve , the bearing
ring (4) together with the roller ring (5) and the IAT sensor (11) is moved in the direction „advance“ or „retard“
either.
• At the circumference of the incremental wheel (12), there are six notches (18) (one notch for each cylinder of
the engine), arranged by symetric division. The sequence of teeth and notches is scanned by the IAT sensor
(11).
• The signal is transmitted to the PCU (10) by means of a conductive foil (17). The signal is utilised as follows:
- to determine the present angle position
- to determine the present timing advance in connection with the engine speed signal
- to sense the speed of the pump drive shaft
• The present angle position determines the trigger point for energising the fuel-quantity solenoid valve (13)
by the PCU (10). This will ensure the correct timing for closing and opening of the valve needle (valve lift) in
accordance with the cam lift (see page 14).
SS03D001
SS03C027
SS03C029
SS00E039
SS03C030
380001487 SS03C032
1.Fuel inlet
2.Leakage oil port
3. Adjusting shim
4.Pressure spring 3
5.Thrust bolt
6.Nozzle body
4
SS99N147
7.Pressure chamber
5
8. Needle
9.Spray orifice 6
7
Opening pressure
8
To fill the injector, pump the system a few times.
9 Increase the pressure in the injector until the buzzing
SS99N149
is audible. Check the opening pressure. If the opening
pressure deviates from the specified value (see
The injectors are equipped with a five-hole nozzle. page 8), the injector must be dismantled to adjust the
The small amount of leakage fuel used to lubricate the opening pressure.
needle is returned to the fuel tank via the overflow li- An adjustment is made by means of altering the adju-
ne. sting shim. The thickness of the adjusting shims va-
ries between 1.00 and 1.90 mm and they are
Removing the injectors available in graduations of 0.05 mm. A thicker adju-
sting shim increases the opening pressure, a thinner
1. Clean the injectors and the surrounding area. Dis-
one reduces the opening pressure. Changing the
connect the pressure lines and the leakage oil line.
thickness of the shim by 0.05 mm changes the ope-
NOTE: Keep in mind the assignment of the injection ning pressure by approx. 5.0 bar. Because the ope-
lines to the connections at the pump and notice how ning pressure of the nozzle drops slightly after being
the injectors are fitted (direction of leakage oil port). adjusted, it should be set approx. 10 bar higher than
the value specified in the technical data. This value is
2. Unscrew the nuts of the injector retaining brackets.
valid for both new and used nozzles.
Remove the brackets and then the injectors from the
cylinder head. Seal off all connecting points by fitting Buzzing properties
protective caps. Testing by means of the hand pump does not fully cor-
3. Remove the sealing washers from the injectors respond to the conditions that the nozzle is subject to
seating in the cylinder head, if they have not already in the engine. The test results are only reliable for new
been taken out together with the injectors. nozzles. Used nozzles do not buzz at certain pump
speeds, which is due to the design of the nozzle.
Checking the nozzles When pumping quickly, however, the buzz is audible
and/or a fine jet of atomised fuel is visible. The jet is
IMPORTANT: When checking the nozzles on the
thicker and less defined in the buzz-free zone.
test stand, it is not permitted to remain in the vicinity
of the nozzle outlet (e.g. with one’s hands). The fuel Tightness of the nozzle
jet, which is ejected at high pressure, can easily Press the test pump lever slowly, until the pressure
penetrate the skin and cause serious injuries. Brea- increases to approx. 20 bar below the setting value.
thing-in fuel spray is detrimental to health. Maintain this pressure for approx. 10 seconds. If no
1. Clean the injectors using cleaning fluid and a soft drops of fuel form at the tip of the nozzle, the nozzle
brush. The carbon deposits must not be knocked off seals correctly. When the nozzle does not perform as
or removed in such a way that the nozzle can be da- demanded, see page 24, chapter "Overhauling injec-
maged. tors".
2. Mount the injectors on the test stand and check the
following points:
Sva 6-51300 EN Edition 05-2003
3001-23
Overhauling injectors
1. Mount the injector in such a way in a fixture that it
will not be damaged.
2. Unscrew the nozzle tensioning nut. Remove the
nozzle and the parts inside the injector body.
3. Clean the nozzle, both inside and outside, in cle-
aning fluid.
4. Steep blocked spray orifices or clean them using a 1
cleaning needle. 2
5. Check the movement of the needle as follows:
1. Sealing washer
2. Rubber ring
3. Sealing ring
3
SS99N150
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The engines are equipped with a FRPPRQUDLO fuel injection system. This system is controlled by the electronic en-
gine management system EEM3. The engines meet Tier 3 emissions standards.
To make sure that the engine continues to meet these emissions standards over its entire service life, the stipulated
periodic service and maintenance work must be carried out with the necessary diligence. Only genuine CNH service
material (filters) may be used.
The stipulated periodic functional check of the injectors should be carried out every 2000 operating hours using the
EST (Service Tool).
Calibration of the fuel injection system should be undertaken using the EST (Service Tool).
Only genuine CNH spare parts may be used to carry out repairs. Maintenance and service work which is not carried
out with due diligence or is not carried out in time and/or the use of any parts which are not genuine spare parts or
service material will result in the manufacturer’s guarantee of the fulfilment of emissions standards becoming void.
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This work may only be undertaken by trained personnel using the required special tools and testing and calibration
equipment.
((0 = Electronic Engine Management. German: Electronic engine management
6$)(7<5(*8/$7,216
7KHUHLVDOZD\VDULVNRILQMXU\ZKHQ •) Always switch the engine off before performing re-
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stand. FDQSHQHWUDWHWKHVNLQDQGFDXVHVHULRXVLQMXU\,IVXFK
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cation and in the vicinity. PHGLDWHO\
•) Make sure the repair area is clean and in good con- •) Naked flames and smoking are not permitted in the
dition. vicinity of fuel tanks or batteries. Electrical sparks
should be avoided.
•) Never use incorrect or unsuitable tools.
•) Disconnect the cable at the negative battery pole (-)
•) Remove all rings, chains and watches before start- before carrying out service or repair work on the
ing work. electrical system.
•) Use modern safety equipment when working. For •) Extended contact with fuel or lubricant
example, protect your eyes when using compressed can irritate the skin.
air for cleaning.
•) Avoid running the engine in idle unnecessarily.
•) Only use JHQXLQH&1+VSDUHSDUWV.
•) When carrying out service work, take measures to
•) Never wash the components of the fuel injection sys- prevent fuel or other fluids from entering the ground
tem while the engine is running. or drains.
•) Only start the engine from the cab using the ignition •) Be careful when washing the engine using a wash-
key. ing facility with a high water pressure. Do not wash,
•) Never start the engine when protective covers are for example, the electrical and fuel systems under
not in place. high pressure as they can easily be damaged.
•) The cooling fan is difficult to see when the engine is •) Never use auxiliary starting fuels on an aerosol basis
running! Loose clothing and long hair may become whilst the pre-glow starting facility is in operation (ex-
caught in rotating engine parts. plosion hazard).
•) If the engine is being started in an enclosed space,
make sure there is sufficient ventilation.
•) Ear muffs must be worn when testing the engine or
working close to the engine to avoid hearing dam-
age.
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Type .............................................................................................................................................................. CP 1H
Design .................................................................................................................... Radial piston pump, 3 cylinders
Lubrication .........................................................................................................................................................Fuel
Max. injection pressure ..............................................................................................................................1100 bar
Transmission ratio of drive gears ......................................................................................................................4 : 3
Injection sequence .................................................................................................................................1-5-3-6-2-4
,QMHFWRUV
Type ..................................................................................................................................................... CRIN 2 - 2V
Number of blowholes...............................................................................................................................................5
)XHO
Required fuel quality ......................................................................................................................EN 590 standard
Fuel supply temperature, max. .............................................................................................................. 70° Celsius
)XHOILOWHU
Pre-filter .......................................................................................................................................... 30 µ Stanadyne
Fine filter ........................................................................................................................................... 5 µ Stanadyne
Delivery pump ................................................................................................................. electric, fitted on pre-filter
Supply voltage ....................................................................................................................................... 12 volts DC
Max. current. ............................................................................................................................................6 amperes
Delivery pressure when engine idling, min. ................................................................................................ 0.75 bar
7LJKWHQLQJWRUTXHV
,QMHFWRUV
Retaining bolt ................................................................................................................................................ 40 Nm
Retaining nuts - cable connection ................................................................................................................ 1.5 Nm
+LJKSUHVVXUHSXPS
Retaining nuts - drive gear wheel (M14) ....................................................................................................... 70 Nm
Retaining bolts ............................................................................................................................................... 30 Nm
)XHOOLQHV
High-pressure line from high-pressure pump to rail ...................................................................................... 30 Nm
High-pressure line from rail to injectors ......................................................................................................... 25 Nm
Low-pressure line to high-pressure pump ..................................................................................................... 25 Nm
-XPSHUOHDGVWDUWLQJDQGHOHFWURZHOGLQJ
Jumper lead starting may only be used with 12V batteries connected in parallel.
Before performing any welding work, turn the start switch to the „0“ position.
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The electric delivery pump (5) draws fuel from the tank through the pre-filter (6). It conveys the fuel through the fuel
filter (8) to the high-pressure pump (11).
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The high-pressure pump pumps fuel into the rail (12) (storage area). When the engine is running, fuel is stored at high
pressure (up to 1100 bar) in the rail and the high-pressure lines, as far as the injectors (14). Electronically controlled
injectors inject the fuel, finely atomised, into the combustion chambers of the cylinders.
The timing of the injection and the volume of fuel injected are controlled by the electronic engine management unit,
the EEM3. The injection volume is determined by both the current pressure in the rail and the time during which an
injector is activated by the EEM3.
The common rail injection system significantly optimises the fuel injection process. This is due to a number of advan-
tages of the common rail injection system:
Fuel is injected at high pressure (up to 1100 bar) through five-hole injector nozzles
The fuel is injected in up to three part-volumes
Key physical parameters are processed by the EEM3 to determine the number, volume and timing of inject-
ed part-volumes:
- Output requirements through FMGR via CAN bus, engine speed
- Engine temperature (coolant), intake air and fuel
- Charge-air pressure, high pressure in rail, fuel delivery pressure, engine oil pressure
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Reduction in harmful emissions
Reduction in specific fuel consumption
Reduction in engine noise
Automatic venting (starting from driver’s seat) without opening the line system
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by pressure control valves on high-pressure pump
by overflow valve in rail
as leaked oil from the injectors
from the overflow connection on the fuel filter (this also aids automatic venting of the fuel system after a filter
change or when the fuel tank is empty).
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If the fuel level falls below the minimum, a warning message is displayed on the ADIC.
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If the delivery pressure between the fuel filter and the high-pressure pump is insufficient, the fuel delivery pressure
sensor (9) activates a warning message on the ADIC. For possible causes of low delivery pressure, refer to Seite 13,
’Checking the fuel delivery pressure’.
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Rail pressure too high:
Error code EEM3 - 382 is stored and displayed.
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Engine oil pressure too low: Zero delivery after 30-second delay.
Error code EEM3 - 99 is stored and displayed.
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Coolant temperature too high: Zero delivery after 30-second delay.
Error code EEM3 - 113 is stored and displayed.
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Engine speed too high (> 3000 rpm): Zero delivery cuts in immediately.
Error code EEM3 - 94 is stored and displayed.
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Upgrade protection error
Error code EEM3 - 172 is stored and displayed.
Self-test for shut-off, hardware error
Error code EEM3 - 221, 222, 223 is stored and displayed.
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There is no need to vent the engine specially after changing the fuel filter or if the fuel tank has run empty. It is sufficient
to turn the start switch to the ON position and allow the electric delivery pump to run for at least 30 seconds. Then
activate the starter (max. 10 seconds). If the engine still will not start, activate the electric delivery pump for at least
another 30 seconds and then attempt to start the engine again.
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1. Clean both filter casings and the line connections.
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The function of the injectors must be checked every 2000 operating hours using the EST (Service Tool) (’run-up’ test).
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1. Clean the injectors, line connections, lines and immediate surroundings.
2. Disconnect the electrical connection, high-pressure line and oil leakage line.
3. Undo the retaining bolt. Remove the retaining bolt and washer, noting the position in which the washer is fitted.
4. Remove the injector and the bracket. Immediately seal the connection openings on the injector with plastic plugs.
5. Remove the injector seal from its seat in the cylinder head if it was not removed along with the injector.
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1. Clean the bore in the cylinder head and the sealing face. If necessary, clean the seat in the cylinder head with a
reamer.
2. Ensure that the sealing face in the cylinder head is clean. Fit a new sealing ring.
3. Fit the injector. Put the bracket in position, aligning the injector to the bracket.
4. Attach the washer with the spherical surface to the brack-
et. Screw in the retaining bolt.
Anzugsdrehmoment ..................................................40 Nm
5. Connect the high-pressure line to the injector.
Anzugsdrehmoment .................................................. 30 Nm
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The high-pressure pump is mounted on the engine control housing on the left-hand side of the engine. It is driven by
gear wheels. The high-pressure pump is a radial piston pump with three cylinders. The high-pressure pump is lubri-
cated by the fuel.
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If necessary the function of the high-pressure pump can be checked using the (67 (Service Tool).
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1. Turn the start switch to the OFF position. Turn the main battery switch (if present) to
the OFF position.
2. Clean the high-pressure pump, the area around it and the line connections.
3. Disconnect the plug connection. Disconnect the fuel lines and immediately seal the connection openings with
plastic plugs.
4. Unscrew the retaining bolts. Remove the high-pressure pump, being careful with the guide ring.
5. Unscrew the retaining nut of the drive gear from the pump shaft, fixing the drive gear using a suitable tool. Use a
suitable extractor to pull the drive gear off the pump shaft.
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6. Remove the guide ring from the pump flange.
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1. Clean the guide ring (A) and the drive gear (B). Check
the mounting flange on the high-pressure pump you plan 1P
to install. Check the O-ring grooves on the pump flange
and on the guide ring. They must be clean and free from
burrs or foreign material. Check the outer cone of the
pump shaft and the inner cone of the drive gear. They 1P
must be dry, free of oil and grease and must not show
any signs of burrs.
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2. Attach an O-ring to both the pump flange and the guide
ring. Apply a thin coat of oil to the O-ring on the pump %
flange. Fit the guide ring. Manually slide the drive gear on
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to the pump shaft. Fit the nut. Fix the drive gear in place
with a suitable tool. Tighten the nut.
Anzugsdrehmoment ..................................................70 Nm
SS05M994
3. Clean the flange face and the bore for inserting the high-
pressure pump on the control unit casing. Apply a thin
coat of oil to the O-ring on the guide ring. Hold the high-
pressure pump in its installation position. Align the guide
ring radially on the pump flange such that the bore (see
arrow) is in line with the bore on the control unit casing.
4. Slide the high-pressure pump into the control unit casing
together with the guide ring. Screw on and tighten the re-
taining bolts (with shim).
Anzugsdrehmoment ................................................. 30 Nm
5. Connect the fuel lines to the high-pressure pump and
tighten them.
Anzugsdrehmoment Low-pressure lines .................. 25 Nm
High-pressure line (pump to rail) .............................. 30 Nm SS05M995
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Ensure that the tank contains sufficient fuel.
Vent the fuel system (see Seite 13).
Start the engine, check the fuel system for leaks and observe how the engine runs.
Carry out a test drive.
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Density at +15 °C 0.82...0.84 kg/dm EN ISO 3675:1998, EN ISO 12185
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Viscosity at +40 °C 2.0...4.5 mm /s EN ISO 3104
Sulphur content max. 350 mg/kg EN ISO 14596:1998
Cetane rating min. 51 EN ISO 5165:1998
Water content max. 200 mg/kg prEN ISO 12937:1996
Lubricity max. 460 microns ISO 12156-1
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Engine output is dependent on the density of the fuel used. The
standard value is 0.84kg/dm³ at +15 °C.
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Engine output is dependent on the viscosity of the fuel used. The
standard value is 3 cSt at +20 °C.
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BLANK PAGE
4002
FUNCTIONAL DESCRIPTION OF
THE CAN BUS
(Basics)
TROUBLESHOOTING ........................................................................................................................................ 21
Interrupting the Transmission ........................................................................................................................ 21
Resumption of the Transmission ................................................................................................................... 21
Realtime Transmission .................................................................................................................................. 21
BLANK PAGE
INTRODUCTION
There is a clear trend in automobile and farm implement technology towards an increasing replacement of mechanical
components by electronic components.
This thereby allows the maker to provide the customer with more comfort and more safety inside the vehicle.
However, this also means that vehicle electronics are becoming ever more complex and are equipped with a growing
number of sensors and actuators.
In the future, these increased requirments can no longer be implemented by autonomous control devices.
The solution to the problem lies in the networking of various electronic modules with a data bus.
The simple motto is: "Less hardware, and more software".
This provides many advantages, which will be described in detail in this document.
DIGITAL TECHNOLOGY
There are only two conditions in digital technology (lat. digitus >finger<). Both of these conditions are defined exactly.
They are termed logical zero and logical one.
Both conditions (logical one and logical zero) are mutually exclusive, i.e. both conditions can never be present
simultaneously.
There are no intermediate values (e.g. lamp lights weakly).
One single such condition is termed within digital technology as a bit (BInary digiT ).
Therefore, using one bit (Bi = 2), exactly two different conditions can be described (e.g. switch closed or switch
open).
Time
0 0 OFF OPEN
1 0 ON OPEN
0 1 OFF CLOSED
1 1 ON CLOSED
This information could be used, e.g. in FMGR control units for recognising the working mode or at the seat switch for
safety conditions.
Possibilities in relation to the number of bits
A single bit has a low data content. Several bits are therefore used in practice.
1 2
2 4
3 8
4 16
5 32
6 64
7 128
8 256
E\WH
1 1 0 0 0 1 1 0
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0 E\WH
1
1
0
0 OLQH
0
1
1
DATA BUS
The term CAN (= Controller Area Network) originates from computer technology and, when related to tractors,
means the electronic coupling (i.e. networking) of control units.
Within a data bus system, individual control units are linked to each other in a network can therefore exchange data.
As all control units connected to the bus participate in the data exchange, the control units in such a system are
also called bus users.
Note:
The bus users are connected in parallel to the data bus.
Data transmission is effected serially.
EEM
Function
The CAN data bus is a bi-directional bus.
This means that every control unit which is connected can transmit and receive.
Conditioning an analogue signal
A sensor transmits an analogue signal, e.g. engine coolant temperature (the voltage is the signal value), to an
assigned control unit
In the control unit, the analogue signal is conditioned (digitalised) by an AD converter and converted into
a numeric code
A data telegram is also created in the control unit
The signal value is a part of the data telegram
Conditioning a digital signal
A sensor transmits a digital signal, e.g. engine speed (the frequency is the signal value), to an assigned control
unit
In the control unit, the digital signal is converted into a numeric code by a code converter
A data telegram is also created in the control unit
The signal value is a part of the data telegram
Forwarding the data telegram
The data telegrams are sent to the data bus. Every control unit connected to the data bus can read and process the
signal value in the data telegram as required.
Message-related addressing
This means that every message is assigned one fixed address (identifier) that identifies the contents of the message
(e.g. engine speed).
The CAN protocol can allow up to 2048 messages in the case of an 11-bit identifier and up to 500 million for a 29-bit
identifier. The data capacity per message is up to 8 bytes.
A receiver evaluates only those messages (data telegrams) that are stored in its list of messages to be received
(acceptance test).
Advantages:
Sensor lines must be led to the nearest control unit. This results in much less cable being used with a
concomitant reduction in plug connections and thereby a reduced number of possible error sources.
Improved EMC (= electromagentic compatibility) and therefore less trouble-prone.
Multiple use of signals and thereby less sensors.
Better and more exact diagnosis possibilities using the CNH Service Tool.
Control units can be programmed when assembled in the vehicle (flashing).
CAN high
CAN low
+12 V
Bit 3
Bit 4
Bit 5
Bit 7
Bit 8
Bit 2
Bit 6
Bit 1
Logical 1
Logical 0
0 1 1 0 1 0 0 1
Bit 4
Bit 5
Bit 7
Bit 8
Bit 2
Bit 6
Bit 1
Logical 1
Logical 0
1 0 0 1 0 1 1 0
Voltage
5
CAN_H
4
CAN_H
CAN_L / CAN_H
3 CAN_H
CAN_L / CAN_H
2 CAN_L
CAN_L / CAN_H
CAN_L
1
CAN_L
0
Time
Recessive Dominant Recessive
min
nom
max
Topology
"Series" system
HI
LO
Data Transmission
Transmission Protocol
All details of a data transmission are regulated in a transmission protocol.
Data telegrams can only be transmitted when the CAN data bus is free (i.e. when, after the last data telegram, there
is a 3 bit space and no control unit starts transmitting). The bus level is thereby logical one.
Arbitration
If several control units start transmitting simultaneously, then a procedure is introduced in which the message with
the highest priority wins through without any time or bit loss ensuing.
Every control unit that looses the arbitration automatically becomes a receiver and repeats its attempt to transmit as
soon as the CAN data bus is free.
Apart from data telegrams, there are also request telegrams for particular messages. Every control unit that is able
to provide the required data telegram then reacts to this request.
If a voltage peak only occurs at one line (e.g. due to EMC problems) then the receivers can recognise this as an
error and ignore the voltage peak.
DATA PROTOCOL
Structure of the CAN Data Frame – Standard Identifier (11 bits) CAN V2.0A
Arbitration
IFS Start Identifier IDE DLC Data CRC ACK EOF IFS
3 Bit 1 Bit 11 Bit 1 Bit 4 Bit 0-8*8 Bit 15 Bit 2 Bit 7 Bit 3 Bit
Bus idle RTR r0 CRC DEL
1 Bit 1 Bit 1 Bit
Control Field
ldentifier Extension – IDE (1 bit)
IDE = LOW – Standard Identifier – there are no further Identifier bits
r0 = 1 reserved bit for subsequent extensions
Data Field
0 - 8 byte data can be transmitted per Data Frame.
Structure of the CAN Data Frame – Standard Identifier (29 bits) CAN V2.0B
Arbitration
Start of Frame
Start bit = Low (dominant). The negative flank is used for for phase synchronization of the receivers.
Arbitration Field
Identification of the address (ID18-ID28)
The smaller the numerical value in the address, the higher the priority. The highet value 7 bits must not all be
recessive.
Substitute Remote Request – SRR (1 bit)
Replacement for the RTR bit from the standard CAN (CAN V2.0A); otherwise meaningless
ldentifier Extension – IDE (1 bit)
IDE = HIGH – there are further 18-bit identifiers in the 2nd. Identifier Field (ID 17-ID 0)
Remote Transmission Request – RTR (last bit of the Arbitration Field)
RTR = LOW – Telegram contains data
RTR = HIGH – Telegram contains request to send data
Control Field
r1 / r0 = 2 reserved bits for subsequent extensions
Data Field
0 - 8 byte data can be transmitted per Data Frame.
IFS Start Identifier IDE DLC CRC ACK EOF IFS IDLE/
3 Bit 1 Bit 11 Bit 1 Bit 4 Bit 15 Bit 2 Bit 7 Bit 3 Bit Next telegram
Bus idle RTR r0 CRC DEL
1 Bit 1 Bit
1 Bit
ERROR DETECTION
Faults can result in errors during data transmission. Such transmission errors must be detected and rectified. In the
CAN protocol, there are two different error-detection levels:
1 Mechanisms on the Data Frame level
2 Mechanisms on the Bit level
TROUBLESHOOTING
Interrupting the Transmission
If any station on the CAN bus detects an error then it interrupts the current transmission by transmitting an error
message. The error message consists of 6 dominant bits.
The error message informs all connected control units of a locally occurring error; these then ignore the
subsequently transmitted messages.
Realtime Transmission
To be able to process data in realtime, the data must be transmitted quickly. This not only presupposes a fast
physical data transmission path, but also requires a fast allocation on the bus if several control units want to transmit
simultaneously.
To take into account the various levels of urgency of messages that are transmitted via the bus, there are various
priorities for the single messages. The advance angle (hydrostat) has, e.g. very high priority, the oil temperature
value medium priority and the service message low priority.
Example:
If several control units want to transmit simultaneously then the bus access conflict is triggered by the respective
identifier via "bit arbitration".
On transmitting the Arbitration Field, the transmitter checks after every bit whether it is still authorized to transmit or
whether another control unit is transmitting a message of higher priority. When a recessive bit transmitted by the first
transmitter is overwritten by a dominant bit from another transmitter then the first transmitter loses its authorization to
transmit (arbitration) and becomes a receiver.
The first control unit (N2) loses the arbitration with bit 3. The third control unit (N3) loses the arbitration with bit 7. The
first control unit (N1) retains access to the bus and can transmit its message.
User 1
Node 1
High priority
User 2
Node 2
Receive only Low priority
User 3
Node 3
Receive only Medium Priority
TRANSMISSION SPEED
Different CAN data busses are used. They are mainly differentiated by their various transmission speeds. If one bit
per second is transmitted on a line then the transmission speed is one baud (Jean Maurice Baudeot – French
lineman)
1 baud (Bd) ........................................................................................................................... 1 bit/sec.
1 kbaud (kBd)..................................................................................................................1024 bits/sec.
A maximum of 135 bits (11-bit identifier) and 160 bits (29-bit identifier) are transmitted for a data telegram.
The number of data telegrams that can be transmitted per second can be calculated from these values as follows:
TELEGRAM LENGTH
Maximum length of a telegram for standard frames (11-bit identifier) = 135 bits.
The transmission time for a telegram is 540 µs at 250 kBd.
Sections Number of bits
Start ............................................................................................................................................................. 1
Identifier ......................................................................................................................................................11
RTR ............................................................................................................................................................. 1
Contrl ........................................................................................................................................................... 6
Data ........................................................................................................................................................... 64
CRC ........................................................................................................................................................... 15
CRC Dlimiter ................................................................................................................................................ 1
Staff .................................................................................................................................................. max. 24
ACK ............................................................................................................................................................. 2
EOF ............................................................................................................................................................. 7
IFS ............................................................................................................................................................... 3
Maximum length of a telegram for standard frames (29-bit identifier) = 160 bits.
The transmission time for a telegram is 640 µs at 250 kBd.
Sections Number of bits
Start ............................................................................................................................................................. 1
Identifier ......................................................................................................................................................11
SRR ............................................................................................................................................................. 1
IDE ............................................................................................................................................................... 1
Identifier ..................................................................................................................................................... 18
RTR ............................................................................................................................................................. 1
Contrl ........................................................................................................................................................... 6
Data ........................................................................................................................................................... 64
CRC ........................................................................................................................................................... 15
CRC Dlimiter ................................................................................................................................................ 1
Staff .................................................................................................................................................. max. 29
ACK ............................................................................................................................................................. 2
EOF ............................................................................................................................................................. 7
IFS ............................................................................................................................................................... 3
SGR
VP30
Sva 6-51350 EN
Transmision bus
Getriebe Bus
AUX
1
Service
EDC
ADIC KPAD TC ECCU ARU
Gerät
ISO Bus
Edition 05-2003
4002-25
CENTRAL GATEWAY
Efficient data bus systems are used in automotive engineering for the communication between individual control
units. However, it has become apparent that it is not useful to connect all control units to the same (common) data
bus.
Different function areas, such as the gearbox management, operating management and engine management, as
well as the distribution of the data bus load, result in bus systems that work parallel. These differ through the
transmission speed, transmission protocol and transmission medium.
The gateway is the connecting link between the data bus systems located in the vehicle. However, a gateway can
also assume additional tasks of a control unit (e.g. operation).
Gateways: FMGR, ECCU and EEM.
SERVICE TOOL
The existence of a common interface between the various data bus systems allows important functions to be
implemented. For example, the various data bus systems can be accessed via a common diagnostics interface for
the CNH SERVICE TOOL. In addition, in the event of a data bus failure, certain important tests are easily accessible
and can thus be carried out in a short time via the diagnostics interface when looking for the fault in the CAN bus
line.
TABLE OF CONTENTS
TABLE OF CONTENTS .........................................................................................................................................3
KEYPADS ............................................................................................................................................................15
Service interval key .........................................................................................................................................15
Odometer key .................................................................................................................................................15
Hectare counter key ........................................................................................................................................16
Hectare performance / hour key .....................................................................................................................16
Menu up scroll key ..........................................................................................................................................16
Enter / Save key ..............................................................................................................................................16
Menu down scroll key .....................................................................................................................................16
Escape key without saving ..............................................................................................................................16
Key for displaying 3-point hitch position front / rear ........................................................................................17
Key for displaying PTO shaft speed front / rear ..............................................................................................17
Wheel slip key .................................................................................................................................................17
Battery voltage key .........................................................................................................................................17
Engine operating hours key ............................................................................................................................17
Key for tractor RESET ....................................................................................................................................18
Key for compressed air trailer braking system ................................................................................................18
Changeover key for driving strategy and speed range display .......................................................................18
SPECIAL TOOLS
SD00C040 SD00D003
SD00C038
SD04A006
MEASURING CABLES (pin diameter - 4 mm)
(1TSW 528-11) "Y" ADAPTER, 26-POLE (ADIC) 38000149226
SD04A002
GENERAL DESCRIPTION
ADIC = Analog-digital instrument cluster
Adjustment buttons
• ADIC lighting (dimmer)
• Time (hours, minutes)
GENERAL NOTES
Handling plug-in connections
• High-pressure cleaning should be avoided in the vicinity of electrical plug-in connections.
• Plug-in connections that connect signal lines from sensors must not be treated with contact or cleaning spray
(e.g. MOS2) as this can cause malfunctions.
NOTE: Plug-in connections must be kept clean and dry.
10
2
1 3
5 4 6 9
7 8
SS04B181
7 8 9 10 11 12 13
6 14
5 15
4 16
3 20
17
21
2 18
22
1 19
28 27 26
25 23
24
SS04B181
3 2
1
5
4
SS04B181
7
8
4 1 2 3 5 6
SS04B182
Display 1
The driving speed is indicated in kilometres per hour in display 1. The display can be switched over to miles per hour
in Setup menu 2.
Display 2
The following values can be called up in display 2 by pressing function keys 7 - 9.
• Lifting height of rear 3-point hitches – Display from approx. 10 - 96 % (press key 7 briefly)
• Lifting height of front 3-point hitches – Display from 0 - 100 % (press key 7 longer)
(front display only possible with front hitch management)
• Rear PTO shaft speed – Display in revs per minute (press key 8 briefly)
• Front PTO shaft speed – Display in revs per minute (press key 8 longer)
• Slip – Display in % (display only possible with radar sensor)
Display 3
The time is displayed in hours and minutes in display 3. The display can be switched over from 12 to 24 hr indication
in Setup menu 1.
ADJUSTMENT BUTTONS
Dimmer adjustment button for ADIC lighting
The brightness of the display instruments and the function keys can be adjusted with the lighting switched on. The
brightness gradually changes on pressing the button (4) for a brief moment.
When the button is kept depressed, the dimmer runs through the whole setting range from bright to dark.
Hours / minutes adjustment button
Turn the ignition switch to ON and keep the Hours button (5) depressed for approx. 5 seconds. The time is adjusted
by one hour / minute by pressing button 5/6 for a short moment. When button 5/6 is kept depressed, you run through
the hours / minutes display.
After making the setting, wait approx. 5 sec. until the values stop flashing. (The new time setting is stored.)
Operating hours setting
The operating hours setting can be adjusted upwards, if necessary (e.g. a new ADIC is fitted).
• Turn the ignition switch to ON and keep the Hours button (5) and Minutes button (6) depressed for 15 seconds.
The value can be increased by pressing the Hours button.
• To store the value which has been set, keep both buttons (5 and 6) depressed for 15 seconds.
NOTE: The operating hours cannot be corrected downwards.
Warnings
These symbols refer to a critical fault during operation of the tractor.
Stop the tractor as soon as possible, determine the cause and rectify the
fault. SS02K039
Warnings are also supported acoustically and are split into
”NON-CRITICAL ALARMS” and ”CRITICAL ALARMS”.
NON-CRITICAL ALARM: In conjunction with the yellow warning lamp – Alarm sounds 2 x 1 second
CRITICAL ALARM: In conjunction with the red ”STOP” warning lamp – Alarm sounds periodically
Graphic symbols
1. COOLANT TEMPERATURE TOO HIGH – Red warning lamp
flashes and alarm sounds periodically.
Information
The information symbols do not actually indicate a fault during operation of the tractor but they should not be ignored.
Take appropriate measures, as required.
1. LC display (LCD)/dot matrix display (DMD) brightness setting.
Service
These symbols inform the driver that basic tractor functions are impaired, for example: Air filter dirty, Service display,
etc.
1. Engine air filter blocked.
Yellow warning lamp flashes twice (no acoustic alarm)
2. Brake fluid level too low – in conjunction with red warning lamp
KEYPADS
1 9
2 10
3 11
4
12
5
13
6
14
7 16 15
8
SS04B183
Odometer key
The odometer key is used to display the distance travelled in km on the
DMD and to save it.
Two displays (”Memory A” and ”Memory B”) are available.
The display ”Memory A” can be used to measure partial distances and
the display ”Memory B” to measure the total distance, for example.
Press the Odometer key (2) once to display Memory A (partial distance)
and once again to display Memory B (total distance).
Display ranges:
0 - 19.999 km → Display: 0.001 km
20 - 199.99 km → Display: 0.01 km
200 - 1,999.9 km → Display: 0.1 km SS02K050
Display ranges:
0 - 199.99 ha → Display: 0.01 ha
200 - 1,999.9 ha → Display: 0.1 ha
2000 - 19,999 ha → Display: 1 ha
SS03A018
The following operating modes can be selected by pressing the key (3) several times:
• OFF
The hectare counter is switched off.
• ON
The hectare counter is switched on. The counting function is active as long as the tractor is driven, independent
of the position of the implement.
• A (AUTOMATIC)
The hectare counter is switched on. The counting function is only active as long as the tractor is driven and the
implement is lowered. Raising the implement interrupts the counting function.
To delete the stored values, keep the key (3) depressed in the OFF operating mode for 3 seconds.
Menu up key or number entry. Press this key several times to scroll the menu upwards or to change a number.
SS02K037
SS02K036
SS04B184
SS04B185
MENU SETTINGS
Setup menu 1
(for the customer)
The following settings can be made in Setup menu 1:
• Switching the beep on/off
• Time display 12 / 24 hour mode changeover
• Setting the working width 6
5
Access:
Turn the ignition switch to the ON position and then keep the Enter
key (6) depressed for 3 seconds.
”SET UP MENU” appears on the DMD.
After 2 seconds, the display automatically switches over to working
7 8
width setting. SS02K033
NOTE: If a fault has occurred (e.g. coolant temperature too high, trailer brake reservoir pressure too low,....), then
the fault must be suppressed by pressing the Tractor reset key (item 14, page 15) for 5 seconds. Otherwise Setup
menu 1 cannot be accessed.
SS03A019
• Press the Enter key (6). A flashing cursor appears at the first place
for entering the working width on the DMD.
• Use the UP scroll key (5) to select the blank space
• Use the DOWN scroll key (7) to shift the cursor to the right to the
next place
• Use the UP scroll key to enter the number 4
• Use the DOWN scroll key to shift the cursor another place to the
right
• Use the UP scroll key to enter the number 5
(if a number is also to be entered at the last place, then proceed in
the same way) SS03A020
SS03N025
Switching over the time display
• Access Setup menu 1 (see page 19)
• Use the scroll bars (5 / 7) to call up the ”CLOCK SETTING”
submenu
• Press the Enter key (6) and set the arrow in the display to 12 / 24 by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6) once again
SS03H004
Setup menu 2
(for the workshops)
The following settings can be made in Setup menu 2:
• Changing the speed display (mph – km/h)
• Programming compressed air sensor available / not available
• Programming the service indicator 6
• Programming the driving speed display 5
(theoretical or via the radar sensor)
Access:
Turn the ignition switch to the ON position and, within 5 seconds, keep
the Enter key (6) and the Escape key (8) depressed (simultaneously) for
3 seconds. 7 8
SS02K033
SS04A034
• Press the Enter key (6) and set the arrow to ”YES” or ”NO” by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6)
SS04A035
SS03N026
SS04A036
• Press the Enter key (6) and select the ”LIGHT” or ”HEAVY” display
by means of the scroll keys (5 / 7)
SS04A037
• Press the Enter key (6) again. A flashing cursor appears at the first
place in the entry field
• Enter the required number by pressing the UP scroll key (5). Jump
to the next place in the entry field by means of the DOWN scroll
key (7).
Use the UP scroll key again to enter the required number. Enter the
third number in the same way.
• Store the setting by pressing the Enter key (6)
SS04B188
NOTE: Enter the hours after which the Service message is to appear (e.g. 250).
Do not enter the operating hours after which the next service is due (e.g. 1250).
This function can only be activated if the radar sensor is installed correctly.
• Access Setup menu 2 (see page 21)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”WHEEL / RADAR” menu appears
SS04B186
• Press the Enter key (6) and select the ”WHEEL” or ”RADAR”
display by means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6).
The radar symbol appears on the top left-hand side of the DMD.
NOTE: If the ADIC is set to ”Radar” and the radar fails (radar
defective, faulty fuse,...), then the signal from the driving speed sensor
is automatically used for the display and the calculations. The radar
signal is automatically used again as soon as the radar sensor is
operating again.
SS04B187
SV03B032
Test conditions
Symbol Meaning of symbol
X.. Plug
Pin Pin
Plug connected
Plug disconnected
NOTE: When measuring the voltage drop of a ground supply cable, the selected test lamp (for loading the cable to
be tested) must be connected from the cable’s terminal to a + supply. The measuring instrument (voltmeter) is
connected parallel to the ground cable.
1TSW 528-11
(available from 2 measuring cables, 1.5 m General
your dealer)
1TSW 528-2
(available from Test lamp, 21 W For loading supply lines
your dealer)
1TSW 516-1
Multimeter
(available from General
(Fluke 79 or similar)
your dealer)
Sva 6-91700 EN
Supply, permanent + (+30)
26 CN1/26 U 21W 26 23 13 - 14 VDC
from F41 (3 Amps)
Supply
23 CN1/23 U 21W 23 Batt. 0.1 - 0.3 VDC
Ground
Supply
22 CN1/22 U 21W 22 23 approx. 0.1 VDC
internal ground connection
Edition 03-2004
4003-25
PLUG CN1 4003-26
Sva 6-91700 EN
Fuel ”OFF”
pre-heating
16 CN1/16 U ”ON”
16 23
12 - 14 VDC
Brake fluid level ok
Indicator, brake fluid 7 CN1/7 U 7 23
Brake fluid level too low
approx. 0 VDC
Edition 03-2004
Plug CN2
Measure- Measure from
Designation Pin Cable Requirements CN2 Ground Value
ment pin to pin
Sva 6-91700 EN
Position ”Transport”
12 - 14 VDC
rear 3-point hitch 17 CN2/17 U "Control" 17 approx. 0 VDC
standard signal
Edition 03-2004
4003-27
Plug CN3 4003-28
Sva 6-91700 EN
Hydr. trailer brake
”Italy”
12 CN3/12 U 12
Trafficators 12 - 14 VDC
trailer I 16 CN3/16 U flashing 16 alternately at
approx. 0 VDC
Trafficators 12 - 14 VDC
trailer II 13 CN3/13 U flashing 13 alternately at
approx. 0 VDC
Edition 03-2004
4003-29
540 54
1000 100
empty 10
red Yellow lamp ”Refuel” lights up
< 1/6 < 30
1/6 30
1/4 38
full 180
0 10
6 124
8 155
10 184
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FUNCTIONAL SCHEMATIC DIAGRAM FOR FRONT AXLE WITH INDEPENDENT SUSPENSION ................29
BLANK PAGE
*(1(5$/'(6&5,37,21
The key electric circuits are shown in the functional schematic diagrams, sub-divided into the individual main com-
ponents, e. g. control units, controllers and display instruments. The complete diagram of the individual electric cir-
cuits and/or functions should help the mechanic gain better comprehension. Faster narrowing down of errors is
thereby possible in the future.
The diagrams are structured so that the supply for each component is shown first. As a rule, the inputs are on the left
and the outputs on the right.
When troubleshooting in the wiring, the circuit diagram and/or list of connectors must be used.
$EEUHYLDWLRQV
ADIC............................................................................................................................ Analogue / digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
DMD ................................................................................................................................... DOT MATRIX DISPLAY
DZG................................................................................................... Crankshaft position signal (upper dead point)
ECCU2 ....................................................................................................................................... Central control unit
EDC.............................................................................................................. Electronic 3-point hitch control system
EEM2 ..........................................................................................................................................Engine control unit
FMGR........................................................................................................... Vehicle/engine/transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU ..........................................................................................................................................Performance monitor
KEY PADS ........................................................................................ Function keys for analogue/digital instrument
NTC.......................................................................................................................Negative temperature coefficient
PCB.....................................................................................Printed circuit board (relay circuit, terminal resistance)
PCU.......................................................................................................................... Electronic pumps - control unit
PTC ........................................................................................................................ Positive temperature coefficient
SGR .................................................................................................................................... Transmission controller
6XSSO\YROWDJHV
On-board voltage ...................................................................................................................................... 12 V +2.0
GSV1 ........................................................................................................................................................... 3 V ±0.2
GSV2 ........................................................................................................................................................... 3 V ±0.2
GSV3 ........................................................................................................................................................... 3 V ±0.2
GSV4 ........................................................................................................................................................ 6.4 V ±0.4
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6XSSO\
A4/3 17 18 CN1a 15 16
X70 CN3
CAN H 3LORWODPSVDQGGLVSOD\VFRQWUROOHG
18 26
CAN L YLD&$1%86
42 25
X6/11 X6/8 X29
3LORWODPSVDQGGLVSOD\V 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
$ $ CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 rpm = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 Lighting ON = 12V
15
X4/52 X4/51 2 A1 ADIC
5 Turn signal left
3 4 A2 EEM2
6 A4 FMGR
4 3 6 Turn signal right A4/3 15-pin plug connection
S A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
6 2 (11) X23/1 13 Turn signal trailer II B3 Compressed air transmitter
1 M CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
6 2 CN3 S3 Test switch for air filter
S 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (16) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
6 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
S X23/1 12 DMD Feed pump pressure OK (>1 bar) = 12 V X4/51 4-pin plug connection
X4/52 4-pin plug connection
J 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
K 17 Coolant level OK = 12 V X6/10 6-pin plug connection
6 2 X6/11 6-pin plug connection
X24/3 % X24/3 CN3 X12/20 12-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X18/1 18-pin plug connection
X20/1 20-pin plug connection
(11) CN1 X23/1 23-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket,
X70 70-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine device carrier
X6/10 % X6/10 CN3 (16) Ground point, starter
1 2 1 3 14 10 Ω
BLANK PAGE
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8 10
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X70 21 48 70 46 69
9 9 CAN H (11)
$
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X7 15 CAN L
0.4V to 4.7V CAN - 42
; 2 2 16 6XSSO\
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 3UHJORZLQJDQG
1 2
X20/1 (11)
12V
CN3 17
$&$102'8/( $$',& 12V
26 16
0 (11)
25 (PHUJHQF\VLJQDO
X70
3 M 1
36 0.8 to 4.4 V
$3&8 2
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12V
5 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
3&8DFWLYDWLRQ 20 2 2.5 V
CAN L
44 1 2.5 V
6 43 5 Emergency shut-down
130 Hz at 900 rpm
% X1/3 S 19 8 DZG
335 Hz at 2300 rpm
1 X70
S 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
Q 1 62 A12 Central print X1/12 Plug connection
% 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
I 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
6ZLWFKHVDQG A30 Print ARU DBD..... ---> X3 4-pin plug connection
VHQVRUV A50/1 Power module X3/12 3-pin plug connection
W X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
% 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
5 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
5 A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
% B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
8 C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
SW 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
% 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
85 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure
BLANK PAGE
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5
$ 2 9 8 10
X5/1 X24/2 1 6 X24/2 21 23 M
1 1 7 13
6 9 9
13 3 (16) (16) 5
X7 15 A4/3 10 14 13 A4/4 X16/21 13 12 3
CAN - CAN H
6 2 16 1 $)0*5 17 1 $6*5
CAN H CAN L X6/9 E F L M H K B
11 11 3 17 3 18 2
CAN L 6XSSO\ 6XSSO\
4 18 2
GND
11 V
6
10 12 6
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
6 3 10 8 NEUTRAL
0 V or 5 V
9 4 X16/21 /,03+20(FLUFXLW
2 11 7 DEAD MAN GND
GSV2 10
6 4 12 6 12 V
6KXWWOHOHYHU 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 $(/(&7521,&6
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6
X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
$&$102'8/( 11 X6/1
12 4
CAN H
CAN +
CAN L
X24/3
CAN -
2 19 A21/5 1
$ X14/15 X10/11 $ X10/12 P8 3,&8 P8/1 1 21 3 3
)$
12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
%UDNH
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
$ X20/1 X23/1 X10/14 12
)$ (7) 6 Ω A31 Multi controller X7 4-pin plug connection
8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
6 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 &OXWFK P8/1 4-pin plug connection X14/14 14-pin plug connection
$$',& CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
CAN H Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
26 6 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
A2 EEM2
CAN H
CAN L
% 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
A4/1 18-pin plug connection 8 3 15 12 1.1 to 4 V
S60/3 Speed button +
S60/4 Speed button -
X24/3
X70
24-pin plug connection
70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 $FFHOHUDWRUSHGDO X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND ---> DBD.....
1 1 X4/59/a 3-pin plug connection
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print
$((0 5 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller 5.8V (16) Ground point, starter
2 10 X4/70 4-pin plug connection
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U
BLANK PAGE
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GSV3 5V
1 S 1 4
% GND
6 2 7 A21/3 <
X4/61 X4/61 A4/2
8 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 6HDWFRQWDFW A21/2 7
5V
6 S 1 11 2
GND
X4/25 X4/25 A4/2 % 2 8
2 1 16 3DUNLQJEUDNHRSHQ 8 3 5 0.2 to 1.2 V A21/3 <
4V
5 1
6 A21/2 GND
W 8
A4/1 1 3
(QJLQHEDFNSUHVVXUH % PTC 1 kΩ to 4.4 kΩ 2
2 1 3 EUDNH 5 2 10
X5 A21/4 A21/3 <
GND 4V
1 2 9 4 1
$ X14/4 A4/1 GND
8 GSV1
18
6 2 1 3 GND 9
S Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 6
6SHHGUDQJHV 12 V
1 A21/3 <
X24/5 A4/1 3 4V
1
23 16 increase "+" < GND
10
7 5 17 decrease "-" 2
3 6HQVRUVDQG 2
1 A4/3 VROHQRLGYDOYHV
12 V
6 5 1 A21/3 <
%UDNHRLOFRROLQJ < 4V
8 2 1
GND
2))
21
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 0DQXDOPRGH
1
6
(16) % Q 10 to 6000 Hz
A21/3
4V
<
I 2 1 1
GND
12
X24/5 A4/1 A21/8
0DQDJHPHQW 2
5 3 1 Q 1
3 DQG % 10 to 6000 Hz
1 4 2 DOOZKHHO I 2
A21/9
X3/23 X24/5 A4/4 1
5.8 V Q
a 1 11 14 3RWHQWLRPHWHU % I 2
10 to 6000 Hz
<
5 b 3 12 15 0 to 5.8 V IRUOLPLWORDG
1
6 c 2 13
GND
5
A21/5
A21/10 10 V
4
Q 1 GND
2))
21 A4/1 % I 2
10 to 6000 Hz 8 2
X24/3 13 3.0 V X17
1 3 18 6ZLWFKIRUSDUNLQJ <
A4/2 A21/6 2
GSV2 LQWHUORFN
1
12 6
% Q 10 to 6000 Hz A21/5
I 2 10 V
A4 FMGR A21/9 2-pin plug connection S2/58/2 Switch, manual mode 5 1
A4/1 18-pin plug connection A21/10 2-pin plug connection S2/59 Switch, all-wheel X24/5 24-pin plug connection
A4/2 18-pin plug connection B24 Speed sensor, cartridge input S2/61 Switch for parking interlock X17 Y - distributor
A4/3 15-pin plug connection B25 Speed sensor, planetary carrier 3/4 S8 Seat switch Y11 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B26 Speed sensor, cartridge output S20 Switch, engine back pressure brake Y12 Solenoid valve for brake oil cooling
A16 EDC print B27 Speed sensor, cartridge output S21 Switch, parking brake Y41 Solenoid valve, clutch 1
A21 SGR transmission controller B32 Temperature sensor, transmission oil S49/1 Switch, pressure filter Y42 Solenoid valve, clutch 2
A21/2 12-pin plug connection B35 Speed sensor, planetary carrier 1/2 X3/23 3-pin plug connection Y43 Solenoid valve, clutch 3 <
A21/3 12-pin plug connection B47 Pressure sensor for transmission X4/25 4-pin plug connection Y44 Solenoid valve, clutch 4 1
system pressure Y45 Solenoid valve, clutch, forward A21/5
A21/4 12-pin plug connection X4/61 4-pin plug connection 4V
A21/5 12-pin plug connection B51 Pressure sensor for transmission X5 2-pin plug connection Y46 Solenoid valve, clutch, reverse 6
lubrication pressure Y57 Solenoid valve, parking interlock ON GND
A21/6 2-pin plug connection X10/4 10-pin plug connection Y58 Solenoid valve, parking interlock OFF 7 2
A21/7 2-pin plug connection R23 Potentiometer for limit load X14/4 14-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection (16) Ground point, starter
BLANK PAGE
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A4/2 3
6
X6/3 X24/3 A4/2 3 3
6
3 10 8 5
2 11 7 1
GSV2
4 12 6
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL $
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2
1 6 (16)
X4/59/b
6KXWWOHOHYHU
X4/59/a
11 FORWARDS $6*5
$ X24/3 10 REVERSE X16/21 /,03+20(FLUFXLW
X2/4/1 X6/15 2 GND
10
19
6 12 V
1 21 14 Select 0 V** for FORWARDS
12 V
3 20 8 Select 0 V** for REVERSE
$ X4/59/c A4/2
GSV3
1 **) Only if the
6 6 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 3DUNLQJEUDNHRSHQ plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
6 2 2 1 1 16
6 6 5 5 A4/2
4 4 3 3 1
6 S8 Seat switch
6 A4/1 A4/1 (QJLQHEDFNSUHVVXUH S8/1 Reversible seat switch
S8/2 Reversible seat switch
2 1 3 3 EUDNH S20 Switch for engine back
4 6LJQDO pressure brake
UHYHUVLQJIDFLOLW\ S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 6HDWFRQWDFW S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 &OXWFK X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
% X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
8 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
. 1 12 6
GSV2
6 X4/70 4-pin plug connection
4 Ω X4/70/1 4-pin plug connection
1 3 6 24 X6/3 6-pin plug connection
% 5 X6/15 6-pin plug connection
2 2
8 3
2 1 A4/1 A4/1 X6/27 6-pin plug connection
X6/58 6-pin plug connection
1 15 15 3 V
Ω X16/21 16-pin plug connection
6 X23/2 23-pin plug connection
A2 EEM2 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(16) 5.8V $FFHOHUDWRUSHGDO X70 70-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (16) Ground point, starter
A4/2 18-pin plug connection GND
1 1 1
A4/4 18-pin plug connection
A12 Central print 5 3 6 . 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 .
K5/62 Relay, accelerator pedal, reversing facility 3
P6 Display, reversing facility 5 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility $((0 X70 X23/2
36 U
(16)
$)0*5
X4/14 X24/3 A4/2 A4/2
GSV2 %UDNH
1 12 6 6
6 Ω
3 4 14 14 3 V
6 2 5 13 13 3 V
4
6
3
6
2))
21 A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 6ZLWFKIRUSDUNLQJ
GSV2
12 6 6 LQWHUORFN
6
2))
21
3 1
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)$
A12 Central print 8
A13 Roof print
A14 Engine print 9
)$
A60 ECCU2
X4/85a 1 2 22 X10/12 $ X10/11 X14/15 $
A62 Reverse fan unit )$
CN1a 26-pin plug connection
'
X4/85b 1 2 6 7 12
CN2/E 26-pin plug connection
CN3 26-pin plug connection
CN3a 26-pin plug connection
CN3b 34-pin plug connection X14/14 X10/14 X23/1 X20/1 $
K5/16 Relay, reverse fan 2 25 34 1 2 3 14 21 26 25 26 19 )$
(16) 4 7 Q 8
P8 ICU CN3a CN3b CN1a CN2/E CN1a
P8 10-pin plug connection $(&&8
P8/1 4-pin plug connection
P8/2 4-pin plug connection
S2/15/6 Switch, HTS A60_GND (7)
6XSSO\ P8 7 5 3 (8)
S2/15/7 Switch, speed reduction
S2/56 Switch for differential lock P8/1 3,&8
S2/74 Reverse fan pushbutton CAN H
15 3 CN3 $$',&
CN1a
P8/2
CAN L CAN H
16 4 3 26
CAN L
4 25
X10/9 CN1a
GSV4
2 10
6 <
CN3b
'LIIHUHQWLDOORFN 12 V
5 1
X24/5 CN3b
5 2 24 Management
3 2
1 1 23 Differential lock ON
6
(16)
X24/5 CN3a +76
7 22 18 RECORD
3
1 24 19 PLAY
6
2))
21 $
6SHHGUHGXFWLRQ
X24/5 CN3a
X4/66
2 1 7 24
3 M
$
6 )$
X1/17
$ 5HYHUVLEOHIDQ
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X10/9 CN1a
GSV4
2 10
6 )URQW372
21
2))
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E <
12 V**
7 1
X3/21 CN3b
(11) GND
Q C 3 X23/2 CN3b 225 Hz at 900 rpm 6 2
% B 2 N 22 490 Hz at 1900 rpm
I A 1 570 Hz at 2300 rpm
$
)$
X24/2 **) Activation for approx. 6 sec. with 3 V, then 12 V
7
GND
6 18 2
(16)
21
2))
X24/5 CN3b
1 A12 Central print
14 33 6.4 V when ON A60 ECCU2
3
7 15 32 6.4 V when OFF B7 Rear PTO speed sensor
B8 Front PTO speed sensor
6 CN1a 26-pin plug connection
5HDU372 CN2/E 26-pin plug connection
2))
CN3a 26-pin plug connection
21 CN3b 34-pin plug connection
S2/70/1 Switch for front PTO
X24/5 CN3a S2/70/2 Switch for rear PTO
5 1 16 20 6.4 V with management ON S2/71 Switch for rear PTO, management
S17/1 External pushbutton, PTO shaft, rear left
6 S17/2 External pushbutton, PTO shaft, rear right
X3/21 3-pin plug connection
2))
X10/9 10-pin plug connection
X23/2 23-pin plug connection
21
CN3a X24/2 24-pin plug connection
1 2 21 6.4 V with pushbutton pressed X24/5 24-pin plug connection
Ω Y4 Solenoid valve, front PTO
6 Y5 Solenoid valve, rear PTO
(11) Ground point, engine device carrier
2))
(16) Ground point, starter
21
CN3a
1 2 22 6.4 V with pushbutton pressed
Ω
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$ X24/2 X20/1 $
$505(67 )$ 6
X24/2 10 13
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$3/8*02'8/( 17 3
$35,17$58 )$ 21
3
6 X14 X1 X18/4 18 2))
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2 7 13 2
X18/1 54c
5V (16) 1 O P X23/2 8 2
1 9 9 *1' ' 16
GSV4
6 X2 8 10
ARU + X5/1
2 X7 15 X24/3 1 54c
5V ARU - X2/12
1 2 16 1 X10/9 2 X10/9 6 8
CAN H (16)
$ 3 17
6 X4 X11 CAN L CN3a 2 X55 13 24 29 47 28 46
12V 4 18 CAN H CN1a 10 CN3a 4 1
1 16 $(&&8 15 $('&
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A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
A16 EDC print % 2 6 2.5 to 7.5 V X55 <
A55 EDC box 8 1 35
GND
1
A60 ECCU2
B9/1 Angle of rotation sensor 6HQVRUVDQG
B10/1 Power sensor, left VROHQRLGYDOYHV 0 to 5 V
B10/2 Power sensor, right ) 3 55 2
B16 Radar sensor % 2 7 approx. 5 V not loaded
CN2/E 26-pin plug connection 8
CN3b 34-pin plug connection 1
H2/1 Diagnosis LED
H2/2 Slip LED
H2/3 RAISE LED ) 3
H2/4 LOWER LED % 2 26 approx. 5 V not loaded <
S2/15/5 RAISE/LOWER pushbutton
S2/73 Switch, slip control 8 1
GND
38 53
GND
1
S14/1 External pushbutton, LOWER, left
S14/2 External pushbutton, LOWER, right 41
S15/1 External pushbutton, RAISE, left 0 to 5 V
19 2
S15/2 External pushbutton, RAISE, right
X3/1 3-pin plug connection 5V
X4/2 4-pin plug connection 9
X4/3 4-pin plug connection 6 6
X4/12 4-pin plug connection
X10/4 10-pin plug connection
X10/9 10-pin plug connection 2)) 2))
X14/4 14-pin plug connection 21 21 $
X24/2 24-pin plug connection X14/4 X4/3
X24/5 24-pin plug connection 1 2 1 2 N +
Ω Ω 5 1
X55 55-pin plug connection
Y6 Solenoid valve, EDC, RAISE 6 6 2
Y7 Solenoid valve, EDC, LOWER N
(16) Ground point, starter 37 3 4
2)) 2))
([WHUQDOSXVKEXWWRQV 3
21 21 +
DQG/('V
1 2 1 2
Ω Ω
X14/4 X4/2
6 12 2
N
4
+
3
X24/5 31 7
N
2
X24/5
1 20
LOWER
36 5 V with pushbutton pressed
19 3 RAISE 1
6 7 21 17 5 V with pushbutton pressed +
14 GND
X14/4 9 X10/4 4
6OLSFRQWURO
X4/12 X3/1 $ CN2/E $ $
)$
1 1 8 Potentiometer R6/5 is shown
Y X24/2 on the previous page
% GND
2 3 5 CN3b (16)
I 3 2 15 21 9 A4/2 X24/2 19
Theoretical speed $
11 505 Hz at 14 km/h )$
Real speed
10 505 Hz at 14 km/h
$
6WDQGDUGVLJQDO CN3b
Ground during transport
15 11
BLANK PAGE
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CAN H
CAN +
CAN L
CAN -
2))
21 CN3a X4/93 $8;
1 2 $ X10/11 CAN H
3
12 6.4 V with pushbutton pressed
Ω 7 CAN L
6 2
CAN +
X10/12 6 1
CAN -
P8/1 3 4 1 2 4
2))
21
3,&8 P8
1 2 13 6.4 V with pushbutton pressed
Ω 7 X14/14 X10/14 X4/94 $8;
6 5 4 7
CAN H
3
CAN L
2))
3 2
(7) CAN +
X23/2 X4/72 21
X4/72 X23/2 1
(8) CAN -
K 3 1 2 2 F 10 6.4 V with pushbutton pressed 4
Ω
6 $
)$
X20/1 X23/1
A X3/10 B
8 Q
2))
X4/72 21
X4/72 X23/2 120 Ω
4 1 2 1 G 11 6.4 V with pushbutton pressed A12 Central print X4/72 4-pin plug connection
A X23/2 Ω
A13 Roof print X4/83 4-pin plug connection
6 X4/90 4-pin plug connection
A14 Engine print
A60 ECCU2 X4/91 4-pin plug connection
2 X4/69 X4/92 4-pin plug connection
2)) B19 Angle of rotation sensor for front power lift
21
X4/69 CN1a 26-pin plug connection X4/93 4-pin plug connection
X23/2 X4/94 4-pin plug connection
CN3a 26-pin plug connection
1 2 2 D 23 6.4 V with pushbutton pressed
CN3b 34-pin plug connection X5/1 Plug connection
Ω
6 P8 ICU X10/9 10-pin plug connection
P8 10-pin plug connection X10/11 10-pin plug connection
P8/1 4-pin plug connection X10/12 10-pin plug connection
2)) S2/7/3 Switch, hydraulic master X10/14 10-pin plug connection
21
X4/69 X23/2 S14/3 External pushbutton, front power lift LOWER X14/14 14-pin plug connection
S15/3 External pushbutton, front power lift RAISE X14/15 14-pin plug connection
1 2 1 C 26 6.4 V with pushbutton pressed S18/1 External push button, AUX BLUE pressure in - X18/4 18-pin plug connection
Ω
S18/2 External push button, AUX BLUE pressure in + X20/1 20-pin plug connection
CN3b S19/1 External push button, AUX BROWN X23/1 23-pin plug connection
X3/22 X23/2 12 (up to DBD... YELOW) pressure in - X23/2 23-pin plug connection
8V S19/2 External push button, AUX BROWN X24/2 24-pin plug connection
3 3 S CN3a (7) Ground point, roof hood, left
(up to DBD... YELOW) pressure in +
% 2 2 T 8 2.5 to 4.7 V S28/1 Switch, front power lift management (8) Ground point, roof hood, right
8 1 1 R
GND
CN1a
X3/10 3-pin plug connection
X3/22 3-pin plug connection
23 X4/69 4-pin plug connection
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X4/45
)$
1
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2
*1'
16 X24/1
2 X2/46
X12/20 8 6 9 10
$
6XSSO\
6
X12/20
7 2 12V when LOWERING
3
1 3 12V when RAISING $$',&
X12/20 X4/45 $ X24/1 CN1
0 V LED ON
11 3 5 13 12 V LED OFF
6
X12/20
7 4 12V with axle locked (OFF)
3
1 5 12V with pushbutton pressed
(calibration)
0V with management
<
GND
1
GND
1 C
% 12V 12 V when RAISING
2 A 2
, 3 B
20.25S: 6.0 to 18.5 mA
20.29S: 7.3 to 16.5 mA
A1 ADIC
A12 Central print <
GND GND
A60 ECCU2 1 C 1
A61 Electronics, suspended front axle % 12V
B33/1 Angle of rotation sensor, LEFT 2 A
B33/2 Angle of rotation sensor, RIGHT , 3 B
20.25S: 6.0 to 18.5 mA 12 V when RAISING and LOWERING 2
CN1 26-pin plug connection 20.29S: 7.3 to 16.5 mA
CN1a 26-pin plug connection
S2/15/1 Switch, front axle with independent
suspension UP/ DOWN
S2/15/2 Switch, front axle with independent <
suspension ON/ OFF $(&&8 CN1a GND
X2/45 X12/20 1
X2/45 2-pin plug connection
X2/46 2-pin plug connection 6 1 12 12V at v > 14 km/h
X4/45 4-pin plug connection 12 V when RAISING and LOWERING 2
X12/20 12-pin plug connection
X24/1 24-pin plug connection
Y14 Solenoid valve, UP / DOWN (black)
Y15 Solenoid valve, LEFT (blue)
Y16 Solenoid valve, RIGHT (green)
BLANK PAGE
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FUNCTIONAL SCHEMATIC DIAGRAM FOR FRONT AXLE WITH INDEPENDENT SUSPENSION ................31
BLANK PAGE
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The functional schematic diagrams show the key electric circuits, divided into individual components e. g. control
units, controllers and display instruments. The fact that individual electrical circuits / functions are illustrated in full
should help the mechanic gain better comprehension. Faster narrowing down of errors is thereby possible in the
future.
The diagrams are structured so that the supply for each component is shown first. As a rule, the inputs are on the left
and the outputs on the right.
When troubleshooting in the wiring, the circuit diagram and/or. list of connectors must be used.
$EEUHYLDWLRQV
ADIC ........................................................................................................................... Analogue / digital instrument
ARU ............................................................................................................................................................. Armrest
AUX ........................................................................................................................................Remote control valve
DMD ................................................................................................................................... DOT MATRIX DISPLAY
ECCU2 ...................................................................................................................................... Central control unit
EDC .................................................................................................................. Electronic power lift control system
EEM3 .........................................................................................................................................Engine control unit
FMGR .......................................................................................................... Vehicle/engine/transmission controller
GSV ................................................................................................................................................... Cyclic supply
HTS ............................................................................................ Field end management (headland management)
ICU .........................................................................................................................................Performance monitor
KEY PADS ....................................................................................... Function keys for analogue/digital instrument
NTC ......................................................................................................................Negative temperature coefficient
PCB ....................................................................................Printed circuit board (relay circuit, terminal resistance)
PTC ....................................................................................................................... Positive temperature coefficient
SGR ................................................................................................................................... Transmission controller
6XSSO\YROWDJHV
On-board voltage ...................................................................................................................................... 12 V +2.0
GSV1 .......................................................................................................................................................... 3 V ±0.2
GSV2 .......................................................................................................................................................... 3 V ±0.2
GSV3 .......................................................................................................................................................... 3 V ±0.2
GSV4 ....................................................................................................................................................... 6.4 V ±0.4
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A4/3 17 18 CN1a 15 16
X89/1 CN3
CAN H 3LORWODPSVDQGGLVSOD\VFRQWUROOHG
35 26
CAN L YLD&$1%86
34 25
X6/11 X6/8 X29
3LORWODPSVDQGGLVSOD\V 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
$ $ CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 min-1 = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 Lighting ON = 12V
15
X4/52 X4/51 2 A1 ADIC
5 Turn signal left
3 4 16 A3 EEM3
6 A4 FMGR
4 3 6 Turn signal right A4/3 15-pin plug connection
S A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
6 2 13 Turn signal trailer II B3 Compressed air transmitter
1 CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
6 2 CN3 S3 Test switch for air filter
S 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (11) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
6 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
S X10/18 12 DMD Feed pump pressure OK. (>1 bar) = 12 V X4/51 4-pin plug connection
X4/52 4-pin plug connection
6 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
7 17 Coolant level OK = 12 V X6/10 6-pin plug connection
6 2 X6/11 6-pin plug connection
X24/3 % X24/3 CN3 X10/3 10-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X10/18 10-pin plug connection
X12/20 12-pin plug connection
CN1 X18/1 18-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket
X89/1 89-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine component carrier, rear
X6/10 % X6/10 CN3
1 2 1 3 14 10 Ω
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8 10 (11)
X30/3 7 13
% 9
0
1 9 X12/1
5V 12V
X30/7 3UHJORZLQJDQG ./3 9 3 M 1
0.4V to 4.7V IXHOGHOLYHU\SXPS 4
; 2 2 16 3 5
3
CAN H X89/1
17 1 2
CAN L 55 4 *1'
GND 4 4 18 X12/1
(11)
X1/30/1 (
P8/1 4 3
3,&8 + -
P8/2
3 .
4 3 5
(12)
1 2
X36/1 X2/19 X2/19
4
$$',& CN3 5
26
25
A1 ADIC X4/4 4-pin plug connection
A3 EEM3 X4/70 4-pin plug connection
A7 ID module X10/18 10-pin plug connection
A12 Central print X12/1 12-pin plug connection
(PHUJHQF\VLJQDO A14 Engine print X18/4 18-pin plug connection
5 X4/70 X24/3 X10/18 X89/1 A30 Print ARU X24/2 24-pin plug connection
4 16 10 79 0.8 to 4.4 V B28 Manual throttle X24/3 24-pin plug connection
CN3 26-pin plug connection X30/1 14-pin plug connection
E10/1 Heating flange X30/3 4-pin plug connection
K5/LP Relay, fuel delivery pump X30/7 4-pin plug connection
K8/2 Relay, heating flange X36/1 36-pin plug connection
M13 Fuel delivery pump X89/1 89-pin plug connection
P8 ICU (2) Ground point, EEM3 control unit
$,'PRGXOH (QJLQHLGHQWLILFDWLRQ P8/1 4-pin plug connection (11) Ground point, engine cable carrier,
X4/4 X89/1
12V P8/2 4-pin plug connection rear
4 21 R8 Potentiometer, accelerator pedal (12) Ground point, engine cable carrier,
GND front
120 Ω 1 29 120 Ω
X1/30/1 Screw connection
CAN L X1/30/EEM Screw connection
2 52
CAN H X2/19 2-pin plug connection
3 53
BLANK PAGE
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% X3/12 X89/1 X16/1 X2/21
12V HP1
5 A 50 9 1
B 47
Fuel OK = 12 V <
GND Water in fuel = 0 V
8 C 65 10
HP2
2
C SH1
X4/29 X36/1 4
GND <
1 25
SW 2.5 kOhm with 20° C C SL1
2 29 13
% 3
5V
33
85 4 34 1.07 V with 1 bar 11
C SH2
atmospheric pressure <
C SL2
X2/22 X36/1 6
W 1 15
% GND 2.5 kOhm with 20° C C SH3
5 2 26 5
<
C SL3
X2/36 X36/1 12
W 1 35
% GND 2.5 kOhm with 20° C C SH4
5 2 8 3
<
C SL4
X3/37 X36/1 14
GND
S 1 24
C SH5
% 2 27 0.5 to 4.5 V 1
85 3 5V
32 <
C SL5
16
X3/38 X36/1
GND C SH6
S 1 12 2
% 2 14 0.5 to 4.5 V <
85 3 5V
13 15
C SL6
X3/39 X36/1
GND
S 1 17
A3 EEM3 X3/37 3-pin plug connection
% 2 21 0.5 to 4.5 V
B20 Engine speed sensor X3/38 3-pin plug connection
85 3 5V
31 B22 Coolant temperature sensor X3/39 3-pin plug connection
B23 'Water in fuel' sensor X3/40 3-pin plug connection
B29 Sensor for charger pressure, X4/29 4-pin plug connection
X2/28 X36/1 charge-air temperature X16/1 16-pin plug connection
Q GND B36 Fuel temperature sensor
1 19 X36/1 36-pin plug connection
% approx. 855 Hz at 900 rpm B37 Oil pressure sensor X89/1 89-pin plug connection
I 2 23 B38 Rail pressure sensor Y20 Solenoid valve, high-pressure pump
B39 Fuel delivery pressure sensor Y21 Injector 1
B40 Camshaft position sensor Y22 Injector 2
X3/40 X36/1 X2/21 2-pin plug connection Y23 Injector 3
Q 1 9 X2/22 2-pin plug connection Y24 Injector 4
GND approx. 52 Hz at 900 rpm
% 2 10 X2/28 2-pin plug connection Y25 Injector 5
I X2/36 2-pin plug connection Y26 Injector 6
3 X3/12 3-pin plug connection
BLANK PAGE
)81&7,21$/6&+(0$7,&',$*5$0)25)0*56*5
$505(67
$ $+<'5267$7
)$ )$ )$
X30/11
$35,17$58 5
(11) )$ )$ )$
X21 X30/1 X18/4
M
$ 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 5
6 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
6 2 16 $)0*5 17 1 $6*5
CAN H CAN L
GND
11 V
11 11 3 17 3 18 2 6XSSO\
CAN L 6XSSO\
4 18 2
6 A23 1 12 2 11 9 10 3
10 12 6
0 V or 5 V
X6/3 X24/3 A4/2 /,03+20(FLUFXLW
6 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
6 4 12 6 12 V
6KXWWOHOHYHU 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE $(/(&7521,&6
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)
X4/59/b
plug connection is linked.
X4/59/a
A21/4 X6/1
11 4
CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
$ X14/15 X10/11 $ X10/12 P8 3,&8 P8/1 3 20 9 2
)$
12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 %UDNH A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
6 Ω
3 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
$ 4
X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
)$ 6 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 &OXWFK A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
Ω A21 SGR transmission controller X6/9 7-pin plug connection
6 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
A23 Electronics X10/12 10-pin plug connection
CAN H
CAN L
BLANK PAGE
$)0*5 $6*5
A4/2 A21/2
GSV3 5V
1 S 1 4
% GND
6 2 7 A21/3 <
X4/61 X4/61 A4/2
8 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 6HDWFRQWDFW A21/2 7
5V
6 S 1 11 2
GND
X4/25 X4/25 A4/2 % 2 8
2 1 16 3DUNLQJEUDNHRSHQ 8 3 5 0.2 to 1.2 V A21/3 <
4V
5 1
6 A21/2 GND
W 8
A4/1 1 3
% PTC 1 kΩ to 4.4 kΩ 2
2 1 3 (QJLQHEDFNSUHVVXUH 2 10
5
EUDNH
X5 A21/4 A21/3 <
$ GND 4V
X14/4 A4/1 1 2 9 4 1
GSV1 GND
8 18 6 2 1 3 GND 9
S Opens at a difference in pressure of 2
1 2 X10/4 6 > 5 bar
6SHHGUDQJHV
X24/5 A4/1 12 V
1 A21/3 <
4V
23 16 increase "+" 3 1
< GND
7 5 17 decrease "-" 10
3 2
1 6HQVRUVDQG 2
A4/3 VROHQRLGYDOYHV
6 %UDNHRLOFRROLQJ 5
12 V
1 A21/3 <
8 < 2 4V
1
2))
GND
21 2 11
X24/5 A4/1 2
5 1 8 5 0DQXDOPRGH A21/7
1
6 (11) % Q 10 to 6000 Hz
A21/3
4V
<
I 2 1 1
GND
X24/5 A4/1 12
0DQDJHPHQW A21/8
5 3 1 2
3 DQG Q 1
1 4 2 DOOZKHHO % I 2
10 to 6000 Hz
BLANK PAGE
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$)0*5
A4/2 3
6
X6/3 X24/3 A4/2 3 3
6
3 10 8 5
2 11 7 1
GSV2
4 12 6
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL $
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2
1 6 (11)
X4/59/b
6KXWWOHOHYHU
X4/59/a
11 FORWARDS $6*5
$ X24/3 10 REVERSE X16/21 /,03+20(FLUFXLW
X2/4/1 X6/15 2 GND
10
19
6 12 V
1 21 14 Select 0 V** with FORWARDS
12 V
3 20 8 Select 0 V** with REVERSE
$ X4/59/c A4/2
GSV3
1 **) Only if the
6 6 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 3DUNLQJEUDNHRSHQ plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
6 2 2 1 1 16
6 6 5 5 A4/2
3 3 6 S8 Seat switch
4 4
6 1 S8/1 Reversible seat switch
A4/1 A4/1 (QJLQHEDFNSUHVVXUH
S8/2 Reversible seat switch
2 1 3 3 EUDNH S20 Switch, engine back
4 6LJQDO pressure brake
UHYHUVLQJIDFLOLW\ S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 6HDWFRQWDFW S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 &OXWFK X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
% X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
8 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
. 1 12 6
GSV2
6 X4/70 4-pin plug connection
4 Ω X4/70/1 4-pin plug connection
1 3 6 24 X6/3 6-pin plug connection
% 5 X6/15 6-pin plug connection
2 2
8 3
2 1 A4/1 A4/1 X6/27 6-pin plug connection
X6/58 6-pin plug connection
1 15 15 3 V
Ω X10/18 10-pin plug connection
6 X16/21 16-pin plug connection
A3 EEM3 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(11) 5.8V $FFHOHUDWRUSHGDO X89/1 89-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (11) Ground point, engine
A4/2 18-pin plug connection GND cable carrier, rear
1 1 1
A4/4 18-pin plug connection
A12 Central print 5 3 6 . 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 .
K5/62 Relay, accelerator pedal , reversing facility 3
P6 Display, reversing facility 5 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility $((0 X89/1 X10/18 X24/3
79 10 16
(11)
$)0*5
X4/14 X24/3 A4/2 A4/2
GSV2 %UDNH
1 12 6 6
6 Ω
3 4 14 14 3 V
6 2 5 13 13 3 V
4
6
3
6
2))
21 A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 6ZLWFKIRUSDUNLQJ
GSV2
12 6 6 LQWHUORFN
6
2))
21
3 1
)81&7,21$/6&+(0$7,&',$*5$0)25(&&8
A1 ADIC X24/2 $ )$
A12 Central print 8 X14/15
A13 Roof print )$
A14 Engine print 9 12
)$
A60 ECCU2 X4/85/a 1 2 22
A62 Reverse fan unit
CN1a 26-pin plug connection X4/85/b 1 2
'
CN2/E 26-pin plug connection
CN3 26-pin plug connection
CN3a 26-pin plug connection
CN3b 34-pin plug connection 2 25 34 1 2 3 14 21 26 25 26 19
K5/FAN Relay, reverse fan (11) X10/12 $ X10/11
P8 ICU
CN3a CN3b CN1a CN2/E CN1a
$(&&8 6 7
P8 10-pin plug connection
P8/1 4-pin plug connection
P8/2 4-pin plug connection A60_GND
S2/15/6 Switch, HTS 6XSSO\
S2/15/7 Switch, speed reduction
S2/56 Switch for differential lock CAN H
15
CN1a
S2/74 Reverse fan pushbutton CAN L (7)
X1/31/1 Screw connection 16 P8 7 5 3 (8)
X4/64 4-pin plug connection 3,&8 $$',&
X10/9 CN1a P8/1 P8/2 CN3
GSV4 CAN H
2 10 3 3 26
CAN L
4 4 25
6
'LIIHUHQWLDOORFN
X24/5 CN3b
24 Management CN3b < X14/14 4
5 2 12 V
3 5 1
1 1 23 Differential lock ON
6 2 X10/14 7
X24/5 CN3a +76
(11)
7 22 18 RECORD
3
1 24 19 PLAY
6 X10/3 6
$
)$
2)) $
21
6SHHGUHGXFWLRQ .)$1 X4/64 X4/66
X24/5 CN3a 4
5 1 7 24 )$ 3 5 4 3 M
1 2 3
6 CN3b 1
X6/2
12 V 2
5HYHUVHIDQ 8 3 1
$
2))
)$
X24/1 21
X24/3 CN3a X1/31/1
4 1 3 22 3 12 V 2
*1'
4
(11)
X4/66 4-pin plug connection X14/15 14-pin plug connection
X4/85/a 4-pin plug connection X24/1 24-pin plug connection
X4/85/b 4-pin plug connection X24/2 24-pin plug connection
X6/2 6-pin plug connection X24/3 24-pin plug connection
X10/3 10-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
16 1
X10/12 10-pin plug connection (7) Ground point, roof hood, left
X10/14 10-pin plug connection (8) Ground point, roof hood, right
Y8
+HDWLQJYDOYH
X14/14 14-pin plug connection (11) Ground point, engine cable carrier, rear 2
(11)
BLANK PAGE
$(&&8
X10/9 CN1a
GSV4
2 10
6 )URQW372
21
2))
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E <
12 V**
7 1
X3/21 CN3b
(11) GND
Q C 3 CN3b 225 Hz at 900 rmp 6 2
% B 2 22 490 Hz at 1900 rmp
I A 1 570 Hz at 2300 rmp
$
)$
X24/2 **) Activation approx. 6 sec. with 3 V, then 12 V
7
GND
6 18 2
(11)
21
2))
X24/5 CN3b
1 14 33 6.4 V when ON
3
7 15 32 6.4 V when OFF A12 Central print
6 A60 ECCU2
5HDU372 B7 Rear PTO speed sensor
B8 Front PTO speed sensor
2))
21
CN1a 26-pin plug connection
CN2/E 26-pin plug connection
X24/5 CN3a CN3a 26-pin plug connection
5 1 16 20 6.4 V with management ON CN3b 34-pin plug connection
6 S2/70/1 Switch for front PTO
S2/70/2 Switch for rear PTO
S2/71 Switch for rear PTO, management
2)) S17/1 External pushbutton for PTO, rear left
21
CN3a S17/2 External pushbutton for PTO, rear right
1 2 21 6.4 V with pushbutton pressed X3/21 3-pin plug connection
Ω X10/9 10-pin plug connection
6 X24/2 24-pin plug connection
X24/5 24-pin plug connection
2)) Y4 Solenoid valve, front PTO
21
CN3a Y5 Solenoid valve, rear PTO
(11) Ground point, engine cable carrier, rear
1 2 22 6.4 V with pushbutton pressed
Ω
BLANK PAGE
)81&7,21$/6&+(0$7,&',$*5$0)25('&
6
$505(67 )$ 3
17 1
$35,17$58
)$ 21
)$ 6 1
18
X18/1
2))
4
6 X30/14 8 2
X30/1 X18/4 ' 16 54c
GSV4
2 1
5V 7 13
1 X24/3 1
9 9
6 X30/2 (11) 1 54c
8 10 $(&&8 CN3a
2 X2/12 X10/9 2 6 8
5V X30/7 2
1 X55 13 24 29 47 28 46 (11)
2 16 CAN H
CAN H 50 $('&
$ 3 17 CAN L
X4 X30/11 52 6XSSO\ 10 4 1 CN3a
6 4 18
CAN L CN1a
1 16 $
BLANK PAGE
$('&
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
A16 EDC print % 2 6 2.5 to 7.5 V X55 <
A55 EDC box 8 1 35
GND
1
A60 ECCU2 6HQVRUVDQG
B9/1 Angle of rotation sensor
B10/1 Power sensor, left VROHQRLGYDOYHV 0 to 5 V
) 3 55 2
B10/2 Power sensor, right
B16 Radar sensor
% 2 7 approx. 5 V not loaded
CN2/E 26-pin plug connection 8 1
CN3b 34-pin plug connection
H2/1 Diagnosis LED
H2/2 Slip LED
) 3 <
H2/3 RAISE LED % GND
H2/4 LOWER LED 2 26 approx. 5 V not loaded 53 1
S2/15/5 RAISE/LOWER pushbutton 8 1
GND
38
S2/73 Switch, slip control 0 to 5 V
S14/1 External pushbutton, LOWER, left 41 19 2
S14/2 External pushbutton, LOWER, right
S15/1 External pushbutton, RAISE, left
S15/2 External pushbutton, RAISE, right 5V
9
X3/1 3-pin plug connection
X3/2 3-pin plug connection 6 6
X4/2 4-pin plug connection
X4/3 4-pin plug connection
2)) 2))
X10/4 10-pin plug connection 21 21 $
X10/9 10-pin plug connection
X14/4 X4/3
X14/4 14-pin plug connection 1 2 1 2 N +
X24/2 24-pin plug connection Ω Ω 5 1
X24/5 24-pin plug connection 6 2
X55 55-pin plug connection
6 N
Y6 Solenoid valve, EDC RAISE 37 3 4
Y7 Solenoid valve, EDC LOWER 2)) 2))
3
(11) Ground point, engine cable carrier, rear 21 21 ([WHUQDOSXVKEXWWRQV +
DQG/('V
1 2 1 2
Ω Ω
X14/4 X4/2
6 12 2
N
4
+
3
X24/5 N
X24/5
DOWN 31 7 2
1 20 36 5 V with pushbutton pressed
19 3 RAISE 1
7 21 17 5 V with pushbutton pressed +
6
14 GND
X14/4 9 X10/4 4
6OLSFRQWURO
X3/2 X3/1 $ CN2/E $ $
)$
Y 1 1 X24/2 8 Potentiometer R6/5 is shown (11)
B16 GND
2 3 5 CN3b on the previous page X24/2 19
I 3 2 15 21 9 A4/2 $
)$
Theoretical speed
11 505 Hz at 14 km/h
Real speed
10 505 Hz at 14 km/h
$
6WDQGDUGVLJQDO CN3b
Ground during transport
15 11
BLANK PAGE
$
$505(67 )81&7,21$/6&+(0$7,&',$*5$0)255(027(
6 X21 X30/11 $35,17$58 X30/1 X18/4 X24/2
)$ $
&21752/9$/9(6
8 6 7 13 17 X4/83 X4/90 $8;
)$ CAN H
7 13 9 9 18 3 3
9 )$ CAN L
1 1 8 10 24 4 2
CAN +
6 10 1 1
CAN -
X30/19 2 1 X30/7 (11)
2 4
2 16
6 CAN H
3 17 X4/91 $8;
CAN L CAN H
4 18 (11) 3
$ X30/5 CAN L
*1' *1'
6 2
3 CAN +
; 9 1
% 1
CAN -
4
2
*1' 3
7
% ; 9 6 1 X4/92 $8;
5 GSV4 CAN H
8 2 3
6 CAN L
9 2
6 4 2 X10/9 X10/9 6 8 CAN +
1
8 CAN -
4
X30/4 CN1a $(&&8 CN3a
*1'
4 10 6.4 V with EDC and AUX ON 4
; 9 9 CAN L X4/93 $8;
1 16 6.4 V with EDC ON 1 CAN H
CAN H 3
% 2 15 CAN L
2
X30/16 $ CAN +
5 9 Ω *1' $ X10/11 X14/15 1
6 )$ CAN -
9 Ω 7 12 4
4
5 X10/12 6 $
5 9
3
Ω X10/14 X10/3 X4/94 $8;
)$ CAN H
9 Ω 7 6 3
1 CAN L
2
2 X14/14 CAN +
1
X30/15 4 CAN -
5 9 Ω 4
6
9 Ω (7)
4 P8 7 5 3 (8)
A X3/10 B
5 P8/1 3,&8
5 9
3
Ω CAN L
4 120 Ω
9 Ω CAN H
1 3
2
X30/12 A12 Central print R20/4 Potentiometer AUX4 X14/14 14-pin plug connection
5 9
4
Ω
A13 Roof print R20/5 Potentiometer AUX5 X14/15 14-pin plug connection
9 Ω A14 Engine print S2/7/3 Switch, hydraulic master X18/4 18-pin plug connection
1 A30 Print ARU S34 Switch AUX5 X21 14-pin plug connection
2 A29 Joystick S35 Joystick pushbutton X24/2 24-pin plug connection
Ω A31 Multi controller S60/6 AUX blue pushbutton X30/1 14-pin plug connection
X30/6 A60 ECCU2 S60/8 Shift pushbutton X30/4 4-pin plug connection
8 B30 Joystick (float position) X30/5 2-pin plug connection
9
N longitudinal direction AUX1 X3/10 3-pin plug connection X30/6 8-pin plug connection
2 B31 Joystick X4/83 4-pin plug connection X30/7 4-pin plug connection
6 N
transverse direction AUX2 X4/90 4-pin plug connection X30/11 16-pin plug connection
3
N B52 Selector lever AUX4 X4/91 4-pin plug connection X30/12 4-pin plug connection
7 CN1a 26-pin plug connection X4/92 4-pin plug connection X30/15 6-pin plug connection
4 Ω CN3a 26-pin plug connection X4/93 4-pin plug connection X30/16 6-pin plug connection
2 P8 ICU X4/94 4-pin plug connection X30/19 2-pin plug connection
4 P8 10-pin plug connection X10/3 10-pin plug connection (7) Ground point, roof hood, left
8 P8/1 4-pin plug connection X10/9 10-pin plug connection (8) Ground point, roof hood, right
1 R20/1 Potentiometer AUX1 X10/11 10-pin plug connection (11) Ground point,
5 R20/2 Potentiometer AUX2 X10/12 10-pin plug connection engine cable carrier, rear
7
R20/3 Potentiometer AUX3 X10/14 10-pin plug connection
BLANK PAGE
)81&7,21$/6&+(0$7,&',$*5$0)255(027(&21752/9$/9(6$'',7,21$/)81&7,216
6
X18/4 CN3a X4/92 $8;
X18/4
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER CAN L
7 7 16 6.4 V with pushbutton pressed 2
$ X10/11 CAN +
1
6 7 CAN -
4
X10/12 6 $
2))
CN3a X10/14 X10/3
21
)$ X4/93 $8;
7 6
CAN H
1 2 12 6.4 V with pushbutton pressed 3
Ω CAN L
6 2
CAN +
4 X14/14 1
CAN -
2))
21
4
X4/72 21
X4/72 120 Ω
4 1 2 1 11 6.4 V with pushbutton pressed
Ω
A12 Central print X4/69 4-pin plug connection
6 A13 Roof print X4/72 4-pin plug connection
A14 Engine print X4/83 4-pin plug connection
2 X4/69 2)) A60 ECCU2 X4/90 4-pin plug connection
21
X4/69 B19 Angle of rotation sensor for front power lift X4/91 4-pin plug connection
CN1a 26-pin plug connection X4/92 4-pin plug connection
1 2 3 23 6.4 V with pushbutton pressed CN3a 26-pin plug connection X4/93 4-pin plug connection
Ω
6 CN3b 34-pin plug connection X4/94 4-pin plug connection
P8 ICU X10/3 10-pin plug connection
P8 10-pin plug connection X10/9 10-pin plug connection
2)) P8/1 4-pin plug connection X10/11 10-pin plug connection
21
X4/69 S2/7/3 Switch, hydraulic master X10/12 10-pin plug connection
1 2 1 26 6.4 V with pushbutton pressed S14/3 External pushbutton, front power lift LOWER X10/14 10-pin plug connection
Ω S15/3 External pushbutton, front power lift, RAISE X14/14 14-pin plug connection
CN3b S18/1 External pushbutton, AUX BLUE pressure in - X14/15 14-pin plug connection
12 S18/2 External pushbutton, AUX BLUE pressure in + X18/4 18-pin plug connection
X3/22 S19/1 External pushbutton, AUX BROWN pressure in - X24/2 24-pin plug connection
8V
3 3 CN3a S19/2 External pushbutton, AUX BROWN pressure in + (7) Ground point, roof hood, left
% 2 2 8 2.5 to 4.7 V S28/1 Switch for front power lift management (8) Ground point, roof hood, right
X3/10 3-pin plug connection (11) Ground point, engine cable carrier, rear
8 1 1
GND
CN1a X3/22 3-pin plug connection
23
BLANK PAGE
)81&7,21$/6&+(0$7,&',$*5$0)25)5217$;/(:,7+,1'(3(1'(176863(16,21
$
X4/45
)$
1
)$
2
*1'
16 X24/1
2 X2/46
X12/20 8 6 9 10
$
6XSSO\
6
X12/20
7 2 12V when LOWERING
3
1 3 12V when RAISING $$',&
X12/20 X4/45 $ X24/1 CN1
0 V LED ON
11 3 5 13 12 V LED OFF
6
X12/20
7 4 12V with axle locked (OFF)
3
1 5 12V with pushbutton pressed
(calibration)
0V with management
<
GND
1
GND
1 C
% 12V 12 V when RAISING
2 A 2
A1 ADIC , 3 B 7.3 to 16.5 mA
A12 Central print
A60 ECCU2
A61 Electronics, front axle with independent
suspension <
GND GND
B33/1 Angle of rotation sensor, LEFT 1 C 1
B33/2 Angle of rotation sensor, RIGHT % 12V
2 A
CN1 26-pin plug connection , 12 V when RAISING and LOWERING
CN1a 26-pin plug connection 3 B 7.3 to 16.5 mA 2
S2/15/1 Switch, front axle with independent
suspension UP/ DOWN
S2/15/2 Switch, front axle with independent
suspension ON/ OFF <
X2/45 2-pin plug connection $(&&8 CN1a GND
X2/45 X12/20 1
X2/46 2-pin plug connection
X4/45 4-pin plug connection 6 1 12 12V when v > 14 km/h
X12/20 12-pin plug connection 12 V when RAISING and LOWERING 2
X24/1 24-pin plug connection
Y14 Solenoid valve, UP / DOWN (black)
Y15 Solenoid valve, LEFT (blue)
Y16 Solenoid valve, RIGHT (green)
BLANK PAGE
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WIRING HARNESS CODING ................................................................................................................................7
COMPONENTS .................................................................................................................................................167
Armrest .....................................................................................................................................................167
Central print A12 (Würth) ..........................................................................................................................168
Central print A12 (Berifors) .......................................................................................................................170
Roof print A13 (Würth) ..............................................................................................................................172
Roof print A13 (Berifors) ...........................................................................................................................173
Engine print A14 (Würth) ..........................................................................................................................174
Engine print A14 (Berifors)........................................................................................................................175
EDC print A16 (Würth) ..............................................................................................................................176
EDC print A16 (Berifors) ...........................................................................................................................177
Can module A27 and plug module A28 to DBD094270............................................................................178
Print ARU A30 as of DBD094271 .............................................................................................................179
Relays .......................................................................................................................................................180
Components - engine and fuel system .....................................................................................................182
Components - transmission ......................................................................................................................186
Components - differential lock ..................................................................................................................189
Components - front PTO...........................................................................................................................190
Components - rear PTO...........................................................................................................................190
Components - individual wheel, sprung front axle ....................................................................................191
Components - brake .................................................................................................................................192
Components - reverse travel equipment...................................................................................................194
Components - hydraulics ..........................................................................................................................196
Components - EDC...................................................................................................................................198
Components - front powerlift.....................................................................................................................199
Components - air conditioning system......................................................................................................200
Components - cab.....................................................................................................................................203
EMPTY PAGE
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; Plug connection for worklight, ; Plug connection for cab wiring harness on right -
engine bonnet and horn engine wiring harness
; Plug connection for engine wiring harness
; Plug connection for headlight
(Berifors)
; Plug connection for engine wiring harness
; Plug connection for EEM2 engine control unit
(Würth)
; Plug connection for instruments wiring harness -
engine wiring harness
$ FMGR plug connection (white) &1 Plug connection for ISO-BUS
$ FMGR plug connection (dark grey) ; Plug connection for cab wiring harness on right -
$ FMGR plug connection (blue) control panel
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F80 Potential 30 ISO-BUS ............................ 20 A F87 Electrical battery main switch,
F81 Potential 30 ISO-BUS ............................ 25 A potential 30.............................................10 A
F82 Potential 30 ISO-BUS ............................ 40 A F104 Engine preheating, potential 30..............20 A
F200 Main fuse .............................................200 A
5HOD\V
K4/2/2 Time relay for interior light (reverse travel equipment)
K5/16 Relay for reversible fan K5/80 Relay for potential 15 ISO-BUS
K5/37 Relay for trailer brake, Italy K5/81 Relay for ECU power, ISO-BUS
K5/42 Relay D+ 2nd alternator K5/82 Relay for power socket, ISO-BUS
K5/54 Relay for electrical battery main switch [54] K6/7 Relay, heated rear window
K5/60 Relay for coupling (reverse travel equipment) K6/8 Relay, heated windscreen
K5/61 Relay for front accelerator K8/2 Relay for heating flange 300A
(reverse travel equipment) Q2 Relay for electrical battery main switch
K5/62 Relay for rear accelerator V8/1 ISO-BUS diode group
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All the cables of a plug on a wiring harness are colour coded.
Below you will find the list of the colours used and their code letters.
&DEOHFRORXURUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH &RGHOHWWHU &RORXU 7\SHRIXVH
A Red Potential 30 (continuous H Orange VDC, stabilised by the E-box
current)
B Beige -- control line (ground end) K Bright blue D+
C White + control line (positive end) L Brown Ground via a box
D Yellow + 15 Si (Potential 15 safety) M Ground strap
E Grey Potential 58 lighting N Pink
F Green Signal line P Colourless Reserve
G Violet + potential 15 (15.1 or 15.2) Black Ground, directly
power activated following to a grounding point
the start switch
127( 7KHÄ&$1+³DQGÄ&$1/³FDEOHVGRQRWFRUUHVSRQGWRWKHDIRUHPHQWLRQHGVWDQGDUG
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The individual wiring harnesses, the assignment of
plugs on the wiring harness and their precise locations
are described in detail on the following pages. The pre-
cise pin assignment and cable codes of the individual
cables are specified for all plugs.
7KHFDEOHFRGHVDUHVWUXFWXUHGDVIROORZV
1. Number of plug bush (pin)
2. Abbreviation - wiring harness
3. Code letter - cable colour
4. Cable number
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ADIC............................................................................................................................. Analogue/ digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
BB light.......................................................................................................................Turn signal side marker lights
DZG.............................................................................................. Signal of crankshaft position (upper dead point)
DMM..............................................................................................................................................Digital multimeter
ECCU2 ....................................................................................................................................... Central control unit
EDC................................................................................................................................Electronic powerlift control
Engine control unit ........................................................................................................................................ (EEM)
FMGR.......................................................................................................Vehicle - engine - transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU .................................................................................................................................................... Power monitor
KEY PADS ...................................................................................... Function keys for analogue / digital instrument
NTC.......................................................................................................................Negative temperature coefficient
PCB....................................................................................Printed circuit board (relay circuit, terminal resistance)
PCU......................................................................................................................... Electronic pumps - control unit
PTC ....................................................................................................................... Positive temperature coefficient
SBB light .......................................................................................................... Final turn signal side marker lights
SGR .................................................................................................................................... Transmission controller
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Ground point, engine component carrier Fig. 1 ( Worklight, right Fig. 3
( Headlight, left Fig. 2 + Signal horn Fig. 2
; Plug connection for worklight,
( Headlight, right Fig. 3
engine bonnet and horn Fig. 4
( Headlight, left Fig. 2 ; Plug connection for headlight Fig. 4
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 1
Fig. 2
Fig. 3
Fig. 4
EMPTY PAGE
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
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' Plug connection 2. alternator, *% Screw connection for alternator,
G2/2/2 Magneton 95A [D+] Fig. 101 Magneton 95A Fig. 101
; Screw connection for engine print,
' Plug connection 2. alternator Fig. 102
potential 30 Fig. 102
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Ground point, engine component
; Trailer socket, 7-pin, front Fig. 106
carrier Fig. 103
; Plug connection for 7-pin trailer
; Power socket, front Fig. 106
socket, front [7pol.vo] Fig. 104
; Screw connection for engine print,
power socket,
front, potential 30 Fig. 105
$GGLWLRQDOOLQHIRUDQJOHRIURWDWLRQVHQVRUIURQW
% Angle of rotation sensor ; Plug connection for angle of rotation sensor
[LAGESENSOR VO] Fig. 107 [LAGE] Fig. 108
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; Plug connection for speed sensor,
% Plug connection for speed sensor Fig. 109
PTO front [PTO] Fig. 110
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; Plug connection for ; Plug connection for
water in fuel [WIF] Fig. 111 sensor B23 [WIF] Fig. 112
$GGLWLRQDOOLQHIRUUHYHUVLEOHIDQ
; Plug connection for
. Relay for reversible fan Fig. 113
reversible fan [LU] Fig. 115
; Plug connection for
; Screw connection for reversible fan Fig. 114
reversible fan [LU] Fig. 116
$GGLWLRQDOOLQHIRUEDWWHU\JURXQG
Screw connection for battery ground -
* Battery terminal Fig. 117
starter Fig. 117
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; Plug connection for potential 30,
* Battery terminal Fig. 118
clock / radio Fig. 118
0 Starter Fig. 119
$GGLWLRQDOOLQHIRUHOHFWULFDOEDWWHU\PDLQVZLWFK
; Plug connection for potential 30,
* Battery terminal Fig. 118
clock / radio Fig. 118
4 Electrical main switch Fig. 120
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0 Starter Fig. 119 4$ Electrical main switch Fig. 120
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* Plug connection for alternator,
; Plug connection for alternator Fig. 121
Magneton 120A, terminal D+, W Fig. 121
$GGLWLRQDOOLQHIRU'HQVRDOWHUQDWRU
* Plug connection for alternator,
; Plug connection for alternator Fig. 122
Denso 140A G2/3 Fig. 122
$GGLWLRQDOOLQHIRUPDLQVZLWFKEDWWHU\
; Plug connection for potential 30,
* Battery terminal Fig. 118
clock / radio Fig. 118
4 Main switch Fig. 123
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0 Starter Fig. 124 4 Main switch Fig. 124
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
Fig. 121
Fig. 122
Fig. 123
Fig. 124
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 19
Fig. 20
Fig. 21
$GGLWLRQDOOLQHDOWHUQDWRU
. Relay D+ 2nd alternator Fig. 101 6 Start switch Fig. 102
; Plug connection for central print,
/ Indicator lamp 2. alternator Fig. 102
potential 15/2 Fig. 103
; Screw-plug connection for
/ Indicator lamp 2. alternator Fig. 102
potential 31, central print Fig. 103
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) Fuse for electrical ; Plug connection for central print,
battery main switch, potential 30 Fig. 104 potential 15/2 Fig. 108
. Relay for electrical ; Plug connection for indicator - electrical
battery main switch [54] Fig. 105 battery main switch [10] Fig. 104
;D Plug connection for potential 58/31,
4 Screw connection 30
electrical
for electrical battery main switch Fig. 106
battery main switch [46a] Fig. 109
;E Plug connection for potential 58/31,
4 Screw connection for electrical
electrical
battery main switch, control circuit Fig. 106
battery main switch [X2/46b] Fig. 109
4 Screw connection for electrical ; Screw-plug connection for
battery main switch, control circuit Fig. 106 potential 31, central print Fig. 108
6 Switch for electrical
battery main switch [BATT.-HS] Fig. 107
$GGLWLRQDOOLQHIRUVLQJOHZKHHOVSUXQJIURQWD[OH
6 Switch for sprung front axle ; Plug connection for potential 58/31,
UP/DOWN [VA auf/ab] Fig. 110 sprung front axle [VA] Fig. 112
6 Switch for sprung ; Plug connection for
front axle ON/OFF [VA ein] Fig. 110 sprung front axle [45] Fig. 113
; Plug connection for cab wiring harness on
; Plug connection for control block,
right - additional line for sprung
sprung front axle [VA] Fig. 114
front axle [45] Fig. 111
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) Fuse for engine preheating, ; Plug connection for fuel delivery pump,
potential 30 Fig. 115 engine preheating Fig. 117
* Screw connection for battery terminal, ; Plug connection for supply,
potential 30 Fig. 115 engine preheating, potential 30 Fig. 118
; Plug connection for diagnosis, ; Plug connection for engine preheating
engine preheating [DIAG] Fig. 116 precaution [WEBASTO] Fig. 119
; Plug connection for clock timer - ; Plug connection for engine preheating,
control unit for engine preheating [16]Fig. 116 clock Fig. 120
; Screw-plug connection for ; Plug connection for engine preheating,
engine print, potential 31 Fig. 116 ECU Fig. 118
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
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Ground point for starter Fig.1 % Rear PTO shaft speed sensor Fig.4
% EDC angle of rotation sensor
$ FMGR plug connection - white [1] Fig.2
[LAGESENSOR] Fig.5
$ FMGR plug connection -
% Power sensor, left Fig.6
dark grey [2] Fig.2
$ FMGR plug connection - blue [3] Fig.2 % Power sensor, right Fig.7
$ FMGR plug connection - grey [4] Fig.2 &1D Plug connection for ECCU2 Fig.8
$B*1'Screw connection for ground point
&1( Plug connection for ECCU2 Fig.8
ECCU2 Fig.8
% Compressed air sensor Fig.3 &1D Plug connection for ECCU2 Fig.9
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
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; Plug connection for air conditioning
system Fig. 101
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; Plug connection for
( Mobile phone socket, left Fig. 102
mobile phone socket, left [13] Fig. 103
$GGLWLRQDOOLQHIRUOLIWLQJSUHVVXUH
6 Changeover switch for lifting / ; Plug connection for lifting /
pressure Fig. 104 pressure Fig. 105
$GGLWLRQDOOLQHIRUK\GUDXOLFWUDLOHUEUDNH
. Relay for trailer brake,
Italy [ITALY] Fig. 106 ; Plug connection for additional line for
trailer brake, Italy,
; Plug connection for trailer brake, trailer brake valve [MGV] Fig. 108
„Italy“, central print [ITALB] Fig. 107
$GGLWLRQDOOLQHIRUK\GUDXOLFWUDLOHUEUDNHVROHQRLGYDOYH
6 Pushbutton for trailer brake valve Fig. 109 < Solenoid valve, trailer brake Fig. 109
; Plug connection for additional line for
trailer brake, Italy,
trailer brake [MGV] Fig. 110
$GGLWLRQDOOLQHIRUVWDQGDUGVLJQDOVRFNHW7
; Plug connection for
; Standard signal socket Fig. 112
standard signal socket [NORMS] Fig. 111
$GGLWLRQDOOLQHIRUVWDQGDUGVLJQDOVRFNHW7
; Plug connection for standard signal
; Plug connection for
socket, instruments wiring harness
standard signal socket [NORMS] Fig. 113
[NORMS] Fig. 114
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; Plug connection for radar sensor,
; Plug connection for radar sensor Fig. 116
central print Fig. 115
$GGLWLRQDOOLQHIRUSRZHUVRFNHWDGGLWLRQDOPRQLWRUFDE
; Screw connection for ; Screw-plug connection for
power socket, cab, 30 A Fig. 117 potential 31, central print Fig. 118
; Plug connection for central print,
; Power socket for cab 30 A Fig. 119
potential 15/2 Fig. 118
$GGLWLRQDOOLQHIRUDGGLWLRQDOVLGHPDUNHUOLJKWVZLGHW\UHV
;/ Plug connection for
;/ Plug connection for additional lights Fig. 120
SBB light, left Fig. 122
;5 Plug connection for
;5 Plug connection for additional lights Fig. 121
SBB light, right Fig. 123
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
Fig. 121
Fig. 122
Fig. 123
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( Cigarette lighter, right [E11] Fig.1 6 Switch for front PTO [PTO VO] Fig.8
+ LED diagnosis Fig.2 6 Switch for rear PTO [PTO HI] Fig.8
6 Switch for rear PTO
+ Slip LED Fig.3
management [PTO M] Fig.8
+ Raise LED Fig.2 6 Switch for traction control [ASR] Fig.3
+ Lower LED Fig.2 ; 2-pin socket 30/31 [2/1] Fig.1
; Plug connection for full-load
6 Switch for hydraulic master [MASTER] Fig.4
potentiometer Fig.10
; Plug connection for
6 Raise / Lower button [INNEN] Fig.4
diagnosis / slip LED [2] Fig.9
; Plug connection for
6 Switch for HTS [HTS] Fig.5
Raise / Lower LED [3] Fig.9
; Plug connection for EDC print -
6 Switch for reducing speed
cigarette lighter,
[DREHZAHLABSENKUNG] Fig.5
2-pin socket [13] Fig.11
6 Switch for differential lock management ; Plug connection for EDC print -
[DIFF HI] Fig.6 armrest (GSV) [4] Fig.9
6 Switch for speed ranges ; Plug connection for cab wiring harness
[RANGE] Fig.7 on right, control panel [9] Fig.12
6 Switch for manual mode ; Plug connection for cab wiring harness
[MAN.MOD] Fig.7 on right, control panel [5] Fig.12
6 Switch for 4-wheel drive management
[4 WD] Fig.6
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
$GGLWLRQDOOLQHIRUSRWHQWLRPHWHUIRUQRPLQDOYDOXHDQG('&OLJKWLQJ
; Plug connection for potentiometer for nominal value and lighting Fig. 101
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; Plug connection for potentiometer for lifting limitation Fig. 102
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; Plug connection for potentiometer for mixing Fig. 103
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; Plug connection for potentiometer for lowering speed Fig. 104
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; Plug connection for potentiometer for slip control Fig. 105
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; Plug connection for potentiometer for limit load Fig. 106
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; Plug connection for EDC print - potentiometer for control panel lighting, right Fig. 107
3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
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$ SGR plug connection, grey Fig.1 6 Switch for 5bar pressure filter Fig.4
$ SGR plug connection, black Fig.1 ; Plug connection for pressure filter Fig.5
$ SGR plug connection, green Fig.1 ; Plug connection for Linde electronics Fig.6
$ SGR plug connection, brown Fig.1 < Solenoid valve for clutch 1 Fig.3
$ Plug connection for speed sensor,
< Solenoid valve for clutch 2 Fig.3
black, planet carrier 1 / 2, B35 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve for clutch 3 Fig.3
grey, cartridge, input B24 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve for clutch 4 Fig.3
brown, planet carrier 3 / 4, B25 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve, clutch, forwards Fig.3
green, cartridge, output B27 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve, clutch, reverse Fig.7
orange, cartridge, output B26 Fig.8
% Temperature sensor, transmission oil Fig.2 < Solenoid valve, parking interlock On Fig.7
% Pressure sensor for transmission system
< Solenoid valve, parking interlock Off Fig.7
pressure Fig.3
% Pressure sensor for transmission lubricating
< 4-wheel drive solenoid valve Fig.7
pressure Fig.3
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
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; Plug connection for Linde electronics
$ Plug connection for Linde electronicsFig. 101
- hydrostat A24 Fig. 103
; Plug connection for Linde electronicsFig. 102
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Fig. 101
Fig. 102
Fig. 103
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
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; Screw connection ; Screw-plug connection for
2. power socket 40 A Fig. 101 potential 31, central print Fig. 101
; Plug connection for central print, ; 2. power socket
potential 15/2 Fig. 101 40 A, rear Fig. 102
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; Plug connection for central print, ; Plug connection for 7-pin trailer socket,
potential 15/2 Fig. 103 front [7pol.vo] Fig. 104
; Plug connection for cab wiring harness on
left - 7-pin trailer
socket, front [7pol.vo] Fig. 103
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Fig. 101
Fig. 102
Fig. 103
Fig. 104
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
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(Plug connection for turn signal, side marker ( Worklight front, right on
and doorway lights, front, left Fig. 101 turn signal - side marker lights Fig. 102
( Plug connection for turn signal ;/ Plug connection for turn signal
side marker lights, front, right Fig. 102 side marker lights, front, left Fig. 103
( Worklight front, left on ;5 Plug connection for turn signal
turn signal - side marker lights Fig. 101 side marker lights front, right Fig. 104
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( Plug connection for turn signal ( Plug connection for turn signal
side marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
( Plug connection for turn signal ( Plug connection for turn signal
side marker lights, front, left Fig. 106 side marker lights front, right Fig. 108
$GGLWLRQDOOLQHIRUVLGHPDUNHUOLJKWVDQGDGGLWLRQDOOLJKWIURQWOHIWDQG
ULJKW
( Additional side marker light, ( Additional side marker light,
front, left Fig. 109 front, right Fig. 111
( Plug connection for turn signal ( Plug connection for turn signal
side marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
( Plug connection for turn signal ( Plug connection for side marker lights,
side marker lights, front, left Fig. 110 front, right Fig. 112
$GGLWLRQDOOLQHIRUDX[LOLDU\KHDGOLJKWVDQGZRUNOLJKWV
Roof ground point, front, left Fig. 113 ( Auxiliary headlights, right Fig. 116
( Roof worklight front,
Roof ground point front, right Fig.114
centre, left [M] Fig. 115
; Socket for auxiliary and ( Roof worklight front,
worklight, front, left Fig. 113 centre, right [M] Fig. 116
; Socket for auxiliary and ( Roof worklight front,
worklight, front, right Fig. 114 exterior, left [A] Fig. 115
( Roof worklight front,
( Auxiliary lamp, left Fig. 115
exterior, right [A] Fig. 116
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( Number plate lighting, ;/ Plug connection for number plate lighting,
roof, left Fig. 117 roof, left Fig. 118
( Number plate lighting, ;5 Plug connection for number plate lighting,
roof, right Fig. 117 roof, right Fig. 119
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; (X4/ASW) Plug connection for ; (X4/ESW) Plug connection for
supply, lighting, all-round light bar Fig. 120 supply, lighting, all-round light bar Fig. 120
; Plug connection for
all-round light, left Fig. 121
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( Worklight, roof, front,
Roof ground point, front left Fig. 122
exterior, right [A] Fig. 125
( Worklight, roof, front,
Roof ground point, front right Fig. 123
interior, left [I] Fig. 124
( Worklight, roof, front, ( Worklight, roof, front,
centre, left[M] Fig. 124 interior, right [I] Fig. 125
( Worklight, roof, front, ; Socket for auxiliary and
centre, right [M] Fig. 125 worklight, front left Fig. 122
( Worklight, roof, front, ; Socket for auxiliary and
exterior, left [A] Fig. 124 worklight, roof, front, Fig. 123
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; Plug connection for electrical
6 Switch for heated mirror [HEIZSP] Fig. 126
mirror, right [SPIEGEL] Fig. 128
; Plug connection for mirror adjustment, ; Plug connection for electrical
roof print [X3/13] Fig. 127 mirror, left [SPIEGEL] Fig. 129
; Plug connection for heated mirror, ; Plug connection for mirror
roof print [15] Fig. 127 adjustment switch Fig. 126
; Plug connection for switch,
heated mirror, roof print [39] Fig. 127
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; Plug connection for roof print, ; Plug connection for temperature sensor Fig.
supply, blower Fig. 130 132
; Plug connection for blower motor, ; Plug connection for potentiometer,
air conditioning Fig. 131 blower Fig. 132
; Plug connection for supply, ; Plug connection for potentiometer,
air conditioning control Fig. 130 air conditioning control Fig. 132
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; Socket for all-round light, left Fig. 133 ; Socket for all-round light, right Fig. 134
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; Plug connection for all-round light,
$ All-round light, left Fig. 135
left Fig. 135
; Plug connection for all-round light,
$ All-round light, right Fig. 136
right Fig. 136
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; Plug connection for wiper motor,
0 Wiper motor, front Fig. 137
hinged windscreen, front Fig. 138
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; Plug connection for roof print,
0 Motor blower, roof Fig. 139
blower Fig. 141
6 Blower switch 1-2-3, roof Fig. 140
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; Plug connection for roof print,
( Front heated windscreen Fig. 142
fronted heated windscreen [90] Fig. 145
. Relay for heated windscreen, ; Plug connection for switch,
front [HZS VO] Fig. 143 windscreen, front, roof print [41] Fig. 145
6 Switch for heated windscreen, ; Screw connection for
front [HZS VO] Fig. 144 ground point, roof print Fig. 145
; Screw connection for potential 30,
roof print, heated windscreens Fig. 145
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; Plug connection for roof print,
( Rear heated windscreen Fig. 146
rear heated windscreen [91] Fig. 149
. Relay for heated rear windscreen ; Plug connection for switch,
[HZS HI] Fig. 147 windscreen, rear, roof print [42] Fig. 149
6 Switch for heated rear windscreen ; Screw connection for
[HZS HI] Fig. 148 ground point, roof print Fig. 149
; Screw connection for potential 30,
roof print, heated windscreens Fig. 149
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; Plug connection for heated mirror,
( Left heated mirror Fig. 150
roof print [15] Fig. 153
; Plug connection for switch,
( Heated mirror, right Fig. 151
heated mirror, roof print [39] Fig. 153
6 Switch for heated mirror [HEIZSP] Fig. 152
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; Plug connection for electronics, ; Plug connection for headlight,
Xenon, input, right Fig. 154 external right rear Fig. 154
; Plug connection for electronics, ; Plug connection for headlight,
Xenon, input, left Fig. 155 internal rear right Fig. 154
; Plug connection for electronics, ; Plug connection for worklight,
Xenon, output, right Fig. 154 external rear left Fig. 155
; Plug connection for electronics, ; Plug connection for worklight,
Xenon, output, left Fig. 155 internal rear left Fig. 155
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Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
Fig. 121
Fig. 122
Fig. 123
Fig. 124
Fig. 125
Fig. 126
Fig. 127
Fig. 128
Fig. 129
Fig. 130
Fig. 131
Fig. 132
Fig. 133
Fig. 134
Fig. 135
Fig. 136
Fig. 137
Fig. 138
Fig. 139
Fig. 140
Fig. 141
Fig. 142
Fig. 143
Fig. 144
Fig. 145
Fig. 146
Fig. 147
Fig. 148
Fig. 149
Fig. 150
Fig. 151
Fig. 152
Fig. 153
Fig. 154
Fig. 155
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
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6 External button for powerlift, front, ; Plug connection for external button,
LOWER [Senken] Fig. 101 powerlift, front [FHW] Fig. 102
6 External button for powerlift, front
RAISE [Heben] Fig. 101
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6 External button for AUX BROWN
; Plug connection for external button,
(up to DBD...YELLOW) pressure in -
front AUX brown [EHS] Fig.104
[Senken] Fig. 103
6 External button for AUX BRAUN
(up to DBD...YELLOW) pressure in +
[Heben] Fig. 103
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Fig. 101
Fig. 102
Fig. 103
Fig. 104
EMPTY PAGE
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$ FMGR plug connection - white [1] Fig. 1 6 Parking interlock switch [PARK] Fig. 7
$ FMGR plug connection -
6 Horn button [HORN] Fig. 7
dark grey [1] Fig. 2
$ FMGR plug connection -
6 Forwards - reverse switch [V/R] Fig. 7
dark grey [2] Fig. 1
$ FMGR plug connection -
6 Brake light switch [BREMSL] Fig. 8
dark grey [2] Fig. 2
$ FMGR plug connection - grey [4] Fig. 1 6 Clutch switch 80% [KUPPL] Fig. 8
$ FMGR plug connection - ; Plug connection for handbrake switch
dark grey [4] Fig. 2 [HANDBREMSE] Fig. 9
% Angle of rotation sensor for clutch ; Plug connection for handbrake switch
[DW-KUPPL Fig. 3 [HANDBREMSE] Fig. 10
; Plug connection for accelerator
+RUQ Plug connection for horn Fig. 4
[FAHRPEDAL] Fig. 10
; Plug connection for
. Relay for clutch [Kupplung] Fig. 5
mobile phone socket, left Fig. 9
. Relay for front accelerator ; Plug connection for
[FAHRPEDAL1] Fig. 5 mobile phone socket, left Fig. 10
. Relay for rear accelerator ; Plug connection for seat switch
[FAHRPEDAL1] Fig. 5 [SITZ RF] Fig. 11
3 Plug connection for reverse travel equipment
display [DISPLAY] Fig. 6
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
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0 Plug connection for motor, 0 Plug connection for motor,
windscreen washer system, rear Fig. 101 screen washer system, front Fig. 101
0 Plug connection for motor, 0 Plug connection for motor,
windscreen washer system, rear Fig. 102 screen washer system, front Fig. 102
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0 Plug connection for motor, 0 Plug connection for wiper motor,
rear angled wiper Fig. 103 hinged windscreen, front Fig. 104
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Fig. 101
Fig. 102
Fig. 103
Fig. 104
EMPTY PAGE
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Screw connection for battery ground - ; Plug connection for potential 30,
starter Fig. 1 ISO-BUS Fig. 4
; Plug connection for LBS socket,
&1 Plug connection for ECCU2 ISO-BUS Fig. 2
ISO-BUS Fig. 8
; Plug connection for cab wiring harness on
) Fuse for potential 30, ISO-BUS Fig. 3 right -
instruments wiring harness ISOBUS Fig. 9
; Plug connection for terminal resistor,
) Fuse for potential 30, ISO-BUS Fig. 3
ISO-BUS Fig. 10
;D Plug connection for cab wiring harness
) Fuse for potential 30, ISO-BUS Fig. 4
on right - ISO-BUS preparations Fig. 11
;E Plug connection for cab wiring harness
) Screw connection for main fuse Fig. 5
on right - ISO-BUS preparations Fig. 11
; Plug connection for LBS socket,
. Relay for potential 15, ISO-BUS Fig. 6
ISO-BUS Fig. 8
. Relay for ECU power, ISO-BUS Fig. 6 ; Socket for diagnosis service tool Fig. 12
; Plug connection for virtual terminal,
. Relay for power socket, ISO-BUS Fig. 7
ISO-BUS Fig. 13
9 ISO-BUS diode group Fig. 7 ; Socket for LBS, ISO-BUS Fig. 14
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Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
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W1/4 Plug connection for radio start X3/5 Plug connection for reserve
X1/6/1 Screw connection X12/20 Plug connection for sprung front axle
2. Power socket 40A X4/51 Plug connection for trailer brake „Italy“
X1/6/2 Screw connection X5/1 Screw-plug connection for potential 31
1. Power socket 40A X6/5 Reserve
X1/8 Screw connection for start switch supply X6/6 Plug connection for instruments wiring
X1/11 Screw connection for potential 30 harness
X1/26 Plug connection for potential 15/2, X10/8 Plug connection for cab wiring harness on left
heating blower X10/14 Plug connection for roof supply
X1/60 Screw connection for power socket, X18/1 Plug connection for instruments wiring
cab 30 A, potential 30 harness
X2/4/1 Screw-plug connection for potential 15/2 X24/1 Plug connection for instruments wiring
X2/4/2 Screw-plug connection for potential 15/2 harness
X3/1 Plug connection for radar sensor X24/2 Plug connection for cab wiring harness on right
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F1 Supply for start switch ........................... 20 A F30 Supply for engine print, potential 15/2......5 A
F2 Power socket for cab, F31 Supply for radar sensor, potential 15/2.....5 A
potential 30 ............................................ 25 A F32 Supply for PTO sensors,
F3 1. Power socket, potential 30 ................ 40 A potential 15/2..........................................10 A
F4 2. Power socket, potential 30 ................ 40 A F33 Supply for hazard warning light system,
F5 Supply, indicator, potential 15/1 ............. 15 A potential 30.............................................10 A
F6 ADIC, keypads potential 15/1 .................. 5 A F34 Headlight, roof right 56b ........................7.5 A
F7 Relay for 56a potential 30...................... 15 A F35 Headlight, roof left 56b ..........................7.5 A
F8 Reserve potential 30................................ 5 A F36 Headlight, engine bonnet, right 56b ......7.5 A
F9 SGR potential 30 ................................... 10 A F37 Headlight, engine bonnet, left 56b.........7.5 A
F10 Supply for ECCU2, potential 30............... 5 A F38 Trailer socket, potential 58L
F11 Relay for worklight, fender, front and rear............................................5 A
potential 30 ............................................ 10 A F39 Trailer socket, potential 58R
F12 Light switch, potential 30 ....................... 10 A front and rear............................................5 A
F13 Cigarette lighter, 2-pin socket, F40 Supply for steering column switch,
diagnosis plug, EDC - print potential 15/1..........................................15 A
potential 30 ........................................... 7.5 A F41 Reserve supply,
F14 FMGR, potential 30 .............................. 7.5 A potential 15/1 X6/5 ...............................7.5 A
F15 Reserve potential 15/2........................... 10 A F42 Reserve supply,
F16 Supply for CAN, FMGR, ARU, AUX, potential 15/1 X6/5 ..................................5 A
changeover switch for diagnosis, ICU F43 Reserve supply,
potential 15/2 ........................................... 5 A potential 15/1 X6/5 ..................................5 A
F17 Blower for heating, potential 15/2 .......... 20 A F44 Reserve supply, potential 15/1 .................5 A
F18 SGR potential 15/1 .................................. 5 A F45 Supply for roof, ICU potential 15/1 ...........5 A
F19 Supply for ARU, EDC, potential 15/1....... 5 A F46 Relay for brake light, Optistop,
F20 Supply for ARU, EDC, potential 15/1....... 5 A potential 15/1..........................................10 A
F21 Supply for D+ relay, ECCU2, EDC .......... 5 A F47 Supply for AUX potential 15/1 ..................5 A
F22 Reserve for supply, terminal 30 X6/5...... 5 A F48 Supply for seat, trailer brake „Italy“
F23 Reserve for supply, terminal 30 X6/5...... 5 A potential 15/1..........................................20 A
F24 58 L Parking right, left, rear, ADIC, F49 Supply for potential 15/1 EDC box ...........5 A
switch lighting, instrument board, F50 Supply for potential 15/1 ECCU2 ...........25 A
trailer socket, front and rear, F51 Supply for potential 15/1 FMGR .............10 A
ISO BUS ............................................... 7.5 A F52 Trailer socket, indicator, right
F25 58 R Parking light, right, rear, ARU, front and rear.........................................7.5 A
switch lighting, control panel, F53 Trailer socket, indicator left
mobile phone socket............................. 7.5 A front and rear.........................................7.5 A
F26 Parallel wiper, horn, interval relay, F54 Reserve supply, potential 30 X6/5...........5 A
potential 15/2 ........................................ 7.5 A F55 Trailer socket, brake light
F27 Sprung front axle, potential 30............... 10 A front and rear..........................................10 A
F28 Sprung front axle, potential 15/2.............. 5 A
F29 Supply for power socket
front and rear, standard signal socket,
reversible fan, potential 15/2 ................. 10 A
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W1/4 Plug connection for radio start X4/51 Plug connection for trailer brake „Italy“
X1/6/1 Screw connection 2. Power socket 40A X5/1 Screw-plug connection for potential 31
X1/6/2 Screw connection 1. Power socket 40A X6/5 Reserve
X1/8 Screw connection for start switch supply X6/6 Plug connection for instruments wiring
X1/11 [X1/61/1] Screw connection for potential 30 harness
X1/26 Plug connection for potential 15/2, X10/8 Plug connection for cab wiring harness on left
heating blower X10/14 Plug connection for roof supply
X1/60 Screw connection for power socket, X18/1 Plug connection for instruments wiring
cab 30 A, potential 30 harness
X2/4/1 Screw-plug connection for potential 15/2 X24/1 Plug connection for instruments wiring
X2/4/2 Screw-plug connection for potential 15/2 harness
X3/1 Plug connection for radar sensor X24/2 Plug connection for cab wiring harness on
X3/5 Plug connection for reserve right
X12/20 Plug connection for sprung front axle
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F1 Supply for start switch ........................... 20 A F30 Supply for engine print, potential 15/2......5 A
F2 Power socket for cab, F31 Supply for radar sensor, potential 15/2.....5 A
potential 30 ............................................ 25 A F32 Supply for PTO sensors,
F3 1. Power socket, potential 30 ................ 40 A potential 15/2..........................................10 A
F4 2. Power socket, potential 30 ................ 40 A F33 Supply for hazard warning light system,
F5 Supply, indicator, potential 15/1 ............. 15 A potential 30.............................................10 A
F6 ADIC, keypads potential 15/1 .................. 5 A F34 Headlight, roof right 56b ........................7.5 A
F7 Relay for 56a potential 30...................... 15 A F35 Headlight, roof left 56b ..........................7.5 A
F8 Reserve potential 30................................ 5 A F36 Headlight, engine bonnet, right 56b ......7.5 A
F9 SGR potential 30 ................................... 10 A F37 Headlight, engine bonnet, left 56b.........7.5 A
F10 Supply for ECCU2, potential 30............... 5 A F38 Trailer socket, potential 58L
F11 Relay for worklight, fender, front and rear............................................5 A
potential 30 ............................................ 10 A F39 Trailer socket, potential 58R
F12 Light switch, potential 30 ....................... 10 A front and rear............................................5 A
F13 Cigarette lighter, 2-pin socket, F40 Supply for steering column switch,
diagnosis connector, EDC - print potential 15/1..........................................15 A
potential 30 ........................................... 7.5 A F41 Reserve supply,
F14 FMGR, potential 30 .............................. 7.5 A potential 15/1 X6/5 ...............................7.5 A
F15 Reserve potential 15/2........................... 10 A F42 Reserve supply,
F16 Supply for CAN, FMGR, ARU, AUX, potential 15/1 X6/5 ..................................5 A
changeover switch for diagnosis, ICU F43 Reserve supply,
potential 15/2 ........................................... 5 A potential 15/1 X6/5 ..................................5 A
F17 Blower for heating, potential 15/2 .......... 20 A F44 Reserve supply, potential 15/1 .................5 A
F18 SGR potential 15/1 .................................. 5 A F45 Supply for roof, ICU potential 15/1 ...........5 A
F19 Supply for ARU, EDC, potential 15/1....... 5 A F46 Relay for brake light, Optistop,
F20 Supply for ARU, EDC, potential 15/1....... 5 A potential 15/1..........................................10 A
F21 Supply for D+ relay, ECCU2, EDC .......... 5 A F47 Supply for AUX potential 15/1 ..................5 A
F22 Reserve for supply, terminal 30 X6/5...... 5 A F48 Supply for seat, trailer brake „Italy“
F23 Reserve for supply, terminal 30 X6/5...... 5 A potential 15/1..........................................20 A
F24 58 L Parking right, left, rear, ADIC, F49 Supply for potential 15/1 EDC box ...........5 A
switch lighting, instrument board, F50 Supply for potential 15/1 ECCU2 ...........25 A
trailer socket, front and rear, F51 Supply for potential 15/1 FMGR .............10 A
ISO BUS ............................................... 7.5 A F52 Trailer socket, indicator, right
F25 58 R Parking light, right, rear, ARU, front and rear.........................................7.5 A
switch lighting, control panel, F53 Trailer socket, indicator left
mobile phone socket............................. 7.5 A front and rear.........................................7.5 A
F26 Parallel wiper, horn, interval relay, F54 Reserve supply, potential 30 X6/5...........5 A
potential 15/2 ........................................ 7.5 A F55 Trailer socket, brake light
F27 Sprung front axle, potential 30............... 10 A front and rear..........................................10 A
F28 Sprung front axle, potential 15/2.............. 5 A
F29 Supply for power socket
front and rear, standard signal socket,
reversible fan, potential 15/2 ................. 10 A
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K2 Trafficator relay K5/10 Relay, light (potential 58)
K3 Interval relay K5/11 Relay potential D+ supply
K5/5 Switchover relay for high beam K5/12 Relay, brake light, Optistop
K5/6 Switchover relay for dipped beam K5/43 Relay, D+ cut-off
K5/7/1 Relay potential 15/1 supply K5/56a Relay for high beam
K5/7/2 Relay potential 15/2 supply K5/56b Relay for dipped beam
K5/9 [K5/3] Relay for worklight, fender
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X1/24 Screw connection for potential 30, supply
heated windscreens X4/65 Plug connection for rear wiper motor
X2/9 Plug connection for blower supply X4/ASW [X4/38] Plug connection for
X2/14 Plug connection for air conditioning system worklight, front
X4/19 Plug connection for front heated windscreen X4/ASW [X4/38] Plug connection for lighting supply,
X4/20 Plug connection for rear heated windscreen all-round light bar
X3/80 Plug connection for mirror adjustment [X3/13] X4/ESW [X4/40] Plug connection for auxiliary lamp
X4/15 Plug connection for heated mirror X4/ESW [X4/40] Plug connection for lighting supply,
X4/16 Plug connection, reserve all-round light bar
X4/17 Plug connection for front wiper motor X4/65 Plug connection for rear wiper motor
X4/39 Plug connection for heated mirror switch X10/11 Plug connection for roof print supply
X4/41 Plug connection for front heated windscreen X10/12 Plug connection for roof wiring harness
switch X10/13 Plug connection for roof wiring harness
X4/42 Plug connection for rear heated windscreen X16/4 Screw connection for potential 30,
switch roof print supply
X4/44 Plug connection for air conditioning control X16/5 Screw connection for potential 31, roof print
)XVHV
F60 Side marker light, front left, F70 2 worklights, rear ....................................10 A
number plate lighting on roof .................. 3 A F71 Heated mirror .......................................7.5 A
F61 Side marker light, front right, ICU F72 Supply for radio, interior lights,
switch lighting, roof, spot, radio and ASW panel supply, potential 30................5 A
ASW panel lighting, activation F74 Reserve potential 30 ..............................25 A
of all worklights ........................................ 5 A F76 Heated rear windscreen .........................25 A
F63 Rear wiper ............................................ 7.5 A F77 Heated front windscreen .......................25 A
F64 Front wiper on hinged windscreen........ 7.5 A F100 Electrically adjustable mirror ....................5 A
F65 Control, air conditioning system............... 5 A F101 ASW panel supply for
F66 Blower / air conditioning system ........... 20 A 4 worklights, front,
F67 4 worklights, front (exterior) ................... 15 A worklight on BB light ..............................25 A
F68 4 worklights, rear, ASW panel F102 4+2 worklights, front ...............................15 A
supply, potential 30 ................................ 10 A F103 Air conditioning pushbutton .....................5 A
F69 All-round light, ASW panel
supply, potential 30 ................................ 15 A
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K5/29 Supply, potential, terminal 15 K5/32 Supply for D+ air conditioning system
K5/30 4 worklights, rear (exterior) K5/33 4+2 worklights, front
K5/31 4 worklights, front (exterior) K5/36 Reserve
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X1/24 Screw connection for potential 30, supply
heated windscreens X4/65 Plug connection for rear wiper motor
X2/9 Plug connection for blower supply X4/ASW [X4/38] Plug connection for
X2/14 Plug connection for air conditioning system worklight, front
X4/19 Plug connection for front heated windscreen X4/ASW [X4/38] Plug connection for lighting supply,
X4/20 Plug connection for rear heated windscreen all-round light bar
X3/80 Plug connection for mirror adjustment [X3/13] X4/ESW [X4/40] Plug connection for auxiliary lamp
X4/15 Plug connection for heated mirror X4/ESW [X4/40] Plug connection for lighting supply,
X4/16 Plug connection, reserve all-round light bar
X4/17 Plug connection for front wiper motor X4/65 Plug connection for rear wiper motor
X4/39 Plug connection for heated mirror switch X10/11 Plug connection for roof print supply
X4/41 Plug connection for front heated windscreen X10/12 Plug connection for roof wiring harness
switch X10/13 Plug connection for roof wiring harness
X4/42 Plug connection for rear heated windscreen X16/4 Screw connection for potential 30,
switch roof print supply
X4/44 Plug connection for air conditioning control X16/5 Screw connection for potential 31, roof print
)XVHV
F60 Side marker light, front left, F70 2 worklights, rear ....................................10 A
number plate lighting on roof .................. 3 A F71 Heated mirror .......................................7.5 A
F61 Side marker light, front right, ICU F72 Supply for radio, interior lights,
switch lighting, roof, spot, radio and ASW panel supply, potential 30................5 A
ASW panel lighting, activation F74 Reserve potential 30 ..............................25 A
of all worklights ........................................ 5 A F76 Heated rear windscreen .........................25 A
F63 Rear wiper ............................................ 7.5 A F77 Heated front windscreen .......................25 A
F64 Front wiper on hinged windscreen........ 7.5 A F100 Electrically adjustable mirror ....................5 A
F65 Control, air conditioning system............... 5 A F101 ASW panel supply for
F66 Blower / air conditioning system ........... 20 A 4 worklights, front,
F67 4 worklights, front (exterior) ................... 15 A worklight on BB light ..............................25 A
F68 4 worklights, rear, ASW panel F102 4+2 worklights, front ...............................15 A
supply, potential 30 ................................ 10 A F103 Air conditioning pushbutton .....................5 A
F69 All-round light, ASW panel
supply, potential 30 ................................ 15 A
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K5/29 Supply, potential, terminal 15 K5/32 Supply for D+ air conditioning system
K5/30 4 worklights, rear (exterior) K5/33 4+2 worklights, front
K5/31 4 worklights, front (exterior) K5/36 Reserve
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X1/2 Plug connection for engine wiring harness, X1/21 Screw-plug connection for engine print,
terminal 50 potential 31
X1/9 Screw connection for fuel filter heating X1/22 Screw-plug connection for engine print,
X1/10 Screw connection for supply, potential 31
potential 30 EEM2 X1/31 Screw connection for engine print, power
X1/11 Plug connection for potential D+ socket, front, potential 30
X1/12 Screw connection for potential 30 X2/5 Screw-plug connection for engine print,
X1/14 Screw connection for PCU potential 30 Denso alternator, potential 15
X1/16 Plug connection for clock, X20/1 Plug connection for engine wiring harness
Webasto engine preheating (Würth)
X1/17 Screw connection for reversible fan
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F89 Potential 15, engine .............................. 15 A F94 Supply for EEM2, PCU,
F90 Air conditioning compressor, pushbutton 5 A potential 30 ............................................25 A
F91 Supply for EDC, potential 30 ................ 7.5 A F95 Reversible fan ........................................15 A
F92 Supply for EEM2, potential 30 ............... 10 A F96 Reserve .................................................7.5 A
F93 Supply for clock, ADIC, radio, F97 Supply for EEM2, potential 15................10 A
potential 30 .............................................. 5 A F98 Fuel filter heating, potential 30 ...............20 A
F99 Power socket, front................................ 30 A
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K5/3 Relay for engine print, potential 15 K8/1 Relay for starter
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X1/2 Plug connection for engine wiring harness, X1/17 Screw connection for reversible fan
terminal 50 X1/21 Screw-plug connection for engine print,
X1/9 Screw connection for fuel filter heating potential 31
X1/10 Screw connection for supply, X1/22 Screw-plug connection for engine print,
potential 30 EEM2 potential 31
X1/11 Plug connection for potential D+ X1/31 Screw connection for engine print, power
X1/12 Screw connection for potential 30 socket, front, potential 30
X1/14 Screw connection for PCU potential 30 X24/12 Plug connection for engine wiring harness
X1/16 Plug connection for clock, (Berifors)
Webasto engine preheating
)XVHV
F90 Air conditioning compressor, pushbutton 5 A F95 Reversible fan ........................................15 A
F91 Supply for EDC, potential 30 ................ 7.5 A F96 Reserve .................................................7.5 A
F92 Supply for EEM2, potential 30 ............... 10 A F97 Supply for EEM2, potential 15................10 A
F93 Supply for clock, ADIC, radio, F98 Fuel filter heating, potential 30 ...............10 A
potential 30 .............................................. 5 A F99 Power socket, front................................ 40 A
F94 Supply for EEM2, PCU,
potential 30 ........................................... 25 A
5HOD\V
K5/3 Relay for engine print, potential 15 K8/1 Relay for starter
('&SULQW$:UWK
/LVWRISOXJV
X2/6 Plug connection for lighting, X4/2 Plug connection for diagnosis LED, slip LED
potentiometer EDC X4/3 Plug connection for raise LED, lower LED
X3/16 Plug connection for potentiometer, X5/6 Plug connection for nominal value
lowering speed potentiometer
X3/17 Plug connection for potentiometer, X6/13 Plug connection for cigarette lighter and
raising speed 2-pin socket
X3/18 Plug connection for potentiometer, X10/4 Plug connection for EDC print - arm rest
EDC mix (GSV)
X3/19 Plug connection for potentiometer, X14/4 Plug connection for EDC print - control panel
slip control
('&SULQW$%HULIRUV
/LVWRISOXJV
X2/6 Plug connection for lighting, X4/2 Plug connection for diagnosis LED, slip LED
potentiometer EDC X4/3 Plug connection for raise LED, lower LED
X3/16 Plug connection for potentiometer, X5/6 Plug connection for nominal value
lowering speed potentiometer
X3/17 Plug connection for potentiometer, X6/13 Plug connection for cigarette lighter and
raising speed 2-pin socket
X3/18 Plug connection for potentiometer, X10/4 Plug connection for EDC print - arm rest
EDC mix (GSV)
X3/19 Plug connection for potentiometer, X14/4 Plug connection for EDC print - control panel
slip control
&DQPRGXOH$DQGSOXJPRGXOH$WR'%'
/LVWRISOXJV
X28/1 Plug connection for ARU - X28/11 Plug connection for ARU - multicontroller II
cab wiring harness on right X28/12 Plug connection for ARU - potentiometer
X28/2 Plug connection for ARU - rapid retraction AUX 5
button X28/13 Plug connection for ARU lighting
X28/3 Plug connection for ARU - man. oper. X28/14 Plug connection for ARU button, EDC Stop
accelerator slider X28/15 Plug connection for ARU - potentiometer
X28/4 Plug connection for ARU - AUX control lever AUX 3 and AUX 4
X28/5 Plug connection for ARU - AUX joystick X28/16 Plug connection for ARU - potentiometer
X28/6 Plug connection for ARU - AUX button AUX 1 and AUX 2
X28/7 Plug connection for ARU CAN - BUS YA1 Plug connection for ARU plug module -
X28/8 Plug connection for ARU reserve CAN module
X28/9 Plug connection for ARU - lighting, switch, YB1 Plug connection for ARU CAN module -
management, front powerlift plug module
3ULQW$58$DVRI'%'
/LVWRISOXJV
X30/1 Plug connection for ARU - X30/9 Plug connection for ARU - lighting, switch,
cab wiring harness on right management, front powerlift
X30/2 Plug connection for ARU - rapid retraction X30/11 Plug connection for ARU - multicontroller II
button X30/12 Plug connection for ARU - potentiometer
X30/3 Plug connection for ARU - man. oper. AUX 5
accelerator slider X30/13 Plug connection for ARU lighting
X30/4 Plug connection for ARU - AUX control lever X30/14 Plug connection for ARU button, EDC Stop
X30/5 Plug connection for ARU - AUX joystick X30/15 Plug connection for ARU - potentiometer
X30/6 Plug connection for ARU - AUX button AUX 3 and AUX 4
X30/7 Plug connection for ARU CAN - BUS X30/16 Plug connection for ARU - potentiometer
X30/8 Plug connection for ARU reserve AUX 1 and AUX 2
5HOD\V
0LQLDWXUHUHOD\
(K6/7, K6/8)
0LQLDWXUHUHOD\
(K5/3, K5/7/1, K5/7/2, K5/12, K5/80, K5/81)
0LFURUHOD\
(K5/5, K5/6, K5/9, K5/10, K5/11, K5/16, K5/29,K5/30,
K5/31, K5/33, K5/37, K5/42, K5/43, K5/54, K5/56a,
K5/56b, K5/60, K5/61, K5/62)
3RZHUUHOD\
(K5/32, K5/82, K8/1)
7LPHUHOD\ZLWKGHOD\
(K4/2/2)
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(K2)
,QWHUYDOUHOD\
(K3)
3RZHUUHOD\
(K8/2)
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(Q2)
'LRGHJURXS
(V8/1)
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0DQRSHUDFFHOHUDWRUVOLGHU%
6&RQWUROVZLWFKFRRODQWOHYHO
(Reed switch)
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%
6HQVRUIRUFKDUJHDLUWHPSHUDWXUH 6HQVRUIRUFKDUJHDLUSUHVVXUH
Temperature [°C] Resistance [Ω] (pin 2-1) Charge-air pressure kPa Voltage [V] (pin 4-1)
-45 39260 50 0.5
-20 13850 80 0.9
0 5500 110 1.3
20 2420 140 1.7
40 1166 170 2.1
60 609 200 2.5
80 340 230 2.9
100 202 260 3.3
120 127 290 3.7
130 102 320 4.1
350 4.5
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0 10 ± 2.5
1/2 95 ± 5
1 180 ± 12
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Air compressor
Pin 2, 4 supply .................................................. ground
Pin 3 activation ................................................ 12 VDC
Current consumption ........................................... 5.6 A
Solenoid valve
Pin 2, 4 supply .................................................. ground
Pin 1 activation ................................................ 12 VDC
Current consumption ........................................... 0.5 A
Coil resistance .....................................................24 Ω
&RRODQWKHDWHU
:HEDVWRFRRODQWKHDWHU
Voltage .................................................................. 12 V
Power .................................................................. 45 W
Warm current ...................................................... 5 kW
perm. Operating overpressure .......................... 2.5 bar
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6\VWHPSUHVVXUHVHQVRU%
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3RWHQWLRPHWHUDFFHOHUDWRUSHGDO5
(double potentiometer)
Power supply, FMGR box ........................5 to 6.5 VDC
Total resistance 2X .......................................4 kΩ ± 20%
Signal, protective resistor 2X ...................1k7 Ω ± 20%
Signal current ................................................ >100 µA
1 = Ground
2 = Supply
3 = Signal, FMGR box (falling)
4 = Signal, FMGR box and EEM2 box (ascending)
R measured 1-2 ............................................ 2 kΩ ± 20%
R measured 1-3 ................................ 1k7Ω to 3k7Ω ± 20%
R measured 1-4 ...............................3k7Ω to 1k7Ω ± 20%
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Proportional
Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Resistance ................................... 4.98 Ω ± 10% at 20°C
Imax .......................................................................1.5 A
Insulation resistance ...................................... >100 kΩ
Activation ...................................... PWM signal 100 Hz
Interference suppression ......................... BZW 06-28B
&RPSRQHQWVUHDU372
5HDU372VKDIWVSHHGVHQVRU%
<6ROHQRLGYDOYHUHDU372VKDIW
Proportional
Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Resistance ................................... 4.98 Ω ± 10% at 20°C
Imax .......................................................................1.5 A
Insulation resistance ...................................... >100 kΩ
Activation ...................................... PWM signal 100 Hz
Interference suppression ......................... BZW 06-28B
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6ROHQRLGYDOYHV<<<
&RPSRQHQWVEUDNH
6ZLWFKIRUEUDNHOLJKW66
Power ........................................................... max. 5 W
Current ....................................................... max. 0.5 A
Pin 1, clocked supply (GSV 2) ........................3.1 VDC
(measured with DMM)
Brake pedals not depressed:
Pin 1 - 2 ...........................................................Interrupt
Pin 1 - 3 ...........................................................Interrupt
Both brake pedals depressed (see graphic symbol):
Pin 1 - 2 ..................................................... approx. 4 Ω
Pin 1 - 3 ...........................................................Interrupt
One brake pedal depressed (steering brake):
Pin 1 - 2 ...........................................................Interrupt
Pin 1 - 3 ..................................................... approx. 4 Ω
6ZLWFKIRUKDQGEUDNH6
66ZLWFKHQJLQHEDFNSUHVVXUHEUDNH
6ZLWFKIRUEUDNHIOXLGOHYHO6
7UDQVPLWWHUFRPSUHVVHGDLULQGLFDWRU%
6ROHQRLGYDOYHIRUWUDLOHUEUDNHÄ,WDO\³<
3XVKEXWWRQIRU
WUDLOHUEUDNHÄ,WDO\³6
&RPSRQHQWVUHYHUVHWUDYHOHTXLSPHQW
3RWHQWLRPHWHUDFFHOHUDWRUSHGDO5
(double potentiometer)
Power supply, FMGR box ........................5 to 6.5 VDC
Total resistance 2X .......................................4 kΩ ± 20%
Signal, protective resistor 2X ...................1k7 Ω ± 20%
Signal current ................................................ >100 µA
1 = Ground
2 = Supply
3 = Signal, FMGR box (falling)
4 = Signal, FMGR box and EEM2 box (ascending)
R measured 1-2 ............................................ 2 kΩ ± 20%
R measured 1-3 ................................ 1k7Ω to 3k7Ω ± 20%
R measured 1-4 ...............................3k7Ω to 1k7Ω ± 20%
&OXWFKVZLWFK6
6HDWVZLWFK6
6ZLWFKUHYHUVLEOHVHDW6
6ZLWFKUHYHUVLEOHVHDW6
6ZLWFKEUDNHSHGDO6
&RPSRQHQWVK\GUDXOLFV
&RQWUROVZLWFKIRUVXSSO\SXPSSUHVVXUH6
-R\VWLFN$
(proportional control)
Measured values for Hall element in ORQJLWXGLQDO
GLUHFWLRQ
Supply voltage .................................................. 5 VDC
Cable, interrupt/short circuit ...................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ...........................1.1 - 1.51 VDC
Signal- lowering /proportional ..............1.51 -2.33 VDC
Signal- neutral .....................................2.33 - 2.67 VDC
Signal- raising /proportional ................2.67 - 3.49 VDC
Signal- raising max. ..............................3.49 - 4.1 VDC
Signal- raising /latched ........................... 4.1 -4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
-R\VWLFN$
(proportional control)
Measured values for Hall element in ODWHUDOGLUHFWLRQ
Supply voltage .................................................. 5 VDC
Cable, interrupt/short circuit ...................... 0 - 0.2 VDC
Signal- lowering max. ............................. 0.2 -0.5 VDC
Signal- lowering /proportional ................0.5 -2.33 VDC
Signal- neutral .....................................2.33 - 2.67 VDC
Signal- raising /proportional ..................2.67 - 4.5 VDC
Signal- raising max. ............................... 4.5 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
&RQWUROOHYHU%
(proportional control)
Measured values for Hall element
Supply voltage .................................................. 5 VDC
Cable, interrupt/short circuit ...................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ...........................1.1 - 1.51 VDC
Signal- lowering /proportional ..............1.51 -2.33 VDC
Signal- neutral .....................................2.33 - 2.67 VDC
Signal- raising /proportional ................2.67 - 3.49 VDC
Signal- raising max. ..............................3.49 - 4.1 VDC
Signal- raising /latched ........................... 4.1 -4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
3RWHQWLRPHWHUIRU$8;FRQWUROYDOYHV
55555
± 10%
R Potentiometer ........................................... 5 kΩ
Potentiometer R20/5
R measured, pin 1 - 2 .............................. 0 - 5 kΩ ± 10%
7HUPLQDWLQJUHVLVWRU
± 5%
Resistance A - B 120 .......................................W
&RPSRQHQWV('&
$QJOHRIURWDWLRQVHQVRUIRU('&%
3RZHUVHQVRU%%
Nominal load....................................................... 60 KN
3RWHQWLRPHWHU5
3RWHQWLRPHWHU5555
6ROHQRLGYDOYHVIRU('&<DQG<
+HDWLQJYDOYH<
5DGDUVHQVRU%
Mounting angle ....................................................... 35°
Output signal ....................................... 131 impulses/ m
Pin 1(+ supply) ................................................. 12 VDC
Pin 2 (supply) .................................................... ground
Pin 3 (signal, square-wave) ............. 505 Hz at 14 km/h
Pin 4 Available (connected to term. 3)
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$LUFRQGLWLRQLQJWHPSHUDWXUHFRQWURO$
X4/44 - Pin 4 (supply) ......................................12 VDC
X4/44 - Pin 2 (supply) ...................................... Ground
X4/44 - Pin 1............................................ Output signal
(Activation of magnetic coupling, compressor)
X4/73 - Pin 1 - 2....................... Temperature sensor R9
X4/73 - Pin 3............................................Sheathing R9
X4/75 - Pin 1 - 2...............................Potentiometer R10
................................................... (Temperature setting)
X4/10 - Pin 3 - 4 ................... Switch, air cond. ON/OFF
3RWHQWLRPHWHUIRUDLUFRQGLWLRQLQJURRI
PRXQWHGEORZHU5
(for setting the speed of the roof blower motor)
53RWHQWLRPHWHUDLUFRQGLWLRQLQJ
WHPSHUDWXUH
for setting temperature with integrated switch (air
conditioning - ON/OFF)
3XVKEXWWRQIRUDLUFRQGLWLRQLQJV\VWHP6
7HPSHUDWXUHVHQVRUIRUDLUFRQGLWLRQLQJ
V\VWHP5
$LUFRQGLWLRQLQJFRPSUHVVRUFRXSOLQJ<
&RPSRQHQWVFDE
0LUURUKHDWLQJ(DQG(
0LUURUKHDWLQJDQGDGMXVWPHQW$$
Mirror adjustment
Pin 2 ........................................ +15/1 adjusting motor 1
Pin 1 .................................... Ground, adjusting motor 1
Pin 3 ........................................ +15/1 adjusting motor 2
Pin 4 ................................... Ground, adjusting motor 2
Mirror heating E18/1 and E18/2
pin 5 .................................................... activation +15/1
Pin 6 ..................................................... Supply, ground
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+HDWHGZLQGVFUHHQIURQW(
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$$
4009A
CONTENTS
WIRING HARNESS DESIGNATION ..................................................................................................................... 7
SOCKETS ........................................................................................................................................................... 14
Blank page
MAIN CONNECTOR
X2/2 Plug connection for main beam headlight, X10/18 Plug connection for engine wiring harness -
engine hood instruments wiring harness
X2/3 Plug connection for dipped headlight, X12/1 Plug connection for engine -
engine hood engine print wiring harness
X3/28 Plug connection for work lamp, X16/1 Plug connection for EEM3 engine control
engine hood and horn unit - injectors engine wiring harness
X36/1 Plug connection for EEM3 engine control
X4/4 Plug connection for ID module
unit - sensors engine wiring harness
X10/3 Plug connection for instruments - X89/1 Plug connection for engine - EEM3 engine
engine print wiring harness control unit wiring harness
A4/1 FMGR plug connection (white) X10/9 Plug connection for cab, right - control panel
A4/2 FMGR plug connection (dark grey) wiring harness
Fuses
F200 Main fuse ............................................. 150 A F200 Main fuse..............................................200 A
(with 2 alternators)
Relay
K4/2/2 Time relay, interior light K5/80 Relay for potential 15 ISO-BUS
K5/37 Relay for Italy trailer brake K5/81 Relay for ECU power ISO-BUS
K5/42 Relay D+ 2nd alternator K5/82 Relay for power socket ISO-BUS
K5/60 Relay for coupling (reverse travel equipment) K6/7 Relay for rear heated windscreen
K5/61 Relay for front accelerator pedal (reverse K6/8 Relay for front heated windscreen
travel equipment) K8/2 Heating flange relay 300A
K5/62 Relay for rear accelerator pedal (reverse Q2 Relay for electrical battery main switch
travel equipment) V8/1 Diode group, ISO-BUS
SOCKETS
X2/1 Socket, 2-pin 30/31 [2/1] X14/30 Power socket for cab 30 A
X10/1 Trailer socket, 7-pin, rear X15 Power socket, front 40 A
X10/2 Trailer socket, 7-pin, front X29 Standard signal socket
X14/1 Power socket 1, rear 40 A X85 Socket for LBS, ISO-BUS
X14/20 Power socket 2, rear 40 A
NOTE: The „CAN H“ and „CAN L“ cables do not correspond to the aforementioned standard.
„CAN H“ is yellow in colour and „CAN L“ green.
Cable codes
The individual wiring harnesses, the arrangement of
connectors on the wiring harness and their precise
location are described in detail on the following pages.
The precise pin assignment and cable codes of the
individual cables are also specified.
Abbreviations
ADIC.......................................................................................................................... Analogue / digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
BB light...................................................................................................................... Turn signal / side marker light
DMM..............................................................................................................................................Digital multimeter
ECCU2 ....................................................................................................................................... Central control unit
EDC...............................................................................................................................Electronic power lift control
EEM3 ..........................................................................................................................................Engine control unit
FMGR........................................................................................................... Vehicle/engine/transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU ..........................................................................................................................................Performance monitor
KEY PADS ........................................................................................ Function keys for analogue/digital instrument
NTC...................................................................................................................... Negative temperature coefficient
PCB............................................................................... Printed circuit board (relay switching, terminal resistance)
PTC ....................................................................................................................... Positive temperature coefficient
SBB light .................................................................................................... Tail light, turn signal / side marker light
SGR .................................................................................................................................... Transmission controller
NOTE: The name in the square brackets [xx] is inscribed on the plug.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Sva 6-93290 EN Edition 01-2006
4009A-23
Fig. 5
Fig. 6
Fig. 7
Fig. 8
(2) Screw connection for ground point, X1/50 Screw connection for engine print,
engine control unit Fig. 1 potential 50 Fig. 11
(11) Ground point, X2/13 Plug connection for electric
engine cable carrier, rear Fig. 2 battery main switch [BHS] Fig. 12
K8/2.30 Screw connection for relay, X3/12 Plug connection for sensor
heating flange 300A Fig. 3 „water in fuel“ Fig. 13
X3/28 Plug connection for work lamp,
M13 Fuel delivery pump Fig. 4
engine hoodand horn [ENG-HOOD] Fig. 14
S3 Test switch for air filter Fig. 5 X4/4 Plug connection for ID module Fig. 15
X10/18 Plug connection for engine
S22 Test switch for coolant level Fig. 6 wiring harness -
instruments wiring harness Fig. 16
X12/1 Plug connection for engine -
S30 Pressure switch, air conditioning Fig. 7
engine print wiring harness Fig. 17
X89/1 Plug connection for engine -
X1/30/1 Screw connection for engine print,
EEM3 engine
potential 30 Fig. 8
control unit wiring harness Fig. 18
Y13 Plug connection for
X1/30/EEMScrew connection for engine print,
magnetic coupling, air
potential 30 Fig. 9
conditioning compressor Fig. 19
X1/31/1 Screw connection for engine print,
potential 31 Fig. 10
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Sva 6-93290 EN Edition 01-2006
4009A-28
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Blank page
2. Additional line for 7-pin trailer socket and power socket at front
(12) Ground point, X4/20 Plug connection for 7-pin trailer
engine cable carrier, front Fig. 105 socket, front [7/3] Fig. 109
X1/15/1 Plug connection for engine print,
X10/2 Trailer socket, 7-pin, front Fig. 110
power socket, front, potential 15 Fig. 106
X1/30/SOCScrew connection for engine print,
X15 Power socket, front Fig. 110
power socket, potential 30 Fig. 107
X1/31/2 Plug connection for 7-pin trailer socket,
front, potential 31, engine print Fig. 108
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
Fig. 121
Fig. 122
Fig. 123
Fig. 124
Fig. 125
Fig. 126
Fig. 127
(12) Ground point, engine cable carrier, X2/36 Plug connection for
front Fig. 1 fuel temperature sensor Fig. 8
X3/37 Plug connection for oil
E10/1+ Screw connection for heating flange Fig. 2
pressure sensor Fig. 9
X3/38 Plug connection for rail
E10/1- Screw connection for heating flange Fig. 3
pressure sensor Fig. 10
K8/2 Screw connection for relay, (87) X3/39 Plug connection for
heating flange Fig. 4 fuel delivery pressure sensor Fig. 11
X2/19 Plug connection for heating X3/40 Plug connection for
flange relay Fig. 5 camshaft position sensor Fig. 12
X2/22 Plug connection for X4/29 Plug connection for charger pressure,
coolant temperature sensor Fig. 6 charged air temperature sensor Fig. 13
X36/1 Plug connection for EEM3
X2/28 Plug connection for engine
engine control unit - sensors
speed sensor Fig. 7
engine wiring harness Fig. 14
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Sva 6-93290 EN Edition 01-2006
4009A-49
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Blank page
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
Fig. 43
Fig. 44
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
Fig. 121
Fig. 122
Fig. 123
E11 Cigarette lighter, right [E11] Fig. 1 S2/70/1 Switch for front PTO shaft [PTO VO] Fig. 8
H2/1 LED for diagnosis Fig. 2 S2/70/2 Switch for rear PTO shaft [PTO HI] Fig. 8
S2/71 Switch for rear PTO shaft
H2/2 LED for slip Fig. 3
management [PTO M] Fig. 8
H2/3 LED for raise Fig. 2 S2/73 Switch for slip control [ASR] Fig. 3
H2/4 LED for lower Fig. 2 X2/1 Socket, 2-pin 30/31 [2/1] Fig. 1
S2/7/3 Switch for X3/23 Plug connection for load
hydraulic master [MASTER] Fig. 4 limit potentiometer Fig. 10
X4/2 Plug connection for LED for
S2/15/5 Raise / lower pushbutton [INNEN] Fig. 4
diagnosis / slip [2] Fig. 9
X4/3 Plug connection for LED for
S2/15/6 Switch for HTS [HTS] Fig. 5
raise / lower [3] Fig. 9
S2/15/7 Switch for speed reduction X6/13 Plug connection for EDC print -
[DREHZAHLABSENKUNG] Fig. 5 cigarette lighter, 2-pin socket [13] Fig. 11
S2/56 Switch for differential lock X10/4 Plug connection for EDC print -
management [DIFF HI] Fig. 6 armrest (GSV) [4] Fig. 9
S2/58/1 Switch for speed ranges X10/9 Plug connection for right cab
[RANGE] Fig. 7 wiring harness, control panel [9] Fig. 12
S2/58/2 Switch for manual mode X24/5 Plug connection for right cab
[MAN.MOD] Fig. 7 wiring harness - control panel [5] Fig. 12
S2/59 Switch for all-wheel drive
management [4 WD] Fig. 6
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
A21/2 Plug connection for SGR grey Fig. 1 S49/1 Switch for pressure filter 5bar Fig. 4
A21/3 Plug connection for SGR black Fig. 1 X5 Plug connection for pressure filter Fig. 5
A21/4 Plug connection for SGR green Fig. 1 X6/1 Plug connection for Linde electronics Fig. 6
A21/5 Plug connection for SGR brown Fig. 1 Y41 Solenoid valve, coupling 1 Fig. 3
A21/6 Plug connection for speed sensor,
Y42 Solenoid valve, coupling 2 Fig. 3
black planetary carrier 1 / 2, B35 Fig. 8
A21/7 Plug connection for speed sensor,
Y43 Solenoid valve, coupling 3 Fig. 3
grey cartridge input B24 Fig. 8
A21/8 Plug connection for speed sensor,
Y44 Solenoid valve, coupling 4 Fig. 3
brown planetary carrier 3 / 4, B25 Fig. 8
A21/9 Plug connection for speed sensor,
Y45 Solenoid valve, coupling, forwards Fig. 3
green cartridge output B26 Fig. 8
A21/10 Plug connection for speed sensor,
Y46 Solenoid valve, coupling, reverse Fig. 7
orange cartridge output B27 Fig. 8
B32 Temperature sensor, gear oil Fig. 2 Y57 Solenoid valve, parking interlock On Fig. 7
B47 Pressure sensor, transmission
Y58 Solenoid valve, parking interlock Off Fig. 7
system pressure Fig. 3
B51 Pressure sensor, transmission
Y59 All-wheel solenoid valve Fig. 7
lubrication pressure Fig. 3
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 101
Fig. 102
Fig. 103
(11) Ground point, engine cable carrier, X4/20 Plug connection for wiring harness, cab,
rear Fig. 1 left - 7-pin trailer socket, front [7/3] Fig. 7
X4/60L Plug connection for SBB light,
B2/1 Sensor for tank content, left Fig. 2
rear left Fig. 3
X6/10 Plug connection for left cab
E8 Work lamp, fender, left Fig. 3 wiring harness - instruments
wiring harness [10] Fig. 8
M5 Plug connection for motor for
X10/1 Trailer socket, 7-pin, rear Fig. 9
windscreen washing system, rear [R] Fig. 4
M6 Plug connection for motor for X10/8 Plug connection for wiring harness,
windscreen washing system, front [F] Fig. 4 cab, left - central print [8] Fig. 6
X1/6/2 Plug connection for
X14/1 Power socket 1, rear 40 A Fig. 9
1st power socket 40 A Fig. 5
X2/4/1 Plug connection for central print,
potential 15/2 Fig. 6
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 101
Fig. 102
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
(7) Roof ground point, front left Fig. 1 E19 Interior light Fig. 8
(8) Roof ground point, front right Fig. 2 E20 Spot light Fig. 9
A6/A Plug connection for radio Fig. 5 K4/2/2 Time relay, interior light Fig. 10
M4/2 Plug connection for rear
A6/B Plug connection for loudspeaker Fig. 5
wiper motor Fig. 10
B14 Loudspeaker, left Fig. 6 P8 Plug connection for ICU Fig. 11
B15 Loudspeaker, right Fig. 7 P8/2 Plug connection for ICU CAN Fig. 11
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
1. Additional line for front left and right turn signal / side marker light and
work lamps
E3/17/30Plug connection for turn signal, side
E36 Work lamp, at front right on turn
marker and doorway lights,
signal / side marker light Fig. 102
front, left Fig. 101
E6/14 Plug connection for turn signal X6/12L Plug connection for turn signal
side marker lights, front, right Fig. 102 side marker lights, front, left Fig. 103
E35 Work lamp, at front left on turn X6/12R Plug connection for turn signal
signal / side marker light Fig. 101 side marker lights, front, right Fig. 104
2. Additional line for front left and right side marker light (wide tyres)
E3/17 Plug connection for turn signal side E6/14 Plug connection for turn signal
marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
E3/17 Plug connection for turn signal side E6/14 Plug connection for turn signal
marker lights, front, left Fig. 106 side marker lights, front, right Fig. 108
3. Additional line for front left and right side marker light and additional
light
E3/1 Additional front left E6/1 Additional front right
side marker light Fig. 109 side marker light Fig. 111
E3/17 Plug connection for turn signal E6/14 Plug connection for turn signal
side marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
E3/17 Plug connection for turn signal E6/14 Plug connection for turn signal
side marker lights, front, left Fig. 110 side marker lights, front, right Fig. 112
NOTE: The plug connection (supply) of the all-round light bar is either plugged into roof print X4/38 or X4/40.
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Fig. 116
Fig. 117
Fig. 118
Fig. 119
Fig. 120
Fig. 121
Fig. 122
Fig. 123
Fig. 124
Fig. 125
Fig. 126
Fig. 127
Fig. 128
Fig. 129
Fig. 130
Fig. 131
Fig. 132
Fig. 133
Fig. 134
Fig. 135
Fig. 136
Fig. 137
Fig. 138
Fig. 139
Fig. 140
Fig. 141
Fig. 142
Fig. 143
Fig. 144
Fig. 145
Fig. 146
Fig. 147
Fig. 148
Fig. 149
Fig. 150
Fig. 151
Fig. 152
Fig. 153
Fig. 154
Fig. 155
Fig. 1
Fig. 2
Fig. 3
Fig. 4
2. Additional line for external button for front remote control valves
S19/1 External button, AUX BROWN
pressure in - [EHR - L] Fig. 103 X4/72 Plug connection for external
pushbutton,
S19/2 External button, AUX BROWN front AUX brown [EHR] Fig. 104
pressure in + [EHR - R] Fig. 103
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Blank page
A4/1 FMGR plug connection - white [1] Fig. 1 S2/61/1 Parking interlock switch [PARK] Fig. 7
A4/1 FMGR plug connection -
S2/75 Button for horn [HORN] Fig. 7
dark grey[1] Fig. 2
A4/2 FMGR plug connection -
S4/4/1 Switch for forwards - reverse [V/R] Fig. 7
dark grey [2] Fig. 1
A4/2 FMGR plug connection -
S5/1 Switch for brake light [BREMSL] Fig. 8
dark grey [2] Fig. 2
A4/4 FMGR plug connection - grey [4] Fig. 1 S46/1 Coupling switch 80% [KUPPL] Fig. 8
A4/4 FMGR plug connection - X4/25 Plug connection for handbrake
dark grey [4] Fig. 2 switch [HANDBREMSE] Fig. 9
B17/1 Angle of rotation sensor, coupling X4/25/1 Plug connection for handbrake
[DW-KUPPL] Fig. 3 switch [HANDBREMSE] Fig. 10
X4/70/1 Plug connection for accelerator
Horn Plug connection for horn Fig. 4
pedal [FAHRPEDAL] Fig. 10
X6/15 Plug connection for mobile phone
K5/60 Relay for coupling [KUPPLUNG] Fig. 5
socket, left Fig. 9
K5/61 Relay for front accelerator pedal X6/15 Plug connection for mobile phone
[FAHRPEDAL1] Fig. 5 socket, left Fig. 10
K5/62 Relay for rear accelerator pedal X6/58 Plug connection for seat switch
[FAHRPEDAL1] Fig. 5 [SITZ RF] Fig. 11
P6 Plug connection for reverse travel
equipment display[DISPLAY] Fig. 6
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 101
Fig. 102
Fig. 103
Fig. 104
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Fig. 1
Fig. 2
Fig. 3
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Fig. 7
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Fig. 101
Fig. 102
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Fig. 105
Fig. 106
Fig. 107
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
Fig. 113
Fig. 114
Fig. 115
Blank page
COMPONENTS
Armrest
List of plugs
W1/4 Radio start plug connection X4/45 Plug connection for sprung front axle
X1/6/1 Screw connection for 2nd power socket 40 A X4/51 Plug connection for „Italy“ trailer brake
X1/6/2 Screw connection for 1st power socket 40 A X5/1 Screw - plug connection for potential 31
X1/8 Screw connection for start switch supply X6/5 Reserve
X1/11 Screw connection for potential 30 X6/6 Plug connection for instruments
X1/26 Plug connection for potential 15/2, wiring harness
heating blower X10/8 Plug connection for wiring harness, cab, left
X1/60 Screw connection for power socket, X14/15 Plug connection for wiring harness
cab 30 A, potential 30 for roof supply (15)
X2/4/1 Screw - plug connection for potential 15/2 X18/1 Plug connection for instruments
X2/4/2 Screw - plug connection for potential 15/2 wiring harness
X3/1 Radar sensor plug connection X24/1 Plug connection for instruments
X3/5 Plug connection for reserve wiring harness
X24/2 Plug connection for right cab wiring harness
Relay
List of plugs
X1/CL Plug connection for central lubrication X1/30/SOC.F
X1/HEATPlug connection for heating GND Screw connection for power socket,
X1/15/1 Plug connection for power socket, front, front, potential 30
potential 15 X1/31/1 Screw connection for potential 31
X1/15/ABS X1/31/2 Screw connection for potential 31
Plug connection for ABS, potential 15 X1/50 Screw connection for starter, potential 50
X1/15FUEL X2/11 Plug connection for ISO-BUS, potential 30 Si
Plug connection for filter heating, potential 15 X2/13 Plug connection for electric battery
X1/30/1 Screw connection for potential 30 main switch
X1/30/2 Screw connection for potential 30 X2/WKL Plug connection for work lamp,
X1/30/ABS engine hood, reserve
Screw connection for ABS, potential 30 X4/64 Plug connection for reverse fan
X1/30/EEM X6/2 Plug connection for supply for EDC
Screw connection for engine control unit, X10/3 Plug connection for instruments -
potential 30 engine print wiring harness
X1/30/ISO X12/1 Plug connection for engine -
Screw connection for ISO-BUS, engine print wiring harness
potential 30
Relay
K4/BATT Time relay, main electrical battery switch K6/WKL-ERelay for work lamp, engine hood
K5/FAN Relay for reverse fan relay K6/HEAT Relay for heating blower
K5/LP Relay for fuel delivery pump relay K8/50 Relay for starter
K5/IGN Relay for engine, potential 15
List of plugs
X1/24 Screw connection for potential 30, X4/44 Plug connection for supply for air
heated windscreens conditioning control
X2/9 Plug connection for supply for blower X4/65 Plug connection for rear wiper motor
X2/14 Plug connection for air conditioning X4/ASW [X4/38] Plug connection for work lamp at front
X2/90 Plug connection for front heated windscreen X4/ASW [X4/38] Plug connection for supply,
X2/91 Plug connection for rear heated windscreen lighting, all-round light bar
X3/80 Plug connection for mirror adjustment [X3/13] X4/ESW [X4/40] Plug connection for auxiliary headlight
X4/15 Plug connection for heated mirror X4/ESW [X4/40] Plug connection for supply,
X4/16 Plug connection for reserve lighting, all-round light bar
X4/17 Plug connection for front wiper motor X6/23 Plug connection for rear wiper motor
X4/39 Plug connection for switch for heated mirror X10/11 Plug connection for roof print supply [11]
X4/41 Plug connection for switch for front X10/12 Plug connection for roof wiring harness [12]
heated windscreen X10/13 Plug connection for roof wiring harness [13]
X4/42 Plug connection for switch for rear X16/4 Screw connection for potential 30,
heated windscreen supply for roof print
X16/5 Screw connection for potential 31, roof print
Fuses
F60 Side marker light, front left, F69 All-round light, ASW panel supply
licence plate lights, roof ........................... 3 A for potential 30........................................15 A
F61 Side marker light front right, F70 2 rear work lamps ..................................10 A
ICU switch lighting for roof, spot F71 Heated mirror ........................................7.5 A
light, radio and ASW panel lighting, F72 Supply for radio, interior light,
activation of all work lamps...................... 5 A ASW panel supply for potential 30 ...........5 A
F63 Rear wiper ............................................ 7.5 A F74 Reserve for potential 30 .........................25 A
F64 Front wiper for hinged windscreen........ 7.5 A F76 Heated windscreen, rear ........................25 A
F65 Control, air conditioning system............... 5 A F77 Heated windscreen, front ......................25 A
F66 Blower / air conditioning system ............ 20 A F100 Electrically adjustable mirror ....................5 A
F67 4 front work lamps (outside) .................. 15 A F101 ASW panel supply for 4 front
F68 4 rear work lamps, ASW panel work lamps, work lamp on BB light ........25 A
supply for potential 30 .......................... 10 A F102 4+2 front work lamps .............................15 A
F103 Air conditioning pushbutton ......................5 A
Relay
K5/29 Supply for potential, terminal 15 K5/32 Supply, D+ air conditioning
K5/30 4 rear work lamps (outside) K5/33 4+2 front work lamps
K5/31 4 front work lamps (outside) K5/36 Reserve
List of plugs
X2/6 Plug connection for lighting, X4/2 Plug connection for LED for diagnosis / slip [2]
potentiometer EDC X4/3 Plug connection for LED for raise / lower [3]
X3/16 Plug connection for lowering speed X5/6 Plug connection for nominal value and
potentiometer lighting potentiometer
X3/17 Plug connection for lift X6/13 Plug connection for cigarette lighter and
limitation potentiometer socket, 2-pin (13)
X3/18 Plug connection for EDC X10/4 Plug connection for EDC print armrest
mixing potentiometer (GSV) [4]
X3/19 Plug connection for X14/4 Plug connection for EDC print - control panel
slip control potentiometer
List of plugs
X30/1 Plug connection for supply, armrest X30/11 Plug connection for supply,
X30/2 Plug connection for ARU - rapid multicontroller print
retraction button X30/12 Plug connection for ARU -
X30/3 Plug connection for ARU - manual potentiometer for R20/5
accelerator slider X30/13 Plug connection for ARU lighting
X30/4 Plug connection for ARU - AUX control lever X30/14 Plug connection for ARU, button for EDC stop
X30/5 Plug connection for ARU - AUX joystick X30/15 Plug connection for ARU - potentiometers
X30/6 Plug connection for ARU - AUX5 button R20/3 and R20/4
X30/7 Plug connection for ARU CAN BUS X30/16 Plug connection for ARU - potentiometers
X30/8 Plug connection for ARU reserve R20/1 and R20/2
X30/9 Plug connection for ARU - lighting, switch for
front power lift management
Relay
Miniature relay
(K6/7, K6/8, K6/WKL-E, K6/HEAT)
Miniature relay
(K5/7/1, K5/7/2, K5/12, K5/80, K5/81)
Contacts ..........................................................changer
Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load.........................................................max. 20/30 A
Resistance 85 - 86 ....................................... 65 Ω ± 10%
Micro relay
(K5/5, K5/6, K5/9, K5/10, K5/11, K5/29, K5/30, K5/31,
K5/33, K5/37, K5/42, K5/43, K5/56a, K5/56b, K5/60,
K5/61, K5/62, K5/LP, K5/FAN, K5/IGN)
Contacts ..........................................................changer
Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load.........................................................max. 15/25 A
Resistance 1 - 2 ................................ 80 Ω±10% at 23°C
Interference suppression resistance ................... 680 Ω
Power relay
(K5/32, K5/82, K8/50)
Contacts ..........................................................changer
Retention period ................................................ 40 sec.
Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load............................................................. max. 10 A
Interval relay
(K3)
Power relay
(K8/2)
Diode group
(V8/1)
Design.......................................................Hall element
PIN 1 supply ...................................................... 5 VDC
PIN 4 supply...................................................... ground
Current consumption ..................................max. 15 mA
PIN 2 signal........................................................... VDC
Load resistance ......................................min. 4.5 kOhm
Insulation resistance ........................................ >100kΩ
(Reed switch)
Design................................................................... NTC
PIN 2 supply ...................................................... 5 VDC
PIN 1................................................................... signal
Measurement range ...............................-50 to +150ºC
Nominal resistance (at 20ºC) ........................2.5 kΩ± 6%
Insulation resistance ...................................... >100 kΩ
Tightening torque ............................................... 20 Nm
Design ...................................................................NTC
PIN 2 supply ..................................................... 5 VDC
PIN 1 ...................................................................signal
Measurement range ............................... -50 to +150ºC
Nominal resistance (at 20ºC) ....................... 2.5 kΩ± 6%
Insulation resistance .......................................>100 kΩ
Tightening torque ............................................... 20 Nm
Air compressor
PIN 2, 4 supply.................................................. ground
PIN 3 activation ................................................ 12 VDC
Current consumption ............................................ 5.6 A
Solenoid valve
PIN 2, 4 supply.................................................. ground
PIN 1 activation ................................................ 12 VDC
Current consumption ............................................ 0.5 A
Coil resistance ......................................................24 Ω
Coolant heater
Transmission components
System pressure sensor B47
Seat switch S8
Brake components
Brake light switches S5, S25
Power ............................................................ max. 5 W
Current ........................................................ max. 0.5 A
PIN 1 cyclic supply (GSV 2) ............................ 3.1 VDC
(measured with DMM)
Brake pedals not depressed:
PIN 1 - 2 ..........................................................interrupt
PIN 1 - 3 ..........................................................interrupt
Both brake pedals depressed (see graphic symbol):
PIN 1 - 2 .................................................... approx. 4 Ω
PIN 1 - 3 ..........................................................interrupt
One brake pedal depressed (steering brake):
PIN 1 - 2 ..........................................................interrupt
PIN 1 - 3 .................................................... approx. 4 Ω
Pushbutton for
trailer brake „Italy“ S50
Hydraulics components
Supply pump pressure control switch S23
Joystick A29
(proportional control)
Measurements for Hall element in
longitudinal direction
Supply voltage .................................................. 5 VDC
Line interrupt/short-circuit ......................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ............................1.1 - 1.51 VDC
Signal- lowering / proportional .............1.51 - 2.33 VDC
Signal- Neutral .....................................2.33 - 2.67 VDC
Signal- raising / proportional ................2.67 - 3.49 VDC
Signal- raising max. ...............................3.49 - 4.1 VDC
Signal- raising/ latched ........................... 4.1 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
Joystick A29
(proportional control)
Measurements for Hall element in transverse direction
Supply voltage .................................................. 5 VDC
Line interrupt/short-circuit ......................... 0 - 0.2 VDC
Signal- lowering max. ............................. 0.2 - 0.5 VDC
Signal- lowering / proportional ...............0.5 - 2.33 VDC
Signal- Neutral .....................................2.33 - 2.67 VDC
Signal- raising / proportional ................2.67 - 3.49 VDC
Signal- raising max. ................................ 4.5 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
Potentiometer R20/5
R measured PIN 1 - 2.............................. 0 - 5 kΩ ± 10%
Terminal resistance
Resistance A - B ..........................................120 Ω ± 5%
EDC components
Angle of rotation sensor EDC B9/1
Nominal load....................................................... 60 KN
Potentiometer R6/1
Heating valve Y8
Cab components
Mirror heating E18/1 and E18/2
Mirror heating
PIN 2 ....................................... +15/1 adjusting motor 1
PIN 1 .................................... ground, adjusting motor 1
PIN 3 ....................................... +15/1 adjusting motor 2
PIN 4 ................................... ground, adjusting motor 2
Mirror heating E18/1 and E18/2
PIN 5 ................................................... activation +15/1
PIN 6 ..................................................... supply, ground
CIRCUIT DIAGRAM
INDEX
Numerics D
4 + 2 front work lamps ......................................... 31 D supply+ ............................................................15
A Display for reverse travel equipment ...................87
Additional front left light ....................................... 27 Door contact switch .............................................35
Additional front right light ..................................... 27 Doorway lights .....................................................35
Additional rear left light ........................................ 27 E
Additional rear right light ..................................... 27 EDC signal 50% ..................................................73
ADIC ........................................................ 53, 55, 57 EDC with raise/lower ...........................................67
Air conditioning .................................................... 45 EDC without raise/lower ......................................65
Air cushion seat ................................................... 47 EEM2 - box with sensors and PCU .....................15
All-round light carrier ........................................... 39 Electrical mirror adjustment .....................37, 39, 41
All-round lights (can be plugged in) ..................... 37 External button, AUX, front .................................97
All-round lights (magnetic) .................................. 41 External button, EDC ..........................................71
Alternator Denso ................................................. 11 External button, power lift, front ..........................97
Alternator Magneton .............................................. 7 F
Alternator Magneton (2nd alternator) .................... 9 Filter heating (preparation) ............................53, 55
Angle of rotation sensor, coupling ....................... 75 Front PTO shaft ...................................................91
Angle of rotation sensor, coupling with Fuel delivery pump ......................................7, 9, 11
reverse travel equipment ..................................... 77 G
Angle of rotation sensor, power lift, front ............. 97 Gearbox electronics ......................................85, 87
Angle of rotation sensor, power lift, rear ....... 65, 67 H
Angled wiper, front .............................................. 49 Headlight .............................................................29
Angled wiper, rear ............................................... 49 Heated windscreen, front ....................................43
Armrest ................................................................ 69 Heated windscreen, rear .....................................43
Armrest, electronics .......... 107, 109, 111, 113, 115 Heating flange .............................................7, 9, 11
ASR with radar sensor ........................................ 51 Heating flange, fuel delivery pump ......................13
AUX valves ........................................................ 105 Heating valve for hydraulic oil ...........................105
Auxiliary headlight and 4 work lamps .................. 29 Horn ....................................................................49
B Horn for reverse travel equipment .......................79
BB light, left ................................................... 23, 25 I
BB light, left and right .......................................... 27 ICU performance monitor ..............................85, 87
BB light, right ................................................. 23, 25 Indicator lights, EDC ...........................................73
Blower (heating) .................................................. 21 Interface, wiring harness, cab, right ..................107
Blower (roof) ........................................................ 47 Interior light .........................................................35
Brake light ........................................................... 17 ISO-BUS ........................................................... 117
Brake light for reverse travel equipment ............. 19 J
Button, AUX 5 ................................................... 111 Joystick with button ...........................................109
Button, EDC - stop and lighting ......................... 111 L
Button, raise/lower EDC ...................................... 71 Licence plate lights, roof .....................................35
Button, rapid retraction ...................................... 111 Limit load potentiometer ......................................75
C LIMP HOME plug connection ........................85, 87
CAN BUS ............................................ 99, 101, 103 Low beam, high beam .........................................29
Cigarette lighter with socket on right, 2-pin ... 61, 63 M
Clutch switch 80% ............................................... 75 Magneton alternator ............................................13
Clutch switch 80% for reverse travel equipment . 77 Manual accelerator slider ..................................109
Control handle for AUX ..................................... 109 Mirror heating ..........................................37, 39, 41
Control signal ...................................................... 69 Multicontroller II .................................................115
Abbreviations
ADIC.................................................................................................................................. Analogue/ digital instrument
ARU................................................................................................................................................................... Armrest
AUX..............................................................................................................................................Remote control valve
BB light............................................................................................................................Turn signal / side marker light
DZG..................................................................................................... Signal for crankshaft position (top dead centre)
DMM...................................................................................................................................................Digital multimeter
ECCU2 ............................................................................................................................................ Central control unit
EDC.....................................................................................................................................Electronic power lift control
EEM2 ...............................................................................................................................................Engine control unit
FMGR................................................................................................................ Vehicle/engine/transmission controller
GSV ..........................................................................................................................................................Cyclic supply
HTS ...................................................................................................Field end management (headland management)
ICU ............................................................................................................................................... Performance monitor
KEY PAD´S ............................................................................................ Function keys for analogue/digital instrument
NTC............................................................................................................................ Negative temperature coefficient
PCB.................................................................................... Printed circuit board (relay switching, terminal resistance)
PCU............................................................................................................................... Electronic pumps - control unit
PTC ............................................................................................................................. Positive temperature coefficient
SBB light .......................................................................................................... tail light, turn signal / side marker light
SGR ..........................................................................................................................................Transmission controller
NOTE: The name in the square brackets [xx] is inscribed on the plug.
Sva 6-51402 EN
Diagnosis LED
for pre-glowing
SS05N001
Edition 12-2005
Designation of sections Electrical equipment
A# Power supply and starter A12 Central print (Würth or Berifors) X1/21 Screw - plug connection for engine print,
Sva 6-51402 EN
A14 Engine print (Würth or Berifors) potential 31
B Heating flange
A50/1 Power module X2/5 Screw - plug connection for engine print,
C Fuel delivery pump Denso alternator, potential 15
E10/1 Heating flange
D Alternator Magneton F1 Fuse Supply for start switch X3/11 Plug connection for alternator
E Supply, potential 15/1 F89 FusePotential 15 for engine X5/1 Screw - plug connection, potential 31, central
F93 Fuse Supply for clock, ADIC, radio, print
potential 30 X18/1 Plug connection for instruments wiring
# Variants on sheets 2, 3, 4 F200 Main fuse harness - central print [1]
G1 Battery X20/1 Plug connection for engine wiring harness
G2/2 Magneton alternator 120A (Würth)
K5/7/1 Relay, potential 15/1 supply X23/1 Plug connection for instruments wiring
harness - engine wiring harness
K5/7/2 Relay, potential 15/2 supply
X24/1 Plug connection for instruments wiring
K8/1 Starter relay
harness - central print [1]
K8/2 Heating flange relay 300A
M1 Starter
M13 Fuel delivery pump
Ground points R27 Resistance
S1 Start switch
1 Battery X0/3/3 Weld point for instruments wiring harness,
11 Engine device carrier potential 31
13 Cab X0/3/ Weld point for instruments wiring harness,
16 Starter potential 31
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X1/2 Plug connection for engine wiring harness,
terminal 50
X1/5 Plug connection for potential 30, clock / radio
X1/8 Plug connection for central print supply,
potential 30, start switch
X1/11 Plug connection for central print supply,
potential 30
X1/12 Plug connection for engine print, potential 30
Edition 12-2005
4010-7
Sheet 2 4010-8
Sva 6-51402 EN
Diagnosis LED
for pre-glowing
SS05N002
Edition 12-2005
Designation of sections Electrical equipment
A# Power supply and starter A12 Central print (Würth or Berifors) X1/11 Plug connection for central print, potential 30
Sva 6-51402 EN
A14 Engine print (Würth or Berifors) X1/12 Plug connection for engine print, potential 30
B Heating flange
A50/1 Power module X1/21 Screw - plug connection for engine print,
C Fuel delivery pump potential 31
E10/1 Heating flange
D Alternator Magneton F1 Fuse, start switch supply X2/5 Screw - plug connection for engine print, Denso
(2nd alternator) F89 Fuse, potential 15 for engine alternator, potential 15
E Supply, potential 15/1 F93 Fuse, supply for clock, ADIC, radio, potential 30 X3/11 Plug connection for alternator
F200 Main fuse X5/1 Screw - plug connection, potential 31, central
G1 Battery print
# Variants on sheets 1, 3, 4 X18/1 Plug connection for instruments wiring harness
G2/2 Magneton alternator 120A
G2/2/2 2nd Magneton alternator 95A - central print [1]
K5/7/1 Relay, potential 15/1 supply X20/1 Plug connection for engine wiring harness
(Würth)
K5/7/2 Relay, potential 15/2 supply
K8/1 Starter relay X23/1 Plug connection for instruments wiring harness
- engine wiring harness
K8/2 Heating flange relay 300A
X24/1 Plug connection for instruments wiring harness
L20/1 Telltale, 2nd alternator
- central print [1]
L20/2 Telltale, 2nd alternator
Ground points M1 Starter
M13 Fuel delivery pump
1 Battery Q1 Master switch
11 Engine device carrier R27 Resistance
13 Cab S1 Start switch
16 Starter X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X1/2 Plug connection for engine wiring harness,
terminal 50
X1/5 Plug connection for potential 30, clock / radio
X1/8 Plug connection for central print supply,
potential 30, start switch
Edition 12-2005
4010-9
Sheet 3 4010-10
Sva 6-51402 EN
Diagnosis LED
for pre-glowing
SS05N003
Edition 12-2005
Designation of sections Electrical equipment
A# Power supply and starter A12 Central print (Würth or Berifors) X2/5 Screw - plug connection for engine print, Denso
Sva 6-51402 EN
A14 Engine print (Würth or Berifors) alternator, potential 15
B Heating flange
A50/1 Power module X3/11 Plug connection for alternator
C Fuel delivery pump X5/1 Screw - plug connection, potential 31, central
E10/1 Heating flange
D Alternator Denso F1 Fuse, start switch supply print
E Supply, potential 15/1 F89 Fuse, potential 15 for engine X18/1 Plug connection for instruments wiring harness
F93 Fuse, supply for clock, ADIC, radio, potential 30 - central print [1]
F200 Main fuse X20/1 Plug connection for engine wiring harness
# Variants on sheets 1, 2, 4 (Würth)
G1 Battery
G2/3 Denso alternator 140A X23/1 Plug connection for instruments wiring harness
K5/7/1 Relay, potential 15/1 supply - engine wiring harness
X24/1 Plug connection for instruments wiring harness
K5/7/2 Relay, potential 15/2 supply
- central print [1]
K8/1 Starter relay
K8/2 Heating flange relay 300A
M1 Starter
M13 Fuel delivery pump
R27 Resistance
Ground points S1 Start switch
X0/3/3 Weld point for instruments wiring harness,
1 Battery potential 31
11 Engine device carrier X0/3/ Weld point for instruments wiring harness,
13 Cab potential 31
16 Starter X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X1/2 Plug connection for engine wiring harness,
terminal 50
X1/5 Plug connection for potential 30, clock / radio
X1/8 Plug connection for central print supply,
potential 30, start switch
X1/11 Plug connection for central print, potential 30
X1/12 Plug connection for engine print, potential 30
X1/21 Screw - plug connection for engine print,
potential 31
Edition 12-2005
4010-11
Sheet 4 4010-12
Sva 6-51402 EN
Diagnosis LED
for pre-glowing
SS05N004
Edition 12-2005
Designation of sections Electrical equipment
A# Power supply, electrical battery A12 Central print (Würth or Berifors) X0/38/3 Weld point for additional line, electrical battery
Sva 6-51402 EN
main switch A14 Engine print (Würth or Berifors) main switch, potential 30
A50/1 Power module X0/38/4 Weld point for additional line, electrical battery
B Starter
E10/1 Heating flange main switch, potential 31
C Heating flange, fuel delivery X1/2 Plug connection for engine wiring harness,
F1 Fuse, start switch supply
pump terminal 50
F87 Fuse, electrical battery main switch,
D Magneton alternator potential 30 X1/5 Plug connection for potential 30, clock / radio
E Supply, potential 15/1 F89 Fuse, potential 15 for engine X1/8 Plug connection for central print supply,
F200 Main fuse potential 30, start switch
G1 Battery X1/11 Plug connection for central print, potential 30
# Variants on sheets 1, 2, 3 X1/12 Plug connection for engine print, potential 30
G2/2 Magneton alternator 120A
K5/7/1 Relay, potential 15/1 supply X1/21 Screw - plug connection for engine print,
K5/7/2 Relay, potential 15/2 supply potential 31
K5/54 Relay, electrical battery main switch [54] X2/5 Screw - plug connection for engine print, Denso
K8/1 Starter relay alternator, potential 15
X2/46a Plug connection for potential 58/31, electrical
K8/2 Heating flange relay 300A
battery main switch [46a]
M1 Starter
X2/46b Plug connection for potential 58/31, electrical
Ground points M13 Fuel delivery pump
battery main switch [X2/46b]
Q2 Electrical battery main switch
X3/11 Plug connection for alternator
1 Battery R27 Resistance
X5/1 Screw - plug connection, potential 31, central
11 Engine device carrier S1 Start switch
print
13 Cab S2/76 Switch, electrical battery main switch [BATT.-
16 Starter HS]
X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X0/38/1 Weld point for additional line, electrical battery
main switch, potential 58
X0/38/2 Weld point for additional line, electrical battery
main switch, potential 31
Edition 12-2005
4010-13
Sheet 5 4010-14
Sva 6-51402 EN
12 V
12 V
12 V
12 V
12 V
5V
Ground
Ground
12 V
Ground
Ground
12 V
DZG
Ground
NTC 32 kOhm to
102 Ohm
1V to approx. 2V
Ground
0.7V to 9V
PTC 1 kOhm to
4.6 kOhm
Ground
CAN L
Emergency
shut-down
Ground
CAN H
12 V
Signal
Ground
SS05N005
Edition 12-2005
Designation of sections Electrical equipment
A D supply+ A2 EEM2 control unit X3/20 Plug connection for engine speed sensor
Sva 6-51402 EN
A2/2 PCU electronic pumps - control unit X4/71 Plug connection for charger pressure,
B EEM2 - box with sensors and
A12 Central print (Würth or Berifors) charged air temperature sensor
PCU
A14 Engine print (Würth or Berifors) X9/7 Plug connection for fuel injection pump [7]
C Supply, EEM2 box
A60 ECCU2 X18/1 Plug connection for instruments wiring harness
B20 Engine speed sensor - central print [1]
B21 Test switch, fuel delivery pressure X20/1 Plug connection for engine wiring harness
B22 Engine temperature sensor (Würth)
B23 Water in fuel sensor X23/1 Plug connection for instruments wiring harness
B29 Sensor for charger pressure/charged air - engine wiring harness
temperature X24/3 Plug connection for instruments wiring
CN3a ECCU2 plug connection harness - cab wiring harness on right [3]
F21 Fuse, supply for D+ relay ECCU2, EDC X70 Plug connection for engine control unit EEM2
F30 Fuse, supply for engine print, potential 15/2
F92 Fuse, supply for EEM2, potential 30
F94 Fuse, supply for EEM2, PCU potential 30
F97 Supply for EEM2, potential 15
Ground points K5/3 Relay, engine print, potential 15
K5/11 Relay, potential D+ supply
K5/42 Relay D+ 2nd alternator
S6 Engine oil pressure switch
W1/4 Radio start plug connection
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/7/22 Weld point for wiring harness, cab, right D+
X1/3 Plug connection for fuel filter pressure sensor
X1/10 Screw connection for engine print, potential
30 EEM2
X1/11A Plug connection for central lubrication
X1/14 Screw connection for engine print, potential
30 EEM2, fuel delivery pump
X2/22 Plug connection for temperature sensor
EEM2 [22]
X3/12 Plug connection for “Water in fuel” sensor
X3/13 Plug connection for sensor B23
Edition 12-2005
4010-15
Sheet 6 4010-16
Sva 6-51402 EN
signal
switch
Steering
Brake light
Brake light
brake switch
GSV2
SS05N006
Edition 12-2005
Designation of sections Electrical equipment
A# Brake light A4 FMGR X18/1 Plug connection for instruments wiring harness
Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2] - central print [1]
B Reserve central print
A12 Central print (Würth or Berifors) X23/1 Plug connection for instruments wiring harness
C Reverse fan - engine wiring harness
A60 ECCU2
A62 Reverse fan X24/2 Plug connection for wiring harness, cab, right
# Variant on sheet 7 CN3a ECCU2 plug connection X24/3 Plug connection for instruments wiring harness
CN3b ECCU2 plug connection - cab wiring harness on right [3]
F8 Fuse, reserve, potential 30
F15 Fuse, reserve, potential 15/2
F46 Fuse, relay, brake light, Optistop,
potential 15/1
K5/12 Relay, brake light, Optistop
K5/16 Reverse fan relay
S2/74 Reverse fan pushbutton
S5 Brake light switch
S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
Ground points potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/30/1 Weld point for additional line, reverse fan,
potential 31
X0/30/2 Weld point for additional line, reverse fan,
potential +
X2/25 Plug connection for reverse fan [LU]
X3/5 Plug connection, reserve
X4/14 Plug connection for brake light, Optistop
X4/66 Plug connection for reverse fan [LU]
X10/8 Plug connection for wiring harness, cab, left -
central print [8]
Edition 12-2005
4010-17
Sheet 7 4010-18
Sva 6-51402 EN
signal
switch
Steering
Brake light
Brake light
brake switch
GSV2
SS05N007
Edition 12-2005
Designation of sections Electrical equipment
A# Brake light for reverse travel A4 FMGR X2/25 Plug connection for reverse fan [LU]
Sva 6-51402 EN
equipment A4/2 FMGR plug connection - dark grey [2] X3/5 Plug connection, reserve
B Reserve central print A12 Central print (Würth or Berifors) X4/14 Plug connection for brake light, Optistop
A60 ECCU2 X4/66 Plug connection for reverse fan [LU]
C Reverse fan
A62 Reverse fan X10/8 Plug connection for wiring harness, cab, left -
CN3a ECCU2 plug connection central print [8]
# Variant on sheet 6 CN3b ECCU2 plug connection X18/1 Plug connection for instruments wiring harness
F8 Fuse, reserve, potential 30 - central print [1]
F15 Fuse, reserve, potential 15/2 X23/1 Plug connection for instruments wiring harness
F46 Fuse, relay, brake light, Optistop, - engine wiring harness
potential 15/1 X24/2 Plug connection for wiring harness, cab, right
K5/12 Relay, brake light, Optistop X24/3 Plug connection for instruments wiring harness
K5/16 Reverse fan relay - cab wiring harness on right [3]
S2/74 Reverse fan pushbutton
S5 Brake light switch
S5/1 Brake light switch for reverse travel
equipment [BREMSL]
Ground points S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/27/12 Weld point for reverse travel equipment wiring
harness, brake
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/30/1 Weld point for additional line, reverse fan,
potential 31
X0/30/2 Weld point for additional line, reverse fan,
potential +
Edition 12-2005
4010-19
Sheet 8 4010-20
Sva 6-51402 EN
SS05N008
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
F10 Fuse, supply, ECCU2, potential 30
B Blower (heating)
F17 Fuse, blower, heating, potential 15/2
F48 Fuse, supply for seat, “Italy” trailer brake,
potential 15/1
K5/37 Relay for Italy trailer brake
M3 Heating blower motor
S7 Switch for handbrake
S50 Trailer brake valve pushbutton
S50/1 Blower switch 1-2-3
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/15/1 Weld point for additional line, hydraulic trailer
brake, potential 31
X0/15/2 Weld point for additional line, hydraulic trailer
brake, potential 15/1
X1/26 Plug connection for potential 15/2, 15 A
heating blower
Ground points X4/25 Plug connection for handbrake switch [25]
11 Engine device carrier X4/50 Plug connection for heating
X4/51 Plug connection for “Italy” trailer brake,
central print [ITALB]
X4/52 Plug connection for additional line, Italy trailer
brake, trailer brake [MGV]
X24/2 Plug connection for wiring harness, cab, right
Y50 Trailer brake solenoid valve
Edition 12-2005
4010-21
Sheet 9 4010-22
Sva 6-51402 EN
SS05N009
Edition 12-2005
Designation of sections Electrical equipment
A Warning light system A12 Central print (Würth or Berifors) X0/3/21 Weld point for instruments wiring harness,
Sva 6-51402 EN
A13 Roof print potential 15, turn signal
B SBB light, left
E3 Front left side marker light X0/3/3 Weld point for instruments wiring harness,
C SBB light, right potential 31
E4 Rear left side marker light
D BB light, left E6 Front right side marker light X0/6/1 Weld point for wiring harness, cab, left,
E BB light, right E7 Rear right side marker light potential 31
E12 Brake light, left X0/7/18 Weld point for wiring harness, cab, right 58R
E13 Brake light, right X0/7/5 Weld point for wiring harness, cab, right,
# Variants on sheets 10, 11 potential 31
E14 Turn signal, front right
E15 Turn signal, rear right X0/28/12 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left X0/28/13 Weld point for roof wiring harness, potential 31
E17 Turn signal, front left X0/28/3 Weld point for roof wiring harness, potential 58
F5 Fuse, supply for turn signal, potential 15/1 X6/12L Plug connection for turn signal / side marker
F24 Fuse, parking light, rear left, ADIC, switch light, front left [BB-L]
lighting for instrument panel, front and rear X6/12R Plug connection for turn signal / side marker
trailer sockets, ISO BUS light, front right [BB-R]
F25 Fuse, parking light, rear right, ARU, switch X10/8 Plug connection for wiring harness, cab, left -
lighting for control panel, mobile phone central print [8]
Ground points X10/11 Plug connection for roof print supply
socket
F33 Fuse, supply for hazard warning light, X10/12 Plug connection for roof wiring harness
8 Roof, front right
potential 30 X14/8 Plug connection for instruments wiring harness
11 Engine device carrier
F60 Fuse, side marker light, front left, licence - steering column [8]
plate lights, roof X14/14 Plug connection for roof supply [14]
F61 Fuse, side marker light front right, ICU switch X14/15 Plug connection for central print - wiring
lighting for roof, spot light, radio and ASW harness for roof supply [15]
panel lighting, activation of all work lamps X18/1 Plug connection for instruments wiring harness
K2 Indicator relay - central print [1]
K5/10 Relay, light, potential 58 X24/1 Plug connection for instruments wiring harness
S2/5 Hazard warning switch [WARN] - central print [1]
S4/2 Turn signal switch, steering column X24/2 Plug connection for wiring harness, cab, right
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
Edition 12-2005
4010-23
Sheet 10 4010-24
Sva 6-51402 EN
SS05N010
Edition 12-2005
Designation of sections Electrical equipment
A# Warning light system for ISO A12 Central print (Würth or Berifors) X0/3/21 Weld point for instruments wiring harness,
Sva 6-51402 EN
BUS and electrical main battery A13 Roof print potential 15, turn signal
switch E3 Front left side marker light X0/3/3 Weld point for instruments wiring harness,
E4 Rear left side marker light potential 31
B SBB light, left
E6 Front right side marker light X0/6/1 Weld point for wiring harness, cab, left,
C SBB light, right potential 31
E7 Rear right side marker light
D BB light, left E12 Brake light, left X0/7/18 Weld point for wiring harness, cab, right 58R
E BB light, right E13 Brake light, right X0/7/5 Weld point for wiring harness, cab, right,
E14 Turn signal, front right potential 31
E15 Turn signal, rear right X0/28/12 Weld point for roof wiring harness, potential 31
# Variants on sheets 9, 11 X0/28/13 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left
E17 Turn signal, front left X0/28/3 Weld point for roof wiring harness, potential 58
F5 Fuse, supply for turn signal, potential 15/1 X2/87 Plug connection for cab wiring harness on
F24 Fuse, parking light, rear left, ADIC, switch right - instruments wiring harness ISO-BUS
lighting for instrument panel, front and rear X6/12L Plug connection for turn signal / side marker
trailer sockets, ISO BUS light, front left [BB-L]
F25 Fuse, parking light, rear right, ARU, switch X6/12R Plug connection for turn signal / side marker
lighting for control panel, mobile phone socket light, front right [BB-R]
Ground points X10/8 Plug connection for wiring harness, cab, left -
F33 Fuse, supply for hazard warning light,
potential 30 central print [8]
11 Engine device carrier
F60 Fuse, side marker light, front left, licence plate X10/11 Plug connection for roof print supply
lights, roof X10/12 Plug connection for roof wiring harnessPlug
F61 Fuse, side marker light front right, ICU switch connection for roof wiring harness
lighting for roof, spot light, radio and ASW panel X14/8 Plug connection for instruments wiring harness
lighting, activation of all work lamps - steering column [8]
K2 Indicator relay X14/14 Plug connection for roof supply [14]
K5/10 Relay, light, potential 58 X14/15 Plug connection for central print - wiring
S2/5 Hazard warning switch [WARN] harness for roof supply [15]
S4/2 Turn signal switch, steering column X18/1 Plug connection for instruments wiring harness
X0/3/1 Weld point for instruments wiring harness, - central print [1]
potential 58L X24/1 Plug connection for instruments wiring harness
- central print [1]
X0/3/10 Weld point for instruments wiring harness, turn
signal on right X24/2 Plug connection for wiring harness, cab, right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
Edition 12-2005
4010-25
Sheet 11 4010-26
Sva 6-51402 EN
SS05N011
Edition 12-2005
Designation of sections Electrical equipment
A Warning light system A12 Central print (Würth or Berifors) X0/3/10 Weld point for instruments wiring harness, turn
Sva 6-51402 EN
A13 Roof print signal on right
B Additional rear left light
E3 Front left side marker light X0/3/11 Weld point for instruments wiring harness, turn
C SBB light, left signal on left
E3/1 Additional front left side marker light
D SBB light, right E4 Rear left side marker light X0/3/21 Weld point for instruments wiring harness,
E Additional rear right light E6 Front right side marker light potential 15, turn signal
E6/1 Additional front right side marker light X0/3/3 Weld point for instruments wiring harness,
F Additional front left light
E7 Rear right side marker light potential 31
G BB light, left and right X0/6/1 Weld point for wiring harness, cab, left,
E12 Brake light, left
H Additional front right light potential 31
E12/1 Additional rear left side marker light
E13 Brake light, right X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/5 Weld point for wiring harness, cab, right,
# Variants on sheets 9, 10 E13/1 Additional rear right side marker light
potential 31
E14 Turn signal, front right
X0/28/12 Weld point for roof wiring harness, potential 31
E15 Turn signal, rear right
X0/28/13 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left
X0/28/3 Weld point for roof wiring harness, potential 58
E17 Turn signal, front left
X6/12L Plug connection for turn signal / side marker
F5 Fuse, supply for turn signal, potential 15/1
light, front left [BB-L]
Ground points F24 Fuse, parking light, rear left, ADIC, switch
X6/12R Plug connection for turn signal / side marker
lighting for instrument panel, front and rear
light, front right [BB-R]
11 Engine device carrier trailer sockets, ISO BUS
X10/8 Plug connection for wiring harness, cab, left -
F25 Fuse, parking light, rear right, ARU, switch
central print [8]
lighting for control panel, mobile phone socket
X10/11 Plug connection for roof print supply
F33 Fuse, supply for hazard warning light,
potential 30 X10/12 Plug connection for roof wiring harness
X14/8 Plug connection for instruments wiring harness
F60 Fuse, side marker light, front left, licence plate
- steering column [8]
lights, roof
X14/14 Plug connection for roof supply [14]
F61 Fuse, side marker light front right, ICU switch
lighting for roof, spot light, radio and ASW panel X14/15 Plug connection for central print - wiring
lighting, activation of all work lamps harness for roof supply [15]
K2 Indicator relay X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/10 Relay, light, potential 58
X24/1 Plug connection for instruments wiring harness
S2/5 Hazard warning switch [WARN]
- central print [1]
S4/2 Turn signal switch, steering column
X24/2 Plug connection for wiring harness, cab, right
X0/3/1 Weld point for instruments wiring harness,
potential 58L
Edition 12-2005
4010-27
Sheet 12 4010-28
Sva 6-51402 EN
SS05N012
Edition 12-2005
Designation of sections Electrical equipment
A Auxiliary headlight and 4 work A12 Central print (Würth or Berifors) X0/5/1 Weld point for engine hood wiring harness,
Sva 6-51402 EN
lamps A13 Roof print potential 31
A64 Work lamp panel X0/6/1 Weld point for wiring harness, cab, left,
B Headlight
E1 Headlight, left potential 31
C Low beam, high beam X0/7/5 Weld point for wiring harness, cab, right,
E2 Headlight, right
D Work lamp, fender E8 Work lamp, fender, left potential 31
E9 Work lamp, fender, right X4/32 Plug connection for headlight
E21 Auxiliary headlight, left X4/40 [X4/ESW] Plug connection for roof print,
E22 Auxiliary headlight, right auxiliary headlight
E33 Work lamp on roof, front, centre, left [M] X5/7 Socket for auxiliary headlight and work lamp,
E34 Work lamp on roof, front, centre, right [M] front left
X5/8 Socket for auxiliary headlight and work lamp,
E37 Work lamp on roof, front, outside, left [A]
front right
E38 Work lamp on roof, front, outside, right [A]
X6/6 Plug connection for instruments wiring
F7 Fuse, relay 56a, potential 30
harness
F11 Fuse, relay, work lamp, fender, potential 30
X10/8 Plug connection for wiring harness, cab, left -
F12 Fuse, light switch, potential 30
central print [8]
F34 Fuse, headlight, roof, right 56b
X10/11 Plug connection for roof print supply
Ground points F35 Fuse, headlight, roof, left 56b X14/8 Plug connection for instruments wiring harness
F36 Fuse, headlight, engine hood, right 56b - steering column [8]
7 Roof, front left F37 Fuse, headlight, engine hood, left 56b X14/14 Plug connection for roof supply [14]
8 Roof, front right F40 Fuse, supply for steering column switch, X14/15 Plug connection for central print - wiring
11 Engine device carrier potential 15/1 harness for roof supply [15]
K5/5 Switchover relay for high beam X16/5 Screw connection for roof print ground point
K5/6 Switchover relay for low beam X18/1 Plug connection for instruments wiring harness
K5/9 Relay, work lamp, fender - central print [1]
K5/56a Relay for high beam X24/1 Plug connection for instruments wiring harness
K5/56b Relay for low beam - central print [1]
S2/1 Light switch [LICHT] X24/2 Plug connection for wiring harness, cab, right
S2/17 Switch for auxiliary headlight X24/6 Plug connection for work lamp panel
S4/1 High/low beam steering column switch
V3/9 Diode
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/3 Weld point for instruments wiring harness,
potential 31
Edition 12-2005
4010-29
Sheet 14 4010-30
Sva 6-51402 EN
SS05N014
Edition 12-2005
Designation of sections Electrical equipment
A Work lamp at rear outside A13 Roof print X4/21 Plug connection for work lamp outside right
Sva 6-51402 EN
A60 ECCU2 at rear
B Work lamp at rear inside
A64 Work lamp panel X4/22 Plug connection for work lamp inside right at
C# 4 + 2 front work lamps rear
CN3a ECCU2 plug connection
D Work lamp, BB light E23/1 Work lamp, roof, at rear, inside left X4/23 Plug connection for work lamp at rear outside
E23/2 Work lamp, roof, at rear, outside left left
E24/1 Work lamp, roof, at rear, inside right X4/24 Plug connection for work lamp inside left at
# Variant on sheet 17
E24/2 Work lamp, roof, at rear, outside right rear
E33 Work lamp, roof, at front centre left [M] X4/38 [X4/ASW] Plug connection for roof print, work
lamp at front
E34 Work lamp, roof, at front centre right [M]
E35 Work lamp, at front left on turn signal / side X5/7 Socket for auxiliary headlight and work lamp,
marker light front left
X5/8 Socket for auxiliary headlight and work lamp,
E36 Work lamp, at front right on turn signal / side
front right
marker light
X6/12L Plug connection for turn signal / side marker
E37 Work lamp on roof, front, outside, left [A]
light, front left [BB-L]
E38 Work lamp on roof, front, outside, right [A]
X6/12R Plug connection for turn signal / side marker
E44 Work lamp on roof, at front inside left [I]
light, front right [BB-R]
Ground points E45 Work lamp on roof, at front inside right [I]
X10/4 Plug connection for EDC print armrest (GSV)
F67 Fuse, 4 work lamps, front outside
X10/12 Plug connection for roof wiring harness
7 Roof, front left F68 Fuse, 4 rear work lamps, ASW panel supply
X10/13 Plug connection for roof wiring harness
8 Roof, front right for potential 30
X14/14 Plug connection for roof supply [14]
F70 Fuse, 2 rear work lamps
X16/4 Screw connection for potential 30, supply for
F101 Fuse, ASW panel supply for 4 front work
roof print
lamps, work lamp on BB light
X24/3 Plug connection for instruments wiring harness
F102 Fuse, 4+2 front work lamps
- cab wiring harness on right [3]
K5/30 Relay 4 rear work lamps (outside)
X24/6 Plug connection for work lamp panel
K5/31 Relay 4 front work lamps (outside)
K5/33 Relay 4+2 front work lamps
S2/63/2 Switch for 4+2 front work lamps
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/2 Weld point for roof wiring harness, work lamp 2
X0/28/6 Weld point for roof wiring harness, work lamp 2
Edition 12-2005
4010-31
Sheet 17 4010-32
Sva 6-51402 EN
SS05N017
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A18 Electronics for Xenon work lamp, right
A19 Electronics for Xenon work lamp, left
# Variant on sheet 14
A64 Work lamp panel
E27 Work lamp, roof, at rear, XENON, left
E29 Work lamp, roof, at rear, XENON, right
F68 Fuse, 4 rear work lamps, ASW panel supply for
potential 30
F70 Fuse, 2 rear work lamps
K5/30 Relay 4 rear work lamps (outside)
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/2 Weld point for roof wiring harness, work lamp 2
X4/21 Plug connection for work lamp outside right at
rear
X4/22 Plug connection for work lamp inside right at
rear
X4/23 Plug connection for work lamp outside left at
Ground points
rear
X4/24 Plug connection for work lamp inside left at rear
X10/12 Plug connection for roof wiring harness
X10/13 Plug connection for roof wiring harness
X16/4 Screw connection for potential 30, supply for
roof print
X24/6 Plug connection for work lamp panel
Edition 12-2005
4010-33
Sheet 18 4010-34
Sva 6-51402 EN
ASW - engine hood
SS05N018
Edition 12-2005
Designation of sections Electrical equipment
A Work lamp, engine hood A13 Roof print X1/7 Plug connection for diagnosis, engine
Sva 6-51402 EN
A14 Engine print (Würth or Berifors) preheating [DIAG]
B WEBASTO engine preheating
A25 Engine preheater ECU X1/9 Screw connection for fuel filter heating
C Licence plate lights, roof A26 WEBASTO clock X1/16 Plug connection for clock timer - control unit,
D Door contact switch A50/2 Power module engine preheating [16]
A64 Work lamp panel X1/17 Screw connection for reverse fan
E Doorway lights
E5/3 Licence plate lights, roof, left X1/21 Screw - plug connection for engine print,
F Interior light E5/4 Licence plate lights, roof, right potential 31
E19 Interior light X1/22 Screw - plug connection for engine print,
E30 Doorway lights, left potential 31
E61 Work lamp, left X2/5 Screw - plug connection for engine print, Denso
alternator, potential 15
E62 Work lamp, right
X2/18 Plug connection for fuel delivery pump,
F89 Fuse, potential 15 for engine
engine preheating
F95 Fuse, reverse fan
X2/24 Plug connection for supply for engine
F98 Fuse, fuel filter heating, potential 30
preheating, potential 30
F104 Fuse, engine preheater, potential 30
X3/28 Plug connection for work lamp, engine hood
K4/2/2 Time relay, interior light and horn
M14 Fuel delivery pump, engine preheating X4/47 Plug connection for engine preheating
Ground points S24/1 Switch for door contact, left precaution [WEBASTO]
S24/2 Switch for door contact, right X4/53 Plug connection for engine preheating clock
X0/3/ Weld point for instruments wiring harness, X4/65L Plug connection for licence plate lights, roof,
potential 31 left
X0/3/9 Weld point for instruments wiring harness, X4/67 Plug connection for work lamp, front left
potential 30 X6/12L Plug connection for turn signal / side marker
X0/5/1 Weld point for engine hood wiring harness, light, front left [BB-L]
potential 31 X6/14 Plug connection for engine preheating ECU
X0/20/1 Weld point for additional line, Webasto heating, X10/11 Plug connection for roof print supply
potential 31
X10/13 Plug connection for roof wiring harness
X0/28/11 Weld point for roof wiring harness, potential 58
X10/14 Plug connection for wiring harness for roof
X0/28/12 Weld point for roof wiring harness, potential 31 supply
X0/28/13 Weld point for roof wiring harness, potential 31 X14/14 Plug connection for roof supply [14]
X0/28/14 Weld point for roof wiring harness, potential 31 X20/1 Plug connection for engine wiring harness
X0/28/15 Weld point for roof wiring harness, potential 31 (Würth)
X0/28/4 Weld point for roof wiring harness, potential 30 X23/1 Plug connection for instruments wiring harness
X0/28/5 Weld point for roof wiring harness, supply for - engine wiring harness
time relay X24/6 Plug connection for work lamp panel
X0/28/9 Weld point for roof wiring harness, potential 31
Edition 12-2005
4010-35
Sheet 19 4010-36
Sva 6-51402 EN
SS05N019
Edition 12-2005
Designation of sections Electrical equipment
A Mirror heating A5/1 All-round light, left X6/24 Plug connection for electric mirror, right
Sva 6-51402 EN
A5/2 All-round light, right [SPIEGEL]
B Electrical mirror adjustment
A13 Roof print X9/1 Plug connection for switch for mirror
C Spot light adjustment
A40 Control unit - mirror adjustment
D All-round lights (can be plugged A41 Electric mirror heating and adjustment X10/12 Plug connection for roof wiring harness
in) A42 Electric mirror heating and adjustment X19/1 Plug connection for all-round light, left
A64 Work lamp panel X19/2 Plug connection for all-round light, right
# Variants on sheets 20, 21 E18/1 Heated mirror, left X24/6 Plug connection for work lamp panel
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW
panel supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
Ground points X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X3/80 Plug connection for mirror adjustment, roof
print [X3/13]
X4/15 Plug connection for heated mirror, roof
print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
X6/23 Plug connection for rear wiper motor
Edition 12-2005
4010-37
Sheet 20 4010-38
Sva 6-51402 EN
SS05N020
Edition 12-2005
Designation of sections Electrical equipment
A Mirror heating A5/1 All-round light, left X6/24 Plug connection for electric mirror, right
Sva 6-51402 EN
A5/2 All-round light, right [SPIEGEL]
B Electrical mirror adjustment
A13 Roof print X9/1 Plug connection for switch for mirror adjustment
C Spot light X10/12 Plug connection for roof wiring harness
A40 Control unit - mirror adjustment
D All-round light carrier A41 Electric mirror heating and adjustment X19/1 Plug connection for all-round light, left
A42 Electric mirror heating and adjustment X19/2 Plug connection for all-round light, right
# Variants on sheets 19, 21 A64 Work lamp panel X24/6 Plug connection for work lamp panel
E18/1 Heated mirror, left
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
Ground points X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X3/80 Plug connection for mirror adjustment, roof
print [X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
X6/23 Plug connection for rear wiper motor
Edition 12-2005
4010-39
Sheet 21 4010-40
Sva 6-51402 EN
SS05N021
Edition 12-2005
Designation of sections Electrical equipment
A Mirror heating A5/1 All-round light, left X6/23 Plug connection for rear wiper motor
Sva 6-51402 EN
A5/2 All-round light, right X6/24 Plug connection for electric mirror, right
B Electrical mirror adjustment
A13 Roof print [SPIEGEL]
C Spot light X9/1 Plug connection for switch for mirror adjustment
A40 Control unit - mirror adjustment
D All-round lights (magnetic) A41 Electric mirror heating and adjustment X10/12 Plug connection for roof wiring harness
A42 Electric mirror heating and adjustment X24/6 Plug connection for work lamp panel
# Variants on sheets 19, 20 A64 Work lamp panel
E18/1 Heated mirror, left
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
Ground points X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X3/80 Plug connection for mirror adjustment, roof
print [X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/33 Socket for all-round light, left, magnetic
X4/34 Socket for all-round light, right, magnetic
X4/39 Plug connection for switch for heated mirror,
roof print [39]
Edition 12-2005
4010-41
Sheet 22 4010-42
Sva 6-51402 EN
SS05N022
Edition 12-2005
Designation of sections Electrical equipment
A Radio preparation A6 Radio X2/91 Plug connection for roof print, rear heated
Sva 6-51402 EN
A6/A Radio plug connection windscreen [91]
B Supply, roof
A6/B Loudspeaker plug connection X4/41 Plug connection for switch for front heated
C Heated windscreen, front windscreen
A12 Central print (Würth or Berifors)
D Heated windscreen, rear A13 Roof print X4/42 Plug connection for switch for rear heated
A14 Engine print (Würth or Berifors) windscreen
B14 Loudspeaker, left X10/11 Plug connection for roof print supply
B15 Loudspeaker, right X10/14 Plug connection for wiring harness for roof
E25 Heated windscreen, front supply
E26 Heated windscreen, rear X14/14 Plug connection for roof supply [14]
F45 Fuse, supply for roof, ICU potential 15/1 X14/15 Plug connection for central print - wiring
harness for roof supply [15]
F76 Fuse, heated windscreen, rear
X16/5 Screw connection for roof print ground point
F77 Fuse, heated windscreen, front
F93 Fuse, supply for clock, ADIC, radio, potential 30 X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/29 Relay supply for potential, potential 15/1
X20/1 Plug connection for engine wiring harness
K6/7 Relay for rear heated windscreen
(Würth)
K6/8 Relay for front heated windscreen
X23/1 Plug connection for instruments wiring harness
Ground points S2/16/1 Switch for rear heated windscreen [HZS HI] - engine wiring harness
S2/16/2 Switch for front heated windscreen [HZS VO]
7 Roof, front left W6 Antenna
11 Engine device carrier X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/39/1 Welded point for additional line, rear heated
windscreen
X1/24 Screw connection for potential 30, roof print,
heated windscreens
X2/90 Plug connection for roof print, front heated
windscreen [90]
Edition 12-2005
4010-43
Sheet 23 4010-44
Sva 6-51402 EN
SS05N023
Edition 12-2005
Designation of sections Electrical equipment
A# Air conditioning A13 Roof print X20/1 Plug connection for engine wiring harness
Sva 6-51402 EN
A14 Engine print (Würth or Berifors) (Würth)
A20 Air conditioning - control X23/1 Plug connection for instruments wiring harness
# Variant on sheet 24 - engine wiring harness
A22 Blower - control
F65 Fuse, air conditioning control Y13 Magnetic coupling for air conditioning
F66 Fuse, blower / air conditioning compressor
F74 Fuse, reserve, potential 30
F90 Fuse, air conditioning compressor, pressure
switch
F103 Fuse, air conditioning, pressure switch
K5/32 Relay supply, D+ air conditioning
K5/36 Reserve
M12 Engine blower, air conditioning
R9 Temperature sensor, air conditioning
R10 Potentiometer for air conditioning - temperature
R11 Potentiometer for air conditioning - roof blower
S30 Pressure switch, air conditioning
Ground points W2 Line for temperature sensor, sheathed
X0/4/4 Weld point for engine wiring harness,
potential 31
X2/9 Plug connection for roof print supply for
blower
X2/14 Plug connection for air conditioning
X2/20 Plug connection for air conditioning blower
motor
X4/16 Plug connection for reserve
X4/44 Plug connection for supply for air conditioning
control
X4/73 Plug connection for temperature sensor
X4/74 Plug connection for blower potentiometer
X4/75 Plug connection for air conditioning control
potentiometer
X10/11 Plug connection for roof print supply
X10/14 Plug connection for wiring harness for roof
supply
Edition 12-2005
4010-45
Sheet 24 4010-46
Sva 6-51402 EN
SS05N024
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
trailer brake A13 Roof print
B Air cushion seat F65 Fuse, air conditioning control
F66 Fuse, blower / air conditioning
C# Blower (roof)
K5/32 Relay supply, D+ air conditioning
M7 Motor for pneumatic seat
# Variant on sheet 23 M10 Motor for blower, roof
S50/2 Blower switch 1-2-3, roof
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X2/9 Plug connection for roof print supply for blower
X4/12 Plug connection for radar sensor
X4/61 Plug connection for Grammer seat
X24/2 Plug connection for wiring harness, cab, right
Ground points
Edition 12-2005
4010-47
Sheet 25 4010-48
Sva 6-51402 EN
SS05N025
Edition 12-2005
Designation of sections Electrical equipment
A Horn A12 Central print (Würth or Berifors) X10/14 Plug connection for wiring harness for roof
Sva 6-51402 EN
A13 Roof print supply
B Steering column switch
F26 Fuse, parallel wiper, horn, interval relay, X14/8 Plug connection for instruments wiring harness
C Parallel wipers, front potential 15/2 - steering column [8]
D Windscreen washing system, F63 Fuse, rear wiper X14/15 Plug connection for central print - wiring
front F64 Front wiper for hinged windscreen harness for roof supply [15]
E Windscreen washing system, H1 Signal horn X18/1 Plug connection for instruments wiring harness
rear K3 Interval relay - central print [1]
M2/1 Motor for parallel wipers, front X23/1 Plug connection for instruments wiring harness
F Angled wiper, front
M2/2 Motor for angled wiper, front - engine wiring harness
G Angled wiper, rear X24/1 Plug connection for instruments wiring harness
M4/2 Wiper motor, rear
M5 Motor for windscreen washing system, rear - central print [1]
M6 Motor for windscreen washing system, front
S2/30 Switch for wiper/washing system, rear [Wi.hi]
S4/3 Steering column switch for wiper/washing
system
X0/3/ Weld point for instruments wiring harness,
potential 31
Ground points
X0/5/1 Weld point for engine hood wiring harness,
potential 31
X0/6/1 Weld point for wiring harness, cab, left,
potential 31
X0/28/20 Weld point for roof wiring harness, potential 53
X3/28 Plug connection for work lamp, engine hood
and horn
X4/1 Plug connection for wiper motor, hinged
screen, front [Wi-VO]
X4/17 Plug connection for roof print, wiper motor,
front [17]
X4/65 Plug connection for roof print, wiper motor,
rear [65]
X5/55 Plug connection for parallel wiper, front
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/23 Plug connection for rear wiper motor
X10/11 Plug connection for roof print supply
Edition 12-2005
4010-49
Sheet 26 4010-50
Sva 6-51402 EN
SS05N026
Edition 12-2005
Designation of sections Electrical equipment
A Power socket, front A12 Central print (Würth or Berifors) X0/6/5 Weld point for wiring harness, cab, left,
Sva 6-51402 EN
A13 Roof print potential R
B Socket, front
A16 EDC print X0/7/10 Weld point for wiring harness, cab, right, radar
C Socket, rear (trailer) A55 EDC box sensor
D Power socket 1, rear A60 ECCU2 X0/25/2 Weld point for wiring harness, control panel,
B16 Radar sensor right, potential 58
E Power socket 2, rear X0/7/5 Weld point for wiring harness, cab, right,
(preparation) CN2/E ECCU2 plug connection
CN3b ECCU2 plug connection potential 31
F Power socket F2 Fuse, power socket for cab, potential 30 X1/6/1 Screw connection for 2nd power socket 40 A
G ASR with radar sensor F3 Fuse, 1st power socket for potential 30 X1/6/2 Screw connection for 1st power socket 40 A
F4 Fuse, 2nd power socket for potential 30 X1/31 Screw connection for engine print, power
socket, front, potential 30
F29 Fuse, supply to front and rear power sockets,
standard signal socket, reverse fan, X1/60 Screw connection for power socket, cab 30 A
potential 15/2 X2/4/1 Plug connection for central print,
F31 Fuse, supply for radar sensor, potential 15/2 potential 15/2
F38 Fuse, trailer socket, potential 58L front and X2/4/2 Screw - plug connection for potential 15/2
rear X3/1 Radar sensor plug connection
F39 Fuse, trailer socket, potential 58R front and X4/12 Radar sensor plug connection
rear X5/1 Screw - plug connection, potential 31, central
Ground points print
F52 Fuse, trailer socket for turn signal, right front
and rear X6/12 Plug connection for wiring harness, cab, left -
11 Engine device carrier 7-pin trailer socket, front [7 Pol.Vo]
F53 Fuse, trailer socket for turn signal, left front
and rear X6/21 Plug connection for 7-pin trailer socket, front
F55 Fuse, trailer socket for brake light, front and [7pol.vo]
rear X10/1 Trailer socket, 7-pin, rear
F99 Fuse, front power socket X10/2 Trailer socket, 7-pin, front
S2/73 Slip control switch [ASR] X10/4 Plug connection for EDC print armrest (GSV)
X0/6/1 Weld point for wiring harness, cab, left, X10/8 Plug connection for wiring harness, cab, left -
potential 31 central print [8]
X0/6/2# Weld point for wiring harness, cab, left, X10/9 Plug connection for wiring harness, cab, right
potential 58L - control panel
X0/6/3 Weld point for wiring harness, cab, left, X14/1 1st power socket, 40 A rear
potential L X14/30 Power socket for cab 30 A
X0/6/4 Weld point for wiring harness, cab, left, X15 Power socket, front
potential 58R X24/2 Plug connection for wiring harness, cab, right
Edition 12-2005
4010-51
Sheet 27 4010-52
Sva 6-51402 EN
If filter heating is fitted, remove line G FILTERHZG and
plug in line B146
SS05N027
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A12 Central print (Würth or Berifors)
B Filter heating (preparation)
A14 Engine print (Würth or Berifors)
C Supply for ADIC
A65 KEY PADS
CN1 ADIC plug connection
# Variant on sheet 28 CN3 ADIC plug connection
F6 Fuse, ADIC, keypads, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
X0/3/22 Weld point for instruments wiring harness,
potential 15/1
X0/3/5 Weld point for instruments wiring harness,
Ground points potential 31
16 Starter X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/4/4 Weld point for engine wiring harness, potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X4/63 Keypads plug connection
X6/6 Plug connection for instruments wiring harness
X18/1 Plug connection for instruments wiring harness
- central print [1]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
Edition 12-2005
4010-53
Sheet 28 4010-54
Sva 6-51402 EN
If filter heating is fitted, remove line G FILTERHZG and
plug in line B146
SS05N028
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A12 Central print (Würth or Berifors)
B Filter heating (preparation)
A14 Engine print (Würth or Berifors)
C# Supply for ADIC, ISO BUS
A65 KEY PADS
CN1 ADIC plug connection
# Variant on sheet 27 CN3 ADIC plug connection
F6 Fuse, ADIC, keypads, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
X0/3/22 Weld point for instruments wiring harness,
potential 15/1
X0/3/ Weld point for instruments wiring harness,
Ground points potential 31
16 Starter X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/4/4 Weld point for engine wiring harness, potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X4/63 Keypads plug connection
X6/6 Plug connection for instruments wiring harness
X18/1 Plug connection for instruments wiring harness
- central print [1]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
Edition 12-2005
4010-55
Sheet 29 4010-56
Sva 6-51402 EN
Ground
RS 232 out
Transmission speed
signal
PTO shaft speed
Check for alternator D+
Check for brake fluid level
Radar screen
50% signal, rear power lift
Ground
SS05N029
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A12 Central print (Würth or Berifors)
B ADIC
B2/1 Sensor for tank content, left
C Socket, diagnosis ADIC
B3 Sensor for compressed air
CN1 ADIC plug connection
CN2 ADIC plug connection
CN3 ADIC plug connection
S13 Test switch for brake fluid
S22 Test switch for coolant level
X0/3/12 Weld point for instruments wiring harness,
handbrake check
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X4/62 Plug connection for diagnosis, ADIC
Ground points
X6/6 Plug connection for instruments wiring harness
X6/8 Plug connection for standard signal
socket [NORMS]
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/11 Plug connection for standard signal socket,
instruments wiring harness [NORMS]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
X29 Standard signal socket
Edition 12-2005
4010-57
Sheet 30 4010-58
Sva 6-51402 EN
SS05N030
Edition 12-2005
Designation of sections Electrical equipment
A Speed sensors, PTO, front and A12 Central print (Würth or Berifors)
Sva 6-51402 EN
rear A60 ECCU2
B Switch for reducing speed B7 Rear PTO shaft speed sensor
B8 Front PTO shaft speed sensor
C Switch for HTS
CN2/E ECCU2 plug connection
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
F32 Fuse, supply for PTO sensors, potential 15/2
S2/15/6 HTS switch [HTS]
S2/15/7 Speed reduction switch
[DREHZAHLABSENKUNG]
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 15
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
Ground points right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X3/21 Plug connection for front PTO shaft speed
sensor [PTO]
X23/2 Plug connection for wiring harness, cab, right
- engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
X24/5 Plug connection for wiring harness, cab, right
- control panel
Edition 12-2005
4010-59
Sheet 31 4010-60
Sva 6-51402 EN
SS05N031
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A16 EDC print
B# Socket, mobile phone, left
E11 Cigarette lighter, right [E11]
C Cigarette lighter with socket on
E11/1 Mobile phone socket, left
right, 2-pin
F13 Fuse, cigarette lighter, 2-pin socket,
D Reserve, EDC print diagnosis socket, EDC print, potential 30
X0/7/17 Weld point for wiring harness, cab, right,
# Variant on sheet 32 handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 30
X2/1 Socket, 2-pin 30/31 [2/1]
X2/4/1 Plug connection for central print, potential 15/2
X2/6 Plug connection for lighting, potentiometer
EDC
X6/13 Plug connection for cigarette lighter and
socket, 2-pin
X6/15 Plug connection for mobile phone socket, left
Ground points X14/4 Plug connection for EDC print - control unit
X24/2 Plug connection for wiring harness, cab, right
Edition 12-2005
4010-61
Sheet 32 4010-62
Sva 6-51402 EN
SS05N032
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A16 EDC print
B# Socket, mobile phone, left for
reverse travel equipment E11 Cigarette lighter, right [E11]
E11/1 Mobile phone socket, left
D Cigarette lighter with socket on
F13 Fuse, cigarette lighter, 2-pin socket, diagnosis
right, 2-pin
socket, EDC print, potential 30
E Reserve, EDC print X0/7/17 Weld point for wiring harness, cab, right,
handbrake
# Variant on sheet 31 X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 30
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/28/8 Weld point for roof wiring harness, all-round
lights
X2/1 Socket, 2-pin 30/31 [2/1]
Ground points X2/4/1 Plug connection for central print, potential 15/2
X2/6 Plug connection for lighting, potentiometer EDC
X6/13 Plug connection for cigarette lighter and socket,
2-pin
X6/15 Plug connection for mobile phone socket, left
X14/4 Plug connection for EDC print - control panel
X24/2 Plug connection for wiring harness, cab, right
Edition 12-2005
4010-63
Sheet 33 4010-64
Sva 6-51402 EN
SS05N033
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A14 Engine print (Würth or Berifors)
B# EDC without raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse, supply for potential 15/1 EDC box
lowering F91 Fuse, supply for EDC, potential 30
X0/7/11 Weld point for wiring harness, cab, right, EDC
GND
# Variant on sheet 34
X0/7/12 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X2/12 Raise/lower plug connection
X20/1 Plug connection for engine wiring harness
Ground points (Würth)
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]
Edition 12-2005
4010-65
Sheet 34 4010-66
Sva 6-51402 EN
SS05N034
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A14 Engine print (Würth or Berifors)
B# EDC with raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse, supply for potential 15/1 EDC box
lowering F91 Fuse, supply for EDC, potential 30
S28 Raise/lower changeover switch
X0/7/11 Weld point for wiring harness, cab, right, EDC
# Variant on sheet 33
GND
X0/7/12 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X2/12 Raise/lower plug connection
Ground points
X20/1 Plug connection for engine wiring harness
(Würth)
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]
Edition 12-2005
4010-67
Sheet 35 4010-68
Sva 6-51402 EN
GSV4
EDC stop
Transport
lift RAISE
Transport/
lift LOWER
Controlling/
Potential 31
Potential 58
Front loader
Potential 15/1
Potential 15/1
Rapid retraction
Rapid retraction
Supply for EDC stop
SS05N035
Edition 12-2005
Designation of sections Electrical equipment
A Control signal A12 Central print (Würth or Berifors) X0/25/5 Weld point for wiring harness, control panel,
Sva 6-51402 EN
A16 EDC print right GSV1
B Power lift, front, raise/lower
A55 EDC box X3/13 Plug connection for sensor B23
C Armrest X10/4 Plug connection for EDC print armrest (GSV)
A60 ECCU2
CN3a ECCU2 plug connection X10/9 Plug connection for wiring harness, cab, right -
F19 Fuse, supply for ARU, EDC potential 15/1 control panel
F20 Fuse, supply for ARU, EDC potential 15/1 X18/4 Plug connection for wiring harness, cab, right
R3 2 kOhm resistance - armrest
R4 2 kOhm resistance X23/2 Plug connection for wiring harness, cab, right -
R5 2 kOhm resistance engine wiring harness
R6 2 kOhm resistance X24/2 Plug connection for wiring harness, cab, right
R7 2 kOhm resistance X24/5 Plug connection for wiring harness, cab, right -
control panel
R8 Potentiometer, accelerator pedal
R9 2 kOhm resistance X55 Plug connection for EDC box
Y60 Front loader solenoid valve
S2/7/3 Hydraulic master switch [MASTER]
S18/1 External push button AUX BLUE, pressure in
- [ATS]
Ground points S18/2 External push button AUX BLUE, pressure in
+[ATH]
X0/7/11 Weld point for wiring harness, cab, right, EDC
GND
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/26 Weld point for wiring harness, cab, right,
transport/control signal
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Edition 12-2005
4010-69
Sheet 36 4010-70
Sva 6-51402 EN
SS05N036
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2]
B Button, raise/lower EDC
A55 EDC box
C External button, EDC
S2/15/5 Raise / lower pushbutton [INNEN]
S14/1 External pushbutton, LOWER, left [SENKEN]
S14/2 External pushbutton, LOWER, right
[SENKEN]
S15/1 External pushbutton, RAISE, left [HEBEN]
S15/2 External pushbutton, RAISE, right [HEBEN]
X0/7/10 Weld point for wiring harness, cab, right, radar
sensor
X0/7/16 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/21 Weld point for wiring harness, cab, right, RAISE
pushbutton
X0/7/25 Weld point for wiring harness, cab, right,
LOWER
X0/7/4 Weld point for wiring harness, cab, right, supply
Ground points for external pushbutton on right
X0/7/6 Weld point for wiring harness, cab, right, supply
for external pushbutton on left
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X24/5 Plug connection for wiring harness, cab, right -
control panel
X55 Plug connection for EDC box
Edition 12-2005
4010-71
Sheet 37 4010-72
Sva 6-51402 EN
transport
Ground during
SS05N037
Edition 12-2005
Designation of sections Electrical equipment
A EDC signal 50% A16 EDC print X3/18 Plug connection for EDC mixing
Sva 6-51402 EN
A55 EDC box potentiometer
B Indicator lights, EDC
A60 ECCU2 X3/19 Plug connection for slip control potentiometer
C Potentiometer, EDC X4/2 Plug connection for LED for diagnosis, LED
CN3b ECCU2 plug connection
D1 Diode for slip
E41 EDC lighting X4/3 Plug connection for LED for raise, LED for
E42 EDC lighting lower
E43 EDC lighting X5/6 Plug connection for setpoint potentiometer
H2/1 LED for diagnosis X10/4 Plug connection for EDC print armrest (GSV)
H2/2 LED for slip X14/4 Plug connection for EDC print - control unit
H2/3 LED for raise
H2/4 LED for lower
R1 2 kOhm resistance
R2 2 kOhm resistance
R6 2 kOhm resistance
R6/1 Setpoint potentiometer
R6/2 Lift limitation potentiometer
Ground points R6/3 Mixing potentiometer
R6/4 Lowering speed potentiometer
R6/5 Slip control potentiometer
R12 0 kOhm resistance
R13 0 kOhm resistance
R14 6.2 kOhm resistance
R19 2 kOhm resistance
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X2/6 Plug connection for lighting, potentiometer
EDC
X3/16 Plug connection for lowering speed
potentiometer
X3/17 Plug connection for lift limitation
potentiometer
Edition 12-2005
4010-73
Sheet 38 4010-74
Sva 6-51402 EN
0.8V to 4.4V
Signal
Handbrake
Signal
Seat switch
3V
0V to 5.8V
1.1V to 4V
4.4V to 0.8V
Ground
5.8 V
Ground
5.8 V
Signal
Engine back
pressure brake
Ground
5.6V
GSV3
Potential 30
Signal 80%
Potential 31
Potential 15/1
signal
Accelerator pedal
SS05N038
Edition 12-2005
Designation of sections Electrical equipment
A Supply, FMGR A2 EEM2 control unit X24/3 Plug connection for instruments wiring harness
Sva 6-51402 EN
A4 FMGR - cab wiring harness on right [3]
B# Clutch switch 80%
A4/1 FMGR plug connection - white [1] X24/5 Plug connection for wiring harness, cab, right -
C# Angle of rotation sensor, coupling control panel
A4/2 FMGR plug connection - dark grey [2]
D# Potentiometer, accelerator pedal A4/3 FMGR plug connection - blue [3] X70 Plug connection for engine control unit EEM2
E# Parking interlock switch A4/4 FMGR plug connection - grey [4]
F# Limit load potentiometer A12 Central print (Würth or Berifors)
B17 Angle of rotation sensor, coupling
G Switch for engine back pressure
F14 Fuse, FMGR, potential 30
brake
F51 Fuse, supply for potential 15/1 FMGR
H# Switch for handbrake, seat switch R8 Potentiometer, accelerator pedal
R23 Limit load potentiometer
# Variants on sheets 39, 40 S2/61 Parking interlock switch [PARKBREMSE]
S8 Seat switch
S20 Engine back pressure brake switch
S21 Switch for handbrake
S46 Coupling switch 80%
Ground points X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/24 Weld point for wiring harness, cab, right GSV3
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X3/23 Plug connection for load limit potentiometer
X4/25 Plug connection for handbrake switch [25]
X4/61 Plug connection for Grammer seat
X4/70 Plug connection for accelerator pedal [70]
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
Edition 12-2005
4010-75
Sheet 39 4010-76
Sva 6-51402 EN
Potential 31
Ground
5.6V
Ground
Potential 30
Signal 80%
1.1V to 4V
Potential 15/1
0.8V to 4.4V
4.4V to 0.8V
5.8 V
Accelerator
pedal signal
SS05N039
Edition 12-2005
Designation of sections Electrical equipment
A# Supply, FMGR A2 EEM2 control unit X0/27/7 Weld point for reverse travel equipment wiring
Sva 6-51402 EN
A4 FMGR harness, potential 31
B# Clutch switch 80% for reverse
A4/1 FMGR plug connection - white [1] X4/70 Plug connection for accelerator pedal [70]
travel equipment
A4/3 FMGR plug connection - blue[3] X4/70/1 Plug connection for accelerator pedal
C# Angle of rotation sensor, [FAHRPEDAL]
A4/4 FMGR plug connection - grey [4]
coupling with reverse travel
A12 Central print (Würth or Berifors) X23/2 Plug connection for wiring harness, cab, right -
equipment
B17 Angle of rotation sensor, clutch engine wiring harness
D# Potentiometer, accelerator pedal B17/1 Angle of rotation sensor, clutch [DW-KUPPL] X24/2 Plug connection for wiring harness, cab, right
for reverse travel equipment X24/3 Plug connection for instruments wiring harness
F14 Fuse, FMGR, potential 30
F51 Fuse, supply for potential 15/1 FMGR - cab wiring harness on right [3]
# Variants on sheets 38, 40 K5/60 Relay for coupling [KUPPLUNG] X70 Plug connection for engine control unit EEM2
K5/61 Relay for front accelerator pedal
[FAHRPEDAL1]
K5/62 Relay for rear accelerator pedal
[FAHRPEDAL1]
R8 Potentiometer, accelerator pedal
R8/1 Potentiometer, accelerator pedal, reverse travel
equipment
Ground points
S46 Coupling switch 80%
S46/1 Coupling switch 80% [KUPPL]
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/27/1 Weld point for seat wiring harness, reverse
travel equipment
X0/27/10 Weld point for reverse travel equipment wiring
harness, accelerator pedal 2
X0/27/11 Weld point for reverse travel equipment wiring
harness, accelerator pedal 1
X0/27/13 Weld point for reverse travel equipment wiring
harness, coupling
X0/27/14 Weld point for reverse travel equipment wiring
harness, coupling
Edition 12-2005
4010-77
Sheet 40 4010-78
Sva 6-51402 EN
Signal for
reverse travel
equipment
active
3V
5.8 V
Signal
Handbrake
Signal
Seat switch
Ground
0V to 5.8V
Signal
Engine back
pressure brake
GSV3
SS05N040
Edition 12-2005
Designation of sections Electrical equipment
A# Parking interlock switch A4 FMGR X0/27/9 Weld point for reverse travel equipment wiring
Sva 6-51402 EN
A4/1 FMGR plug connection - white [1] harness, GSV2
B# Potentiometer, limit load for
A4/2 FMGR plug connection - dark grey [2] X4/25 Plug connection for handbrake switch [25]
reverse travel equipment
A4/4 FMGR plug connection - grey [4] X4/25/1 Plug connection for switch for handbrake
C# Switch for engine back pressure [HANDBREMSE]
A70 Seat switch
brake, handbrake for reverse
H1/1 Signal horn for reverse travel equipment X6/23 Plug connection for rear wiper motor
travel equipment
R23 Limit load potentiometer X6/27 Plug connection for seat switch ARU -
D# Seat switch for reverse travel S2/61 Parking interlock switch [PARKBREMSE] console for reverse travel equipment
equipment X6/58 Plug connection for seat switch [SITZ RF]
S2/61/1 Parking interlock switch [PARK]
E# Horn for reverse travel S2/74 Reverse fan pushbutton X24/3 Plug connection for instruments wiring harness
equipment S8 Seat switch - cab wiring harness on right [3]
S8/1 Reversible seat switch X24/5 Plug connection for wiring harness, cab, right -
control panel
# Variants on sheets 38, 39 S8/2 Reversible seat switch
S20 Engine back pressure brake switch
S21 Switch for handbrake
X0/3/1 Weld point for instruments wiring harness,
potential 58L
Ground points X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/24 Weld point for wiring harness, cab, right GSV3
X0/27/1 Weld point for seat wiring harness, reverse
travel equipment
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/27/4 Weld point for reverse travel equipment wiring
harness, parking interlock
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point for reverse travel equipment wiring
harness, potential 15/2
Edition 12-2005
4010-79
Sheet 41 4010-80
Sva 6-51402 EN
4WD
Management
Brake oil
cooling valve 2
GSV1
Brake oil
cooling valve 1
Manual mode
0-14 km/h
0-25 km/h
All-wheel drive ON
Differential lock ON
Differential lock management
Differential lock solenoid valve
SS05N041
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
manual mode A4/1 FMGR plug connection - white [1]
B# Switch for differential lock, all- A4/3 FMGR plug connection - blue[3]
wheel drive management A16 EDC print
A60 ECCU2
C# Solenoid valves, brake oil
cooling CN3b ECCU2 plug connection
S2/56 Switch for differential lock management
[DIFF HI]
# Variant on sheet 42 S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
S2/59 Switch for all-wheel drive management
[4WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Ground points X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control unit
X24/5 Plug connection for wiring harness, cab, right -
control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2
Edition 12-2005
4010-81
Sheet 42 4010-82
Sva 6-51402 EN
All-wheel drive
ON
4WD
Management
Brake oil
cooling valve 2
GSV1
Brake oil
cooling valve 1
Manual mode
0-14 km/h
0-25 km/h
Differential lock ON
Differential lock management
Differential lock solenoid valve
SS05N042
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
manual mode for reverse travel A4/1 FMGR plug connection - white [1]
equipment A4/3 FMGR plug connection - blue [3]
B# Switch for differential lock, all- A16 EDC print
wheel drive management for A60 ECCU2
reverse travel equipment CN3b ECCU2 plug connection
C# Solenoid valves, brake oil S2/56 Switch for differential lock management
cooling [DIFF HI]
S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
# Variant on sheet 41 S2/59 Switch for all-wheel drive management
[4WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Ground points X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control panel
X24/5 Plug connection for wiring harness, cab, right -
control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2
Edition 12-2005
4010-83
Sheet 43 4010-84
Sva 6-51402 EN
Load ground for
reverse gear
with max.
200mA
Forwards
Neutral
Reverse
Dead man
Plug X4/59b in here in
an emergency
SS05N043
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2]
B Gearbox electronics
A12 Central print (Würth or Berifors)
C LIMP HOME plug connection
A13 Roof print
D# Shuttle lever A21 SGR transmission controller
A23 Linde electronics
# Variant on sheet 44 A24 Hydrostat
F9 Fuse, SGR, potential 30
F18 Fuse, SGR, potential 15/1
P8 ICU
S4/4 Shuttle lever
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/12 Weld point for roof wiring harness, potential 31
Ground points
X0/28/3 Weld point for roof wiring harness, potential 58
X4/59/a Plug connection for LIMP HOME [A]
X4/59/b Plug connection for LIMP HOME [A]
X4/59/c Plug connection for LIMP HOME [B]
X6/1 Plug connection for Linde electronics
X6/3 Plug connection for instruments wiring
harness - steering column [3]
X6/9 Plug connection for Linde electronics -
hydrostat A24
X10/12 Plug connection for roof wiring harness
X16/21 SGR plug connection
X24/2 Plug connection for wiring harness, cab, right
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
Edition 12-2005
4010-85
Sheet 44 4010-86
Sva 6-51402 EN
Reverse
Forwards
Neutral
Dead man
Load ground for
reverse gear
with max.
200mA
SS05N044
Edition 12-2005
Designation of sections Electrical equipment
A ICU performance monitor A4 FMGR X4/59/c Plug connection for LIMP HOME [B]
Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2] X6/1 Plug connection for Linde electronics
B Gearbox electronics
A12 Central print (Würth or Berifors) X6/3 Plug connection for instruments wiring harness
C LIMP HOME plug connection - steering column [3]
A13 Roof print
D# Shuttle lever A21 SGR transmission controller X6/9 Plug connection for Linde electronics -
E Display for reverse travel A23 Linde electronics hydrostat A24
equipment A24 Hydrostat X10/12 Plug connection for roof wiring harness
F9 Fuse, SGR, potential 30 X16/21 SGR plug connection
F18 Fuse, SGR, potential 15/1 X24/2 Plug connection for wiring harness, cab, right
# Variant on sheet 43 X24/3 Plug connection for instruments wiring harness
P6 Display for reverse travel equipment
P8 ICU - cab wiring harness on right [3]
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch [V/R]
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Ground points X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/27/2 Weld point for reverse travel equipment wiring
harness “V”
X0/27/3 Weld point for reverse travel equipment wiring
harness “R”
X0/27/5 Weld point for reverse travel equipment wiring
harness, setting off
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point for reverse travel equipment wiring
harness, potential 15/2
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X4/59/a Plug connection for LIMP HOME [A]
X4/59/b Plug connection for LIMP HOME [A]
Edition 12-2005
4010-87
Sheet 45 4010-88
Sva 6-51402 EN
Ground
Ground
Ground
GND opens at a
difference in
pressure of
> 5 bar
Ground
Ground
Ground
4V
Ground
Ground
4V
4V
10V
10V
4V
4V
Ground
PTC 1 kOhm to
4.4 kOhm
4V
4V
10 to 6000Hz
10 to 6000Hz
0.2V to 3.1V
5V
Ground
10 to 6000Hz
10 to 6000Hz
0.2V to 1.2V
5V
10 to 6000Hz
SS05N045
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
B24 Speed sensor, cartridge input
B Speed sensors, cartridge
B25 Speed sensor, planetary carrier 3/4
C Sensors, cartridge switch
B26 Speed sensor, cartridge output
B26 Speed sensor, cartridge output
B32 Speed sensor, temperature sensor,
transmission oil
B35 Speed sensor, planetary carrier 1/2
B47 Pressure sensor, transmission system
pressure
B51 Pressure sensor, transmission lubrication
pressure
S49/1 Pressure filter switch 5bar
X5 Plug connection for pressure filter
X17 Plug connection for parking interlock ground
Y41 Solenoid valve, coupling 1
Y42 Solenoid valve, coupling 2
Y43 Solenoid valve, coupling 3
Ground points
Y44 Solenoid valve, coupling 4
Y45 Solenoid valve, coupling, forward
Y46 Solenoid valve, coupling, reverse
Y57 Solenoid valve, parking interlock On
Y58 Solenoid valve, parking interlock Off
Y59 All-wheel solenoid valve
Edition 12-2005
4010-89
Sheet 46 4010-90
Sva 6-51402 EN
12V for
PTO shaft
at front active
12V for
PTO shaft
at rear active
SS05N046
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
CN2/E ECCU2 plug connection
B Front PTO shaft
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
S2/70/1 Switch for front PTO shaft [PTO VO]
S2/70/2 Switch for rear PTO shaft [PTO HI]
S2/71 Switch for rear PTO shaft management
[PTO M]
S17/1 External pushbutton, PTO shaft, rear left
S17/2 External pushbutton, PTO shaft, rear right
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X24/5 Plug connection for wiring harness, cab, right -
Ground points control panel
Y4 Solenoid valve for front PTO shaft [PTO VO]
Y5 Solenoid valve for rear PTO shaft [PTO]
Edition 12-2005
4010-91
Sheet 47 4010-92
Sva 6-51402 EN
Potential 15/2
12V
during
locked
DOWN
Ground
Ground
Potential 30
v<14 km/h
12V during
12V during
12 V during
management
12V during UP
Check for
front axle 12V during
ACTIVE 12V during UP UP / DOWN
12V during
UP / DOWN
12 V
Signal flow
12 V
Signal flow
Ground
Ground
BLUE BLACK GREEN
SS05N047
Edition 12-2005
Designation of sections Electrical equipment
A Spring-mounted front axle A12 Central print (Würth or Berifors) X2/45 Plug connection for wiring harness, cab, right
Sva 6-51402 EN
A60 ECCU2 - sprung front axle [45]
B Supply, ECCU2
A61 Electronics, front axle with independent X2/46 Plug connection for potential 58/31, sprung
suspension front axle [GE.VA]
# Variant on sheet 48 B33/1 Angle of rotation sensor X4/45 Plug connection for sprung front axle [45]
B33/2 Angle of rotation sensor X12/20 Plug connection for control block, sprung
CN1a ECCU2 plug connection front axle [VA]
CN2/E ECCU2 plug connection X24/2 Plug connection for wiring harness, cab, right
CN3a ECCU2 plug connection Y14 Solenoid valve for sprung front axle, pilot valve
CN3b ECCU2 plug connection Y15 Solenoid valve for sprung front axle, left
F10 Fuse, supply, ECCU2, potential 30 Y16 Solenoid valve for sprung front axle, right
F27 Fuse, sprung front axle, potential 30
F28 Fuse, sprung front axle, potential 15/2
F50 Fuse, supply for potential 15/1 ECCU2
S2/15/1 Switch for sprung front axle UP/DOWN
[VA auf/ab]
S2/15/2 Switch for sprung front axle IN/OUT [VA ein]
Ground points X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/7 Plug connection for OP.CHG
Edition 12-2005
4010-93
Sheet 48 4010-94
Sva 6-51402 EN
Potential 15/2
12V
during
locked
DOWN
Ground
Ground
Potential 30
12V during
12V during
v< 14 km/h
12 V during
management
12V during UP
Check for 12V during
front axle UP / DOWN
ACTIVE 12V during UP
12 V
Signal flow
12 V
Signal flow
Ground
Ground
12V during UP / DOWN
BLUE BLACK GREEN
SS05N048
Edition 12-2005
Designation of sections Electrical equipment
A Spring-mounted front axle A12 Central print (Würth or Berifors) X2/87 Plug connection for cab wiring harness on right
Sva 6-51402 EN
A60 ECCU2 - instruments wiring harness ISO-BUS
B Supply, ECCU2 for ISO BUS
A61 Electronics, sprung front axle X4/45 Plug connection for sprung front axle [45]
B33/1 Angle of rotation sensor X4/85/a Plug connection for cab wiring harness, right
# Variant on sheet 47 B33/2 Angle of rotation sensor - ISO BUS preparation
CN1a ECCU2 plug connection X4/85/b Plug connection for cab wiring harness, right
CN2/E ECCU2 plug connection - ISO BUS preparation
CN3a ECCU2 plug connection X12/20 Plug connection for control block, sprung front
CN3b ECCU2 plug connection axle [VA]
F10 Fuse, supply, ECCU2, potential 30 X24/2 Plug connection for wiring harness, cab, right
F27 Fuse, sprung front axle, potential 30 Y14 Solenoid valve for sprung front axle, UP/DOWN
F28 Fuse, sprung front axle, potential 15/2 Y15 Solenoid valve for sprung front axle, left
F50 Fuse, supply for potential 15/1 ECCU2 Y16 Solenoid valve for sprung front axle, right
S2/15/1 Switch for sprung front axle UP/DOWN
[VA auf/ab]
S2/15/2 Switch for sprung front axle IN/OUT [VA ein]
X0/3/1 Weld point for instruments wiring harness,
Ground points potential 58L
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/7 Plug connection for OP.CHG
X2/45 Plug connection for wiring harness, cab, right -
sprung front axle [45]
X2/46 Plug connection for potential 58/31, sprung
front axle [GE.VA]
Edition 12-2005
4010-95
Sheet 49 4010-96
Sva 6-51402 EN
SS05N049
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
B19 Angle of rotation sensor [LAGESENSOR VO]
B Angle of rotation sensor, power
lift, front CN1a ECCU2 plug connection
CN3a ECCU2 plug connection
C External button, AUX, front
CN3b ECCU2 plug connection
D External button, power lift, front S14/3 External button, power lift, front LOWER
[Senken]
S15/3 External button, power lift, front RAISE
[Heben]
S19/1 External button, AUX BROWN (to
DBD...YELLOW) pressure in - [Lower]
S19/2 External button, AUX BROWN (to
DBD...YELLOW) pressure in + [Raise]
S28/1 Pushbutton, front power lift management
X0/4/3 Weld point for engine wiring harness GSV4
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/23/1 Weld point for additional line, external
pushbutton for front power lift GSV4
Ground points X3/22 Plug connection for angle of rotation sensor,
front power lift [LAGE]
X4/69 Plug connection for external button for front
power lift [FHW]
X4/72 Plug connection for external pushbutton,
front AUX brown [EHS]
X18/4 Plug connection for cab wiring harness, right -
armrest
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
Edition 12-2005
4010-97
Sheet 50 4010-98
Sva 6-51402 EN
SS05N050
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A2 EEM2 control unit
A65 KEY PADS
CN3 ADIC plug connection
P8 ICU
P8/1 Plug connection for ICU CAN [DISP]
P8/2 Plug connection for ICU CAN
X0/3/13 Weld point for instruments wiring harness,
potential 15 CAN BUS
X0/3/14 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/3/16 Weld point for instruments wiring harness,
CAN L
X0/3/17 Weld point for instruments wiring harness,
potential 15 CAN BUS
X0/3/18 Weld point for instruments wiring harness,
Ground points potential GND CAN BUS
X0/3/19 Weld point for instruments wiring harness,
CAN H
X0/3/20 Weld point for instruments wiring harness,
CAN L
X4/63 Keypads plug connection
X10/14 Plug connection for instruments wiring harness
- supply for roof wiring harness
X14/14 Plug connection for instruments wiring harness
- supply for roof [14]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X70 Plug connection for engine control unit EEM2
Edition 12-2005
4010-99
Sheet 51 4010-100
Sva 6-51402 EN
SS05N051
Edition 12-2005
Designation of sections Electrical equipment
A CAN BUS A1 ARU connector module - CAN module X24/3 Plug connection for instruments wiring harness
Sva 6-51402 EN
A4 FMGR - cab wiring harness on right [3]
A4/4 FMGR plug connection (grey) [4]
A21 SGR transmission controller
A60 ECCU2
CN1a ECCU2 plug connection
CN3 ADIC plug connection
S31 CAN SGR/FMGR changeover switch
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X0/7/35 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/36 Weld point for wiring harness, cab, right,
CAN H
X0/7/37 Weld point for wiring harness, cab, right, CAN L
X0/7/38 Weld point for wiring harness, cab, right,
Ground points potential 31 CAN BUS
X0/7/43 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/44 Weld point for wiring harness, cab, right,
CAN H
X0/7/45 Weld point for wiring harness, cab, right, CAN L
X0/7/46 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
X0/7/51 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/52 Weld point for wiring harness, cab, right,
CAN H
X0/7/53 Weld point for wiring harness, cab, right, CAN L
X0/7/54 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
X9/17 Socket for diagnosis service tool
[DIAGNOSE]
X16/21 SGR plug connection
Edition 12-2005
4010-101
Sheet 52 4010-102
Sva 6-51402 EN
up to DBD094270
up to DBD094270
as of DBD094271
SS05N052
Edition 12-2005
Designation of sections Electrical equipment
A CAN BUS A4 FMGR X5/1 Screw - plug connection, potential 31, central
Sva 6-51402 EN
A4/3 FMGR plug connection (blue) [3] print
A12 Central print (Würth or Berifors) X18/4 Plug connection for cab wiring harness, right -
A27 CAN module (to DBD094270) armrest
A28 Connector module (to DBD094270) X24/2 Plug connection for wiring harness, cab, right
A30 Print ARU (ab DBD094271) X55 Plug connection for EDC box
A55 EDC box
F16 Fuse, supply for CAN, FMGR, ARU, AUX,
diagnosis changeover switch, ICU
potential 15/2
F47 Fuse, supply for AUX potential 15/1
X0/7/27 Weld point for wiring harness, cab, right,
potential 30 CAN BUS
X0/7/28 Weld point for wiring harness, cab, right,
CAN H
X0/7/29 Weld point for wiring harness, cab, right, CAN L
X0/7/30 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
Ground points X0/7/31 Weld point for wiring harness, cab, right,
potential 30 CAN BUS
X0/7/32 Weld point for wiring harness, cab, right,
CAN H
X0/7/33 Weld point for wiring harness, cab, right, CAN L
X0/7/34 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
X0/7/39 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/40 Weld point for wiring harness, cab, right,
CAN H
X0/7/41 Weld point for wiring harness, cab, right, CAN L
X0/7/42 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
Edition 12-2005
4010-103
Sheet 53 4010-104
Sva 6-51402 EN
SS05N053
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
CN3b ECCU2 plug connection X4/94 Plug connection for AUX 5
B Heating valve for hydraulic oil
X0/7/5 Weld point for wiring harness, cab, right, Y8 Heating valve
potential 31
X0/9/10 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/11 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/12 Weld point for wiring harness, AUX CAN H
X0/9/13 Weld point for wiring harness, AUX CAN L
X0/9/20 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/21 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/22 Weld point for wiring harness, AUX CAN H
X0/9/23 Weld point for wiring harness, AUX CAN L
X0/9/30 Weld point for wiring harness, AUX potential 15
CAN BUS
Ground points X0/9/31 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/32 Weld point for wiring harness, AUX CAN H
X0/9/33 Weld point for wiring harness, AUX CAN L
X0/9/40 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/41 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/42 Weld point for wiring harness, AUX CAN H
X0/9/43 Weld point for wiring harness, AUX CAN L
X0/9/50 Weld point for wiring harness, AUX CAN H
X0/9/51 Weld point for wiring harness, AUX CAN L
X3/10 Plug connection for terminal resistance
X4/83 Plug connection for remote control
valves [EHS]
X4/90 Plug connection for AUX 1
X4/91 Plug connection for AUX 2
X4/92 Plug connection for AUX 3
Edition 12-2005
4010-105
Sheet 54 4010-106
Sva 6-51402 EN
up to DBD094270
as of DBD094271
up to DBD094270
Lighting, potential 58
External button, power lift, front, raise
Transport
EDC stop
Potential 31
Potential 15
GSV
Front loader solenoid valve
Controlling
Output for EDC stop
SS05N054
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
right A28 Connector module (to DBD094270)
B Armrest, electronics A30 Print ARU (ab DBD094271)
C1 Condenser
C2 Condenser
C3 Condenser
C4 Condenser
L1 Disturbance protection
L2 Disturbance protection
V1/1 Diode
V1/2 Z diode
V1/3 Protective diode CAN H
V1/4 Protective diode CAN L
X18/4 Plug connection for cab wiring harness, right -
armrest
X28/1 Plug connection for ARU - wiring harness,
cab, right,
Ground points X28/7 Plug connection for ARU CAN - BUS
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)
Edition 12-2005
4010-107
Sheet 55 4010-108
Sva 6-51402 EN
up to DBD094270
as of DBD094271
up to DBD094270
SS05N055
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A28 Connector module (to DBD094270)
B Control handle for AUX
A29 Joystick
C Manual accelerator slider
A30 Print ARU (from DBD094271)
D Armrest, electronics B28 Manual accelerator slider
B30 Longitudinal joystick
B31 Transverse joystick
B52 Control lever
S35 Joystick button
X28/3 Plug connection for ARU - manual
accelerator slider
X28/4 Plug connection for ARU - AUX control lever
X28/5 Plug connection for ARU - AUX joystick
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)
Ground points
Edition 12-2005
4010-109
Sheet 56 4010-110
Sva 6-51402 EN
up to DBD094270
as of DBD094271
up to DBD094270
SS05N056
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A28 Connector module (to DBD094270)
B Reserve
A30 Print ARU (from DBD094271)
C Button, rapid retraction
E28/1 Lighting ARU
D Button, EDC - stop and lighting R12 0 Ohm resistance
E Armrest, electronics R13 0 Ohm resistance
R14 6.2 kOhm resistance
R15 1.2 kOhm resistance
R16 6.2 kOhm resistance
R17 2 kOhm resistance
S2/72 Rapid retraction button
S33 EDC stop button
S34 Button for 5th AUX
X28/2 Plug connection for ARU - rapid retraction
button
X28/6 Plug connection for ARU - AUX button
X28/8 Plug connection for ARU reserve
Ground points X28/9 Plug connection for ARU - lighting, switch for
front power lift management
X28/13 Plug connection for ARU lighting
X28/14 Plug connection for ARU, button for EDC
stop
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)
Edition 12-2005
4010-111
Sheet 57 4010-112
Sva 6-51402 EN
up to DBD094270
as of DBD094271
up to DBD094270
SS05N057
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
control valves A28 Connector module (to DBD094270)
B Armrest, electronics A30 Print ARU (from DBD094271)
R20/1 Potentiometer for 1st AUX
R20/2 Potentiometer for 2nd AUX
R20/3 Potentiometer for 3rd AUX
R20/4 Potentiometer for 4th AUX
R20/5 Potentiometer for 5th AUX
R28/1 470 Ohm resistance
R28/2 560 Ohm resistance
R28/3 470 Ohm resistance
R28/4 560 Ohm resistance
R28/5 470 Ohm resistance
R28/6 560 Ohm resistance
R28/7 470 Ohm resistance
R28/8 560 Ohm resistance
R28/9 470 Ohm resistance
Ground points R28/10 560 Ohm resistance
X28/12 Plug connection for ARU - potentiometer for
AUX 5
X28/15 Plug connection for ARU - potentiometer for
AUX 3 and AUX 4
X28/16 Plug connection for ARU - potentiometer for
AUX 1 and AUX 2
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)
Edition 12-2005
4010-113
Sheet 58 4010-114
Sva 6-51402 EN
up to
DBD094270
as of
DBD094271
up to DBD094270
SS05N058
Edition 12-2005
Designation of sections Electrical equipment
Sva 6-51402 EN
A28 Connector module (to DBD094270)
B Armrest, electronics
A30 Print ARU (from DBD094271)
A31 Multicontroller II
S60/1 F/R button
S60/2 Cruise control button
S60/3 Speed button +
S60/4 Speed button -
S60/5 HTS button
S60/6 AUX blue button
S60/7 EDC Transport/control button
S60/8 Shift button (floating switch)
X4 Plug connection for ARU multicontroller II - print
X21 Plug connection for multicontroller II - print
X28/11 Plug connection for ARU - multicontroller II
X28/19 Plug connection for ARU - shift button
YA1 Plug connection for ARU connector module -
Ground points CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)
Edition 12-2005
4010-115
Sheet 59 4010-116
Sva 6-51402 EN
SS05N059
Edition 12-2005
Designation of sections Electrical equipment
A ISO-BUS A12 Central print (Würth or Berifors) X0/32/3 Weld point for wiring harness, ISO-BUS
Sva 6-51402 EN
A60 ECCU2 potential 30
CN1a ECCU2 plug connection X0/32/4 Weld point for wiring harness, ISO-BUS
CN3b ECCU2 plug connection potential 15/1
CN4 Plug connection for ISO-BUS X0/32/5 Weld point for wiring harness, ISO-BUS
F50 Fuse, supply, ECCU2, potential 15/1 potential 15/1
F80 Fuse, potential 30 ISO-BUS X0/32/6 Weld point for wiring harness, ISO-BUS
F81 Fuse, potential 30 ISO-BUS potential 30
F82 Fuse, potential 30 ISO-BUS X0/32/7 Weld point for wiring harness, ISO-BUS
CAN 31
K5/80 Relay for potential 15 ISO-BUS
K5/81 Relay for ECU Power ISO-BUS X0/32/8 Weld point for wiring harness, ISO-BUS CAN L
X0/32/9 Weld point for wiring harness, ISO-BUS CAN H
K5/82 Relay for power socket ISO-BUS
X1/80 Plug connection for potential 30 ISO-BUS
P9 Virtual terminal
V8/1 Diode group, ISO-BUS X2/86 Plug connection for socket LBS ISO-BUS
X3/85 Plug connection for terminal resistance ISO-
X0/7/8 Weld point for wiring harness, cab, right,
BUS
potential 15
X4/85/a Plug connection for cab wiring harness, right -
X0/32/1 Weld point for wiring harness, ISO-BUS
ISO BUS preparation
Ground points potential 31
X0/32/10 Weld point for wiring harness, ISO-BUS X4/85/b Plug connection for cab wiring harness, right -
CAN 15 ISO BUS preparation
16 Starter
X4/86 Plug connection for socket LBS ISO-BUS
X0/32/11 Weld point for wiring harness, ISO-BUS
CAN GND X9/17 Socket for diagnosis service tool [DIAGNOSE]
X0/32/12 Weld point for wiring harness, ISO-BUS CAN L X9/20 Socket for ISO-BUS
X0/32/13 Weld point for wiring harness, ISO-BUS CAN H X12/8 Plug connection for virtual terminal ISO-BUS
X0/32/14 Weld point for wiring harness, ISO-BUS X24/2 Plug connection for wiring harness, cab, right
CAN 15 X85 Socket for LBS, ISO-BUS
X0/32/15 Weld point for wiring harness, ISO-BUS
CAN 31
X0/32/16 Weld point for wiring harness, ISO-BUS CAN L
X0/32/17 Weld point for wiring harness, ISO-BUS CAN H
X0/32/18 Weld point for wiring harness, ISO-BUS
CAN 15
X0/32/19 Weld point for wiring harness, ISO-BUS
potential 30
X0/32/2 Weld point for wiring harness, ISO-BUS
potential 30
Edition 12-2005
4010-117
$
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Additional marker light, front left .......................... 25 EDC signal 50% ..................................................71
Additional marker light, front right ....................... 25 EDC with raise/lower ...........................................65
Additional marker light, rear left .......................... 25 EDC without raise/lower ......................................63
Additional marker light, rear right ........................ 25 EEM3 box supply ................................................13
ADIC ........................................................ 51, 53, 55 EEM3 box with sensors and injectors .................15
Air conditioning .................................................... 43 Electrical mirror adjustment .....................35, 37, 39
Air cushion seat ................................................... 45 External button, AUX, front .................................95
All-round light carrier 45 ...................................... 37 External button, power lift, front ..........................95
All-round lights (can be plugged in) ..................... 35 )
All-round lights (magnetic) .................................. 39 Filter heating (preparation) ............................51, 53
Angle of rotation sensor, coupling ....................... 73 Front power lift, Raise / Lower ............................67
Angle of rotation sensor, coupling with Front PTO ...........................................................89
reverse travel equipment ..................................... 75 Fuel delivery pump ............................................7, 9
Angle of rotation sensor, power lift, front ............. 95 *
Angle of rotation sensor, power lift, rear ....... 63, 65 Gearbox electronics ......................................83, 85
Angled wiper, front .............................................. 47 +
Angled wiper, rear ............................................... 47 Headlight .............................................................27
Armrest ................................................................ 67 Heated windscreen, front ....................................41
Armrest, electronics .......... 105, 107, 109, 111, 113 Heated windscreen, rear .....................................41
ASR with radar sensor ........................................ 49 Heating ................................................................21
AUX valves ........................................................ 103 Heating flange ...................................................7, 9
AUX5 button ...................................................... 109 Heating flange, fuel delivery pump ......................11
Auxiliary headlight and 4 work lamps .................. 27 Heating valve for hydraulic oil ...........................103
% Horn ....................................................................47
BB light, left ......................................................... 23 Horn for reverse travel equipment .......................77
BB light, left and right .......................................... 25 ,
BB light, right ....................................................... 23 ICU performance monitor ..............................83, 85
Blower (roof) ........................................................ 45 Indicator lights, EDC ...........................................71
Bosch and Magneton generator ............................ 9 Interface, wiring harness, cab, right ..................105
Bosch generator .............................................. 7, 11 Interior light .........................................................33
Brake light ........................................................... 17 ISO-BUS ........................................................... 115
Brake light for reverse travel equipment ............. 19 Italy brake ............................................................21
Button, EDC - stop and lighting ......................... 109 -
Button, rapid retraction ...................................... 109 Joystick with button ...........................................107
& /
CAN BUS .............................................. 97, 99, 101 Licence plate lights, roof .....................................33
Cigarette lighter with socket on right, 2-pin ... 59, 61 Limit load potentiometer ......................................73
Clutch switch 80% ............................................... 73 LIMP HOME plug connection ........................83, 85
Clutch switch 80% for Low beam, high beam .........................................27
reverse travel equipment ..................................... 75 0
Control handle for AUX ..................................... 107 Manual accelerator slider ..................................107
' Mirror heating ..........................................35, 37, 39
D supply+ ............................................................ 13 Multicontroller II .................................................113
Display for reverse travel equipment ................... 85
Door contact switch ............................................. 33
Doorway lights ..................................................... 33
$EEUHYLDWLRQV
ADIC ................................................................................................................................. Analogue/ digital instrument
ARU .................................................................................................................................................................. Armrest
AUX .............................................................................................................................................Remote control valve
BB light ...........................................................................................................................Turn signal / side marker light
DMM ..................................................................................................................................................Digital multimeter
ECCU2 ........................................................................................................................................... Central control unit
EDC ....................................................................................................................................Electronic power lift control
EEM3 ..............................................................................................................................................Engine control unit
FMGR ............................................................................................................... Vehicle/engine/transmission controller
GSV .........................................................................................................................................................Cyclic supply
HTS ..................................................................................................Field end management (headland management)
ICU .............................................................................................................................................. Performance monitor
ID module ................................................................................................. Identification module for engine electronics
KEY PADS ............................................................................................ Function keys for analogue/digital instrument
NTC ...........................................................................................................................Negative temperature coefficient
PCB .........................................................................................Printed circuit board (relay circuit, terminal resistance)
PTC ............................................................................................................................ Positive temperature coefficient
SBB light .......................................................................................................... tail light, turn signal / side marker light
SGR .........................................................................................................................................Transmission controller
127( 7KHGHWDLOVLQVTXDUHEUDFNHWV>[[@DUHZULWWHQRQWKHFRQQHFWRU
127( 7KLVV\PEROLVRQO\XVHGRQOLQHVIRUWKHUHYHUVHWUDYHOHTXLSPHQW
Sva 6-93360 EN
SS06A001
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Power supply and starter A3 EEM3 control unit X1/30/1 Screw connection for engine print,
Sva 6-93360 EN
A12 Central print potential 30
B Heating flange
A14 Engine print X1/30/2 Screw connection for engine print,
C Fuel delivery pump potential 30
E10/1 Heating flange
D Bosch generator F1 Fuse, start switch supply X1/31/1 Screw connection for engine print,
E Power supply, potential 15, cab F200 Main fuse potential 31
GND F208 Fuse, fuel delivery pump X1/50 Screw connection for engine print,
F212 Fuse, ADIC, ICU, radio memory, potential 30 potential 50
F213 Fuse, main electrical battery switch, X2/17 Plug connection for generator D+
# Variants on sheet 2, 3 X2/19 Plug connection for heating flange relay
potential 30
F217 Fuse, power supply, warning light system, X2/BATT Plug connection for engine print - main
potential 30 electrical battery switch
G1 Battery X5/1 Screw-plug connection, potential 31, central
G2/2 Generator, Bosch, 120A print
K5/7/1 Relay, potential 15/1 supply X10/3 Plug connection for engine print - instruments
K5/7/2 Relay, potential 15/2 supply wiring harness
X10/18 Plug connection for instruments wiring
K5/LP Relay, fuel delivery pump
harness - engine wiring harness [INSTR]
*URXQGSRLQWV K8/2 Heating flange relay 300A
X12/1 Plug connection for engine wiring harness -
K8/50 Relay, starter
engine print
1 Battery M1 Starter
X18/1 Plug connection for instruments wiring
11 Engine cable carrier, rear M13 Fuel delivery pump
harness - central print [1]
12 Engine cable carrier, front S1 Start switch
X24/1 Plug connection for instruments wiring
16 Starter X0/3/2 Weld point for instruments wiring harness, harness - central print [1]
potential 15/1 X36/1 Plug connection for EEM3 engine control unit
X0/3/16 Weld point for instruments wiring harness - engine sensors wiring harness
CAN L
X89/1 Plug connection for EEM3 engine control unit
X0/42/1 Weld point for engine wiring harness, - engine wiring harness
potential 31
X0/42/3 Weld point for engine wiring harness,
potential 30 (radio)
X1/5 Plug connection for potential 30, ADIC, ICU,
radio, warning light system
X1/8 Plug connection for central print supply,
potential 30, start switch
X1/11 Plug connection for central print, potential 30
Edition 01-2006
4010A-7
6KHHW 4010A-8
Sva 6-93360 EN
SS06A002
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Power supply and starter A3 EEM3 control unit X1/5 Plug connection for potential 30, ADIC, ICU,
Sva 6-93360 EN
A12 Central print radio, warning light system
B Heating flange
A14 Engine print X1/8 Plug connection for central print supply,
C Fuel delivery pump potential 30, start switch
E10/1 Heating flange
D Bosch and Magneton generator F1 Fuse, start switch supply X1/11 Plug connection for central print, potential 30
E Supply for potential 15 F200 Main fuse X1/30/1 Screw connection for engine print, potential 30
F208 Fuse, fuel delivery pump X1/30/2 Screw connection for engine print, potential 30
F212 Fuse, ADIC, ICU, radio memory, potential 30 X1/31/1 Screw connection for engine print, potential 31
# Variants on sheet 1, 3 X1/50 Screw connection for engine print, potential 50
F213 Fuse, main electrical battery switch,
potential 30 X2/17 Plug connection for generator D+
F217 Fuse, power supply, warning light system, X2/19 Plug connection for heating flange relay
potential 30 X2/BATT Plug connection for engine print - main
G1 Battery electrical battery switch
G2/2 Generator, Bosch, 120A X5/1 Screw-plug connection, potential 31, central
G2/2/2 Generator, 2 Magneton, 95A print
K5/7/1 Relay, potential 15/1 supply X10/3 Plug connection for engine print - instruments
K5/7/2 Relay, potential 15/2 supply wiring harness
K5/42 Relay D+ 2nd generator X10/18 Plug connection for instruments wiring harness
*URXQGSRLQWV - engine wiring harness [INSTR]
K5/LP Relay, fuel delivery pump
K8/2 Heating flange relay 300A X12/1 Plug connection for engine wiring harness -
1 Battery
engine print
11 Engine cable carrier, rear K8/50 Relay, starter
L20/1 Indicator light, 2nd generator X18/1 Plug connection for instruments wiring harness
12 Engine cable carrier, front
- central print [1]
16 Starter L20/2 Indicator light, 2nd generator
X24/1 Plug connection for instruments wiring harness
M1 Starter
- central print [1]
M13 Fuel delivery pump
X36/1 Plug connection for EEM3 engine control unit -
Q1 Main switch engine sensors wiring harness
S1 Start switch
X89/1 Plug connection for EEM3 engine control unit -
X0/3/16 Weld point for instruments wiring harness, engine wiring harness
CAN L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/42/1 Weld point for engine wiring harness,
potential 31
X0/42/3 Weld point for engine wiring harness,
potential 30 (radio)
Edition 01-2006
4010A-9
6KHHW 4010A-10
Sva 6-93360 EN
SS06A003
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Power supply for main electrical A3 EEM3 control unit X1/11 Plug connection for central print, potential 30
Sva 6-93360 EN
battery switch A12 Central print X1/30/1 Screw connection for engine print, potential 30
B Starter A14 Engine print X1/30/2 Screw connection for engine print, potential 30
E10/1 Heating flange X1/31/1 Screw connection for engine print, potential 31
C Heating flange, fuel delivery
F1 Fuse, start switch supply X1/50 Screw connection for engine print, potential 50
pump
F200 Main fuse X2/17 Plug connection for generator D+
D Bosch generator F208 Fuse, fuel delivery pump X2/19 Plug connection for heating flange relay
E Supply for potential 15 F212 Fuse, ADIC, ICU, radio memory, potential 30 X2/BATT Plug connection for engine print - main
F213 Fuse, main electrical battery switch, electrical battery switch
potential 30 X5/1 Screw-plug connection, potential 31, central
# Variants on sheet 1, 2
F217 Fuse, power supply, warning light system, print
potential 30 X10/3 Plug connection for engine print - instruments
G1 Battery wiring harness
G2/2 Generator, Bosch, 120A X10/18 Plug connection for instruments wiring harness
K4/BATT Time relay, main electrical battery switch - engine wiring harness [INSTR]
K5/7/1 Relay, potential 15/1 supply X12/1 Plug connection for engine wiring harness -
K5/7/2 Relay, potential 15/2 supply engine print
K5/LP Relay, fuel delivery pump X18/1 Plug connection for instruments wiring harness
*URXQGSRLQWV - central print [1]
K8/2 Heating flange relay 300A
K8/50 Relay, starter X24/1 Plug connection for instruments wiring harness
1 Battery
- central print [1]
11 Engine cable carrier, rear M1 Starter
M13 Fuel delivery pump X89/1 Plug connection for EEM3 engine control unit -
12 Engine cable carrier, front
engine wiring harness
16 Starter Q2 Electrical main battery switch
S1 Start switch
X0/3/16 Weld point for instruments wiring harness,
CAN L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/42/1 Weld point for engine wiring harness,
potential 31
X0/42/3 Weld point for engine wiring harness,
potential 30 (radio)
X1/5 Plug connection for potential 30, ADIC, ICU,
radio, warning light system
X1/8 Plug connection for central print supply,
potential 30, start switch
Edition 01-2006
4010A-11
6KHHW 4010A-12
Sva 6-93360 EN
Potential 30
Potential 15
Potential 31
SS06A004
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A7 ID module
B EEM3 box supply
A12 Central print
A14 Engine print
A60 ECCU2
B23 ’Water in fuel’ sensor
CN3a ECCU2 plug connection
F21 Fuse, supply for D+ relay, ECCU2, EDC
F30 Fuse, supply for engine print, potential 15/2
F203 Fuse, supply for EEM3, potential 30
F204 Fuse, central lubrication, potential D+
F207 Fuse, supply for EEM3, potential 15
K5/11 Relay, potential D+ supply
K5/43 Relay, D+ cut-off
K5/IGN Relay, engine, potential 15
W1/4 Plug connection for radio start
X0/7/22 Weld point for cab wiring harness, right D+
*URXQGSRLQWV X0/42/1 Weld point for engine wiring harness,
potential 31
2 EEM3 control unit X0/42/2 Weld point for engine wiring harness,
potential 30 (EEM3)
X1/30/EEM Screw connection Motorprint Potential 30
X1/CL Plug connection, central lubrication
X3/12 Plug connection, ’water in fuel’ sensor
X4/4 Plug connection, ID module
X10/3 Plug connection for engine print - instruments
wiring harness
X12/1 Plug connection for engine wiring harness -
engine print
X18/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
X89/1 Plug connection for EEM3 engine control unit -
engine wiring harness
Edition 01-2006
4010A-13
6KHHW 4010A-14
Sva 6-93360 EN
Signal
Supply
Signal
Signal
Ground
Ground
Ground
Ground
Signal
Ground
Ground
Signal
5V
5V
Signal
Signal
5V
Ground
Ground
SS06A005
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
injectors B20 Engine speed sensor
B22 Engine temperature sensor
B29 Sensor for charger pressure/charged air
temperature
B36 Fuel temperature sensor
B37 Oil pressure sensor
B38 Rail pressure sensor
B39 Fuel delivery pressure sensor
B40 Camshaft position sensor
X2/21 Plug connection, solenoid valve, high-
pressure pump
X2/22 Plug connection, temperature sensor
EEM3 [22]
X2/28 Plug connection, engine speed sensor
X2/36 Screw connection, fuel temperature sensor
X3/37 Plug connection, oil pressure sensor
*URXQGSRLQWV X3/38 Plug connection, rail pressure sensor
X3/39 Plug connection, fuel delivery pressure
sensor
X3/40 Plug connection, camshaft position sensor
X4/29 Plug connection, charge-air pressure/charge-
air temperature sensor
X16/1 Plug connection, EEM3 engine control unit -
engine injection nozzles wiring harness
X36/1 Plug connection for EEM3 engine control unit
- engine sensors wiring harness
Y20 Solenoid valve, high-pressure pump
Y21 Screw connection, injector, 1st cylinder
Y22 Screw connection, injector, 2nd cylinder
Y23 Screw connection, injector, 3rd cylinder
Y24 Screw connection, injector, 4th cylinder
Y25 Screw connection, injector, 5th cylinder
Y26 Screw connection, injector, 6th cylinder
Edition 01-2006
4010A-15
6KHHW 4010A-16
Sva 6-93360 EN
signal
switch
Steering
Brake light
Brake light
brake switch
GSV2
SS06A006
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Brake light A4 FMGR X24/2 Plug connection for cab wiring harness, right -
Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2] central print
B Reserve central print
A12 Central print X24/3 Plug connection for instruments wiring harness
C Reverse fan - cab wiring harness on right [3]
A14 Engine print
A60 ECCU2
# Variant on sheet 7 A62 Reverse fan
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
F8 Fuse, reserve, potential 30
F15 Fuse, reserve, potential 15/2
F46 Fuse, relay for brake light, Optistop,
potential 15/1
F211 Fuse, supply for reverse fan, potential 30
K5/12 Relay, brake light, Optistop
K5/FAN Relay, reverse fan
S2/74 Reverse fan pushbutton
S5 Brake light switch
*URXQGSRLQWV S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/3/18 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X3/5 Plug connection, reserve
X4/14 Plug connection for brake light, Optistop
X4/66 Plug connection for reverse fan [LU]
X4/64 Plug connection for reverse fan
X6/2 Plug connection for engine print, supply
EDC [2]
X10/8 Plug connection for wiring harness, cab, left -
central print [8]
X18/1 Plug connection for instruments wiring harness
- central print [1]
Edition 01-2006
4010A-17
6KHHW 4010A-18
Sva 6-93360 EN
signal
switch
Steering
Brake light
Brake light
brake switch
GSV2
SS06A6A007
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Brake light for reverse travel A4 FMGR X6/2 Plug connection for engine print, supply
Sva 6-93360 EN
equipment A4/2 FMGR plug connection - dark grey [2] EDC [2]
A12 Central print X10/8 Plug connection for wiring harness, cab, left -
B Reserve central print
A14 Engine print central print [8]
C Reverse fan X18/1 Plug connection for instruments wiring harness
A60 ECCU2
A62 Reverse fan - central print [1]
# Variant on sheet 6 CN3a ECCU2 plug connection X24/2 Plug connection for cab wiring harness, right -
CN3b ECCU2 plug connection central print
F8 Fuse, reserve, potential 30 X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
F15 Fuse, reserve, potential 15/2
F46 Fuse, relay for brake light, Optistop,
potential 15/1
F211 Fuse, supply for reverse fan, potential 30
K5/12 Relay, brake light, Optistop
K5/FAN Relay, reverse fan
S2/74 Reverse fan pushbutton
S5 Brake light switch
*URXQGSRLQWV S5/1 Switch for brake light, reverse travel equipment
[BREMSL]
S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/3/16 Weld point for instruments wiring harness,
CAN L
X0/3/18 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/12 Weld point for reverse travel equipment wiring
harness, brake
X3/5 Plug connection, reserve
X4/14 Plug connection for brake light, Optistop
X4/64 Plug connection for reverse fan
X4/66 Plug connection for reverse fan [LU]
Edition 01-2006
4010A-19
6KHHW 4010A-20
Sva 6-93360 EN
SS06A008
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A14 Engine print
B Heating
F10 Fuse, supply, ECCU2, potential 30
F17 Fuse, heating blower, potential 15/2
F48 Fuse, supply for seat, ’Italy’ trailer brake,
potential 15/1
K5/37 Relay for trailer brake, Italy
K6/HEAT Relay for heating blower
M3 Heating blower motor
S7 Switch for handbrake
S50 Pushbutton for trailer brake valve
S50/1 Blower switch 1-2-3
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/15/1 Weld point for additional line, hydraulic trailer
brake, potential 31
X0/15/2 Weld point for additional line, hydraulic trailer
brake, potential 15/1
*URXQGSRLQWV
X1/26 Plug connection, potential 15/2, 15 A heating
blower
X1/HZG Plug connection, heating GND
X4/25 Plug connection for handbrake switch [25]
X4/50 Plug connection for heating
X4/51 Plug connection for ’Italy’ trailer brake, central
print [ITALB]
X4/52 Plug connection for additional line, Italy trailer
brake [MGV]
X24/2 Plug connection for cab wiring harness, right -
central print
Y50 Solenoid valve, trailer brake
Edition 01-2006
4010A-21
6KHHW 4010A-22
Sva 6-93360 EN
SS06A009
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Warning light system with ISO- A12 Central print X0/3/4 Weld point for instruments wiring harness, turn
Sva 6-93360 EN
BUS A13 Roof print signal, right
E3 Front left side marker light X0/3/5 Weld point for instruments wiring harness,
B SBB light, left
E4 Rear left side marker light potential 31
C SBB light, right X0/3/17 Weld point for instruments wiring harness,
E6 Front right side marker light
D BB light, left E7 Rear right side marker light potential 15 CAN BUS
E BB light, right E12 Brake light, left X0/6/1 Weld point for wiring harness, cab, left,
E13 Brake light, right potential 31
E14 Turn signal, front right X0/7/5 Weld point for wiring harness, cab, right,
# Variant on sheet 10 potential 31
E15 Turn signal, rear right
X0/7/18 Weld point for wiring harness, cab, right 58R
E16 Turn signal, rear left
E17 Turn signal, front left X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/12 Weld point for roof wiring harness, potential 31
F5 Fuse, supply for turn signal, potential 15/1
X0/28/13 Weld point for roof wiring harness, potential 31
F24 Fuse, parking light, rear left, ADIC, switch
lighting for instrument panel, trailer socket, front X2/87 Plug connection for cab wiring harness on right
and rear, ISO-BUS - instruments wiring harness ISO-BUS
F25 Fuse, parking light, rear right, ARU, switch X6/12L Plug connection for turn signal / side marker
lighting for control panel, mobile phone socket light, front left [BB-L]
*URXQGSRLQWV F33 Fuse, supply for hazard warning light, X6/12R Plug connection for turn signal / side marker
potential 30 light, front right [BB-R]
8 Roof, front right X10/8 Plug connection for wiring harness, cab, left -
F60 Fuse, side marker light, front left, licence plate
11 Engine cable carrier, rear lights, roof central print [8]
F61 Fuse, side marker light front right, ICU switch X10/11 Plug connection for roof print supply
lighting for roof, spot light, radio and ASW panel X10/12 Plug connection for roof wiring harness
lighting, activation of all work lamps X14/8 Plug connection for instruments wiring harness
K2 Indicator relay - steering column [8]
K5/10 Relay, light, potential 58 X14/14 Plug connection for roof supply [14]
S2/5 Hazard warning switch [WARN] X14/15 Plug connection for central print - wiring
S4/2 Turn signal switch, steering column harness for roof supply [15]
X0/3/1 Weld point for instruments wiring harness, X18/1 Plug connection for instruments wiring harness
potential 58L - central print [1]
X0/3/2 Weld point for instruments wiring harness, X24/1 Plug connection for instruments wiring harness
potential 15/1 - central print [1]
X0/3/3 Weld point for instruments wiring harness, X24/2 Plug connection for cab wiring harness, right -
potential 15/2 central print
Edition 01-2006
4010A-23
6KHHW 4010A-24
Sva 6-93360 EN
SS06A010
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Warning light system A12 Central print X0/3/3 Weld point for instruments wiring harness,
Sva 6-93360 EN
A13 Roof print potential 15/2
B Additional marker light, rear left
E3 Front left side marker light X0/3/4 Weld point for instruments wiring harness, turn
C SBB light, left E3/1 Additional front left side marker light signal, right
D SBB light, right E4 Rear left side marker light X0/3/5 Weld point for instruments wiring harness,
E6 Front right side marker light potential 31
E Additional marker light, rear right X0/3/17 Weld point for instruments wiring harness,
E6/1 Additional front right side marker light
F Additional marker light, front left E7 Rear right side marker light potential 15 CAN BUS
E12 Brake light, left X0/6/1 Weld point for wiring harness, cab, left,
G BB light, left and right
potential 31
E12/1 Additional rear left side marker light
H Additional marker light, front X0/7/5 Weld point for wiring harness, cab, right,
E13 Brake light, right
right potential 31
E13/1 Additional rear right side marker light
# Variant on sheet 9 X0/7/18 Weld point for wiring harness, cab, right 58R
E14 Turn signal, front right
X0/28/3 Weld point for roof wiring harness, potential 58
E15 Turn signal, rear right
X0/28/12 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left
X0/28/13 Weld point for roof wiring harness, potential 31
E17 Turn signal, front left
X6/12L Plug connection for turn signal / side marker
F5 Fuse, supply for turn signal, potential 15/1
light, front left [BB-L]
F24 Fuse, parking light, rear left, ADIC, switch
X6/12R Plug connection for turn signal / side marker
lighting for instrument panel, trailer socket, front
*URXQGSRLQWV light, front right [BB-R]
and rear, ISO-BUS
X10/8 Plug connection for wiring harness, cab, left -
F25 Fuse, parking light, rear right, ARU, switch
11 Engine cable carrier, rear central print [8]
lighting for control panel, mobile phone socket
X10/11 Plug connection for roof print supply
F33 Fuse, supply for hazard warning light,
X10/12 Plug connection for roof wiring harness
potential 30
X14/8 Plug connection for instruments wiring harness
F60 Fuse, side marker light, front left, licence plate
lights, roof - steering column [8]
X14/14 Plug connection for roof supply [14]
F61 Fuse, side marker light front right, ICU switch
lighting for roof, spot light, radio and ASW panel X14/15 Plug connection for central print - wiring
lighting, activation of all work lamps harness for roof supply [15]
K2 Indicator relay X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/10 Relay, light, potential 58
X24/1 Plug connection for instruments wiring harness
S2/5 Hazard warning switch [WARN]
- central print [1]
S4/2 Turn signal switch, steering column
X24/2 Plug connection for cab wiring harness, right -
X0/3/1 Weld point for instruments wiring harness,
central print
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
Edition 01-2006
4010A-25
6KHHW 4010A-26
Sva 6-93360 EN
SS06A011
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Auxiliary headlight and 4 work A12 Central print X0/6/1 Weld point for wiring harness, cab, left,
Sva 6-93360 EN
lamps A13 Roof print potential 31
A64 Work lamp panel X0/7/5 Weld point for wiring harness, cab, right,
B Headlight
E1 Headlight, left potential 31
C Low beam, high beam E2 Headlight, right X2/2 Plug connection for high beam headlight,
D Work lamp, fender E8 Work lamp, fender, left engine bonnet
E9 Work lamp, fender, right X2/3 Plug connection for low beam headlight, engine
E21 Auxiliary headlight, left bonnet
E22 Auxiliary headlight, right X4/40 [X4/ESW] Plug connection for roof print,
auxiliary headlight
E33 Work lamp, roof, front left centre [M]
X5/7 Socket for auxiliary headlight and work lamp,
E34 Work lamp, roof, front right centre [M]
front left
E37 Work lamp, roof, at front, outside left [A]
X5/8 Socket for auxiliary headlight and work lamp,
E38 Work lamp, roof, at front, outside right [A]
front right
F7 Fuse, relay 56a, potential 30
X6/6 Plug connection for instruments wiring harness
F11 Fuse, relay, work lamp, fender, potential 30
X10/8 Plug connection for wiring harness, cab, left -
F12 Fuse, light switch, potential 30 central print [8]
F34 Fuse, headlight, roof, right 56b X10/11 Plug connection for roof print supply
F35 Fuse, headlight, roof, left 56b X14/8 Plug connection for instruments wiring harness
*URXQGSRLQWV F36 Fuse, headlight, engine hood, right 56b - steering column [8]
F37 Fuse, headlight, engine hood, left 56b X14/14 Plug connection for roof supply [14]
7 Roof, front left F40 Fuse, supply for steering column switch, X14/15 Plug connection for central print - wiring
8 Roof, front right potential 15/1 harness for roof supply [15]
11 Engine cable carrier, rear K5/5 Switchover relay for high beam X16/5 Screw connection for roof print ground point
K5/6 Switchover relay for low beam X18/1 Plug connection for instruments wiring harness
K5/9 Relay, work lamp, fender - central print [1]
K5/56a Relay for high beam X24/1 Plug connection for instruments wiring harness
K5/56b Relay for low beam - central print [1]
S2/1 Light switch [LICHT] X24/2 Plug connection for cab wiring harness, right -
S2/17 Switch for auxiliary headlight central print
S4/1 High/low beam steering column switch X24/6 Plug connection for work lamp panel
V3/9 Diode
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/5/1 Weld point for engine hood wiring harness,
potential 31
Edition 01-2006
4010A-27
6KHHW 4010A-28
Sva 6-93360 EN
SS06A013
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Work lamp at rear outside A13 Roof print X4/21 Plug connection for work lamp, at rear, outside
Sva 6-93360 EN
A60 ECCU2 right
B Work lamp at rear inside
A64 Work lamp panel X4/22 Plug connection for work lamp, at rear, inside
C# Work lamp, at front, 6 right
CN3a ECCU2 plug connection
D Work lamp, BB light E23/1 Work lamp, roof, at rear, inside left X4/23 Plug connection for work lamp, at rear, outside
E23/2 Work lamp, roof, at rear, outside left left
E24/1 Work lamp, roof, at rear, inside right X4/24 Plug connection for work lamp, at rear, inside
# Variant on sheet 16
E24/2 Work lamp, roof, at rear, outside right left
E33 Work lamp, roof, at front, centre left [M] X4/38 [X4/ASW] Plug connection for roof print, work
lamp at front
E34 Work lamp, roof, at front, centre right [M]
E35 Work lamp, front left, on turn signal/ X5/7 Socket for auxiliary headlight and work lamp,
side marker light front left
X5/8 Socket for auxiliary headlight and work lamp,
E36 Work lamp, front right, on turn signal/side
front right
marker light
X6/12L Plug connection for turn signal / side marker
E37 Work lamp, roof, at front, outside left [A]
light, front left [BB-L]
E38 Work lamp, roof, at front, outside right [A]
X6/12R Plug connection for turn signal / side marker
E44 Work lamp, roof, at front, inside left [I]
light, front right [BB-R]
E45 Work lamp, roof, at front, inside right [I]
*URXQGSRLQWV X10/4 Plug connection for EDC print armrest (GSV)
F67 Fuse, 4 work lamps, at front, outside
X10/12 Plug connection for roof wiring harness
7 Roof, front left F68 Fuse, 4 rear work lamps, ASW panel supply for
X10/13 Plug connection for roof wiring harness
8 Roof, front right potential 30
X14/14 Plug connection for roof supply [14]
F70 Fuse, 2 rear work lamps
X16/4 Screw connection for potential 30, supply for
F101 Fuse, ASW panel supply for 4 work lamps, at
roof print
front, work lamps on BB light
X24/3 Plug connection for instruments wiring harness
F102 Fuse, 4+2 front work lamps
- cab wiring harness on right [3]
K5/30 Relay, 4 work lamps, at rear (outside)
X24/6 Plug connection for work lamp panel
K5/31 Relay, 4 work lamps, at front (outside)
K5/33 Relay, 4+2 work lamps, at front
S2/63/2 Switch, 4+2 work lamps, at front
X0/28/2 Weld point for roof wiring harness, work lamp 2
X0/28/6 Weld point for roof wiring harness, work lamp 2
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
Edition 01-2006
4010A-29
6KHHW 4010A-30
Sva 6-93360 EN
SS06A016
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A18 Electronics, xenon work lamp, right
A19 Electronics, xenon work lamp, left
# Variant on sheet 13
A64 Work lamp panel
E27 Work lamp, roof, at rear, XENON, left
E29 Work lamp, roof, at rear, XENON, right
F68 Fuse, 4 rear work lamps, ASW panel supply for
potential 30
F70 Fuse, 2 rear work lamps
K5/30 Relay, 4 work lamps, at rear (outside)
X0/28/2 Weld point for roof wiring harness, work lamp 2
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X2/26 Plug connection for electronics, xenon input,
right
X2/27 Plug connection for electronics, xenon input,
left
X4/10 Plug connection for electronics, xenon output,
*URXQGSRLQWV
right
X4/11 Plug connection for electronics, xenon output,
left
X4/21 Plug connection for work lamp, at rear, outside
right
X4/22 Plug connection for work lamp, at rear, inside
right
X4/23 Plug connection for work lamp, at rear, outside
left
X4/24 Plug connection for work lamp, at rear, inside
left
X10/12 Plug connection for roof wiring harness
X10/13 Plug connection for roof wiring harness
X16/4 Screw connection for potential 30, supply for
roof print
X24/6 Plug connection for work lamp panel
Edition 01-2006
4010A-31
6KHHW 4010A-32
Sva 6-93360 EN
SS06A017
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Work lamp, engine hood A13 Roof print X2/WKL Plug connection for work lamp, engine bonnet,
Sva 6-93360 EN
A14 Engine print reserve
B Reserve for engine print
A64 Work lamp panel X3/28 Plug connection for work lamp, engine hood
C Licence plate lights, roof and horn
E5/3 Licence plate lights, roof, left
D Door contact switch E5/4 Licence plate lights, roof, right X4/65L Plug connection for licence plate lights, roof, left
E Doorway lights E19 Interior light X4/67 Plug connection for work lamp, front left
E30 Doorway lights, left X6/1 Plug connection for Linde electronics
F Interior light
E61 Work lamp, left X6/12L Plug connection for turn signal / side marker
E62 Work lamp, right light, front left [BB-L]
F201 Fuse for work lamp, engine bonnet X10/3 Plug connection for engine print - instruments
F202 Fuse for work lamp, engine bonnet, reserve wiring harness
F206 Fuse, reserve (potential 15) X10/11 Plug connection for roof print supply
F209 Fuse, reserve (potential 30) X10/13 Plug connection for roof wiring harness
F214 Fuse for fuel filter, heating, potential 15 X10/14 Plug connection for wiring harness for roof
F215 Fuse for ABS supply supply
F218 Fuse for ABS supply, potential 30 X12/1 Plug connection for engine wiring harness -
K4/2/2 Time relay for interior light engine print
K6/WKL Relay for work lamp, engine bonnet X14/14 Plug connection for roof supply [14]
*URXQGSRLQWV X24/6 Plug connection for work lamp panel
S24/1 Switch for left door contact
S24/2 Switch for right door contact
X0/5/1 Weld point for engine hood wiring harness,
potential 31
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/5 Weld point for roof wiring harness, supply for
time relay
X0/28/9 Weld point for roof wiring harness, potential 31
X0/28/11 Weld point for roof wiring harness, potential 58
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X1/15/ABS Plug connection for ABS, potential 15
X1/15/FUELPlug connection for filter heating, potential 15
X1/30/ABS Screw connection for ABS, potential 30
Edition 01-2006
4010A-33
6KHHW 4010A-34
Sva 6-93360 EN
SS06A018
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Mirror heating A5/1 All-round light, left X9/1 Plug connection for switch for mirror adjustment
Sva 6-93360 EN
A5/2 All-round light, right X10/12 Plug connection for roof wiring harness
B Electrical mirror adjustment
A13 Roof print X19/1 Plug connection for all-round light, left
C Spot light A40 Control unit - mirror adjustment X19/2 Plug connection for all-round light, right
D All-round lights (can be plugged A41 Electric mirror heating and adjustment X24/6 Plug connection for work lamp panel
in) A42 Electric mirror heating and adjustment
A64 Work lamp panel
E18/1 Heated mirror, left
# Variants on sheet 19, 20 E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
X0/13/1 Weld point for additional line, mirror heating
*URXQGSRLQWV supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X3/80 Plug connection for mirror adjustment, roof print
[X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
X6/23 Plug connection for rear wiper motor
X6/24 Plug connection for electric mirror, right
[SPIEGEL]
Edition 01-2006
4010A-35
6KHHW 4010A-36
Sva 6-93360 EN
SS06A019
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Mirror heating A5/1 All-round light, left X6/23 Plug connection for rear wiper motor
Sva 6-93360 EN
A5/2 All-round light, right X6/24 Plug connection for electric mirror, right
B Electrical mirror adjustment
A13 Roof print [SPIEGEL]
C Spot light X9/1 Plug connection for switch for mirror adjustment
A40 Control unit - mirror adjustment
D All-round light carrier A41 Electric mirror heating and adjustment X10/12 Plug connection for roof wiring harness
A42 Electric mirror heating and adjustment X19/1 Plug connection for all-round light, left
# Variants on sheet 18, 20 A64 Work lamp panel X19/2 Plug connection for all-round light, right
E18/1 Heated mirror, left X24/6 Plug connection for work lamp panel
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
*URXQGSRLQWV X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X3/80 Plug connection for mirror adjustment, roof print
[X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
Edition 01-2006
4010A-37
6KHHW 4010A-38
Sva 6-93360 EN
SS06A020
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Mirror heating A5/1 All-round light, left X4/39 Plug connection for switch for heated mirror,
Sva 6-93360 EN
A5/2 All-round light, right roof print [39]
B Electrical mirror adjustment
A13 Roof print X6/23 Plug connection for rear wiper motor
C Spot light X6/24 Plug connection for electric mirror, right
A40 Control unit - mirror adjustment
D All-round lights (magnetic) A41 Electric mirror heating and adjustment [SPIEGEL]
A42 Electric mirror heating and adjustment X9/1 Plug connection for switch for mirror adjustment
A64 Work lamp panel X10/12 Plug connection for roof wiring harness
# Variants on sheet 18, 19
E18/1 Heated mirror, left X24/6 Plug connection for work lamp panel
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
*URXQGSRLQWV X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X3/80 Plug connection for mirror adjustment, roof print
[X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/33 Socket for all-round light, left, magnetic
X4/34 Socket for all-round light, right, magnetic
Edition 01-2006
4010A-39
6KHHW 4010A-40
Sva 6-93360 EN
SS06A021
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Radio preparation A6 Radio X4/41 Plug connection for front heated windscreen
Sva 6-93360 EN
A6/A Plug connection for radio switch
B Supply, roof
A6/B Plug connection for loudspeaker X4/42 Plug connection for rear heated windscreen
C Heated windscreen, front switch
A12 Central print
D Heated windscreen, rear A13 Roof print X10/3 Plug connection for engine print - instruments
A14 Engine print wiring harness
B14 Loudspeaker, left X10/11 Plug connection for roof print supply
B15 Loudspeaker, right X10/14 Plug connection for wiring harness for roof
E25 Heated windscreen, front supply
E26 Heated screen, rear X14/14 Plug connection for roof supply [14]
F45 Fuse, supply for roof, ICU potential 15/1 X14/15 Plug connection for central print - wiring
harness for roof supply [15]
F76 Fuse, heated windscreen, rear
X16/5 Screw connection for roof print ground point
F77 Fuse, heated windscreen, front
F212 Fuse, ADIC, ICU, radio memory, potential 30 X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/29 Relay for supply, potential 15/1
K6/7 Relay for rear heated windscreen
K6/8 Relay for front heated windscreen
*URXQGSRLQWV S2/16/1 Switch for rear heated windscreen [HZS HI]
S2/16/2 Switch for front heated windscreen [HZS VO]
7 Roof, front left W6 Antenna
11 Engine cable carrier, rear X0/3/14 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/13 Weld point for roof wiring harness, potential 31
X0/39/1 Welded point for additional line, rear heated
windscreen
X1/24 Screw connection, potential 30, roof print,
heated windscreens
X2/90 Plug connection for roof print, front heated
windscreen [90]
X2/91 Plug connection for roof print, rear heated
windscreen [91]
Edition 01-2006
4010A-41
6KHHW 4010A-42
Sva 6-93360 EN
SS06A022
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Air conditioning A13 Roof print X12/1 Plug connection for engine wiring harness -
Sva 6-93360 EN
A14 Engine print engine print
A20 Air conditioning - control Y13 Magnetic coupling, air conditioning compressor
# Variant on sheet 23
A22 Blower - control
F65 Fuse, air conditioning control
F66 Fuse, blower / air conditioning
F74 Fuse, reserve, potential 30
F103 Fuse, air conditioning, pressure switch
F205 Fuse for air-conditioning compressor
K5/32 Supply, D+ air conditioning
K5/36 Reserve
M12 Engine blower, air conditioning
R9/1 Temperature sensor for air conditioning system
R10 Potentiometer for air conditioning - temperature
R11 Potentiometer for air conditioning - roof blower
S30 Pushbutton for air conditioning system
W2 Line for temperature sensor, sheathed
*URXQGSRLQWV X0/42/1 Weld point for engine wiring harness,
potential 31
X2/9 Plug connection for roof print supply for blower
X2/14 Plug connection for air conditioning system
X2/20 Plug connection for blower motor, air
conditioning
X4/16 Plug connection, reserve
X4/44 Plug connection for air conditioning control
supply
X4/73 Plug connection for temperature sensor
X4/74 Plug connection for blower potentiometer
X4/75 Plug connection for air conditioning control
potentiometer
X10/3 Plug connection for engine print - instruments
wiring harness
X10/11 Plug connection for roof print supply
X10/14 Plug connection for wiring harness for roof
supply
Edition 01-2006
4010A-43
6KHHW 4010A-44
Sva 6-93360 EN
SS06A023
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A13 Roof print
B Blower (roof)
F65 Fuse, air conditioning control
F66 Fuse, blower / air conditioning
# Variant on sheet 22 K5/32 Supply, D+ air conditioning
M7 Motor for pneumatic seat
M10 Motor for blower, roof
S50/2 Blower switch 1-2-3 roof
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X2/9 Plug connection for roof print supply for
blower
X4/44 Plug connection for air conditioning control
supply
X4/61 Plug connection for Grammer seat
X24/2 Plug connection for cab wiring harness, right -
*URXQGSRLQWV central print
Edition 01-2006
4010A-45
6KHHW 4010A-46
Sva 6-93360 EN
SS06A024
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Horn A12 Central print X10/11 Plug connection for roof print supply
Sva 6-93360 EN
A13 Roof print X10/14 Plug connection for wiring harness for roof
B Steering column switch
F26 Fuse for parallel wiper, horn, interval relay, supply
C Parallel wipers, front potential 15/2 X14/8 Plug connection for instruments wiring harness
D Windscreen washing system, F63 Fuse for rear wiper - steering column [8]
front F64 Front wiper on hinged windscreen X14/15 Plug connection for central print - wiring
E Windscreen washing system, H1 Signal horn harness for roof supply [15]
rear K3 Interval relay X18/1 Plug connection for instruments wiring harness
M2/1 Motor for parallel wipers, front - central print [1]
F Angled wiper, front
M2/2 Motor for angled wiper, front X23/1 Plug connection for instruments wiring harness
G Angled wiper, rear - engine wiring harness
M4/2 Wiper motor, rear
M5 Motor for windscreen washing system, rear X24/1 Plug connection for instruments wiring harness
- central print [1]
M6 Motor for windscreen washing system, front
S2/30 Switch for wiper/washing system, rear [Wi.hi]
S4/3 Steering column switch for wiper/washing
system
X0/3/16 Weld point for instruments wiring harness,
CAN L
*URXQGSRLQWV
X0/5/1 Weld point for engine hood wiring harness,
potential 31
X0/6/1 Weld point for wiring harness, cab, left,
potential 31
X0/28/20 Weld point for roof wiring harness, potential 53
X3/28 Plug connection for work lamp, engine hood
and horn
X4/1 Plug connection for wiper motor, hinged
windscreen, front [Wi-VO]
X4/17 Plug connection for roof print, wiper motor,
front [17]
X4/65 Plug connection for roof print, wiper motor,
rear [65]
X5/55 Plug connection, front parallel wiper
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/23 Plug connection for rear wiper motor
Edition 01-2006
4010A-47
6KHHW 4010A-48
Sva 6-93360 EN
SS06A025
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Power socket, front A12 Central print X0/7/10 Weld point for wiring harness, cab, right, radar
Sva 6-93360 EN
A14 Engine print sensor
B Socket, front X0/25/2 Weld point for wiring harness, control panel,
A16 EDC print
C Socket, rear (trailer) A55 EDC box right, potential 58
D Power socket 1, rear A60 ECCU2 X0/7/5 Weld point for wiring harness, cab, right,
B16 Radar sensor potential 31
E Power socket 2, rear CN2/E ECCU2 plug connection X1/6/1 Screw connection for 2nd power socket, 40 A
(preparation) CN3b ECCU2 plug connection X1/6/2 Screw connection for 1st power socket, 40 A
F Power socket F2 Fuse for power socket, cab, potential 30 X1/15/1 Plug connection for power socket, front,
F3 Fuse, 1st power socket for potential 30 potential 15
G ASR with radar sensor X1/30/SOC Screw connection for power socket, front,
F4 Fuse, 2nd power socket for potential 30
potential 30
F29 Fuse, supply to front and rear power sockets,
standard signal socket, reverse fan, X1/31/2 Screw connection for engine print,
potential 15/2 potential 31
F31 Fuse, supply for radar sensor, potential 15/2 X1/60 Screw connection for power socket, cab, 30 A
F38 Fuse, trailer socket, potential 58L front and X2/4/1 Plug connection for central print, potential 15/2
rear X2/4/2 Screw-plug connection, potential 15/2
F39 Fuse, trailer socket, potential 58R X3/1 Plug connection for radar sensor
front and rear X3/2 Radar sensor plug connection
F52 Fuse, trailer socket for turn signal, right front X5/1 Screw - plug connection, potential 31, central
*URXQGSRLQWV print
and rear
F53 Fuse, trailer socket for turn signal, left front X6/12 Plug connection for cab wiring harness, left -
11 Engine cable carrier, rear
and rear 7-pin trailer socket, front [7 Pol.Vo]
12 Engine cable carrier, front X10/1 Trailer socket, 7-pin, rear
F55 Fuse, trailer socket for brake light, front and
rear X10/2 Trailer socket, 7-pin, front
F216 Fuse for power socket, front, potential 15 X10/4 Plug connection for EDC print armrest (GSV)
F221 Fuse for power socket, front, potential 30 X10/8 Plug connection for wiring harness, cab, left -
S2/73 Switch for slip control [ASR] central print [8]
X0/6/1 Weld point for wiring harness, cab, left, X10/9 Plug connection for wiring harness, cab, right -
potential 31 control panel
X0/6/2 Weld point for wiring harness, cab, left, X14/1 Power socket 1, rear, 40 A
potential 58L X14/30 Power socket, cab, 30 A
X0/6/3 Weld point for wiring harness, cab, left, X15 Power socket, front
potential L X24/2 Plug connection for cab wiring harness, right -
X0/6/4 Weld point for wiring harness, cab, left, central print
potential 58R X55 Plug connection for EDC box
X0/6/5 Weld point for wiring harness, cab, left,
potential R
Edition 01-2006
4010A-49
6KHHW 4010A-50
Sva 6-93360 EN
Supply for potential 15
Supply for potential 15
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A ADIC A1 ADIC
Sva 6-93360 EN
A12 Central print
B Filter heating (preparation)
A65 KEY PADS
C Supply for ADIC CN1 Plug connection for ADIC
CN3 Plug connection for ADIC
# Variant on sheet 27 F6 Fuse for ADIC, KEY PADS, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/4 Weld point for instruments wiring harness,
turn signal, right
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/3/11 Weld point for instruments wiring harness,
turn signal, left
X0/3/14 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/3/16 Weld point for instruments wiring harness
*URXQGSRLQWV CAN L
X0/7/17 Weld point for wiring harness, cab, right,
11 Engine cable carrier, rear handbrake
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/42/1 Weld point for engine wiring harness,
potential 31
X4/63 Plug connection for KEY PADS
X6/6 Plug connection for instruments wiring
harness
X10/18 Plug connection for instruments wiring
harness - engine wiring harness [INSTR]
X18/1 Plug connection for instruments wiring
harness - central print [1]
X24/1 Plug connection for instruments wiring
harness - central print [1]
X24/3 Plug connection for instruments wiring
harness - cab wiring harness on right [3]
Edition 01-2006
4010A-51
6KHHW 4010A-52
Sva 6-93360 EN
Check for sprung front axle
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A ADIC A1 ADIC
Sva 6-93360 EN
A12 Central print
B Filter heating (preparation)
A65 KEY PADS
C# Supply for ADIC, ISO BUS
CN1 Plug connection ADIC
CN3 ADIC plug connection
# Variant on sheet 26 F6 Fuse for ADIC, KEY PADS, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
*URXQGSRLQWV X0/7/5 Weld point for wiring harness, cab, right,
potential 31
11 Engine cable carrier, rear
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/42/1 Weld point wiring harness Motor Potential 31
X4/63 Plug connection KEY PAD´S
X6/6 Plug connection for instruments wiring harness
X10/18 Plug connection for instruments wiring harness
- engine wiring harness [INSTR]
X18/1 Plug connection for instruments wiring harness
- central print [1]
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
Edition 01-2006
4010A-53
6KHHW 4010A-54
Sva 6-93360 EN
Ground
RS 232 out
Transmission speed
signal
Radar screen
PTO shaft speed
50% signal, rear power lift
Ground
Potential 15
SS06A028
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A12 Central print
B ADIC
B2/1 Fuel tank level transmitter, left
B3 Compressed air transmitter
CN1 Plug connection for ADIC
CN2 Plug connection for ADIC
CN3 Plug connection for ADIC
S13 Control switch for brake fluid
S22 Control switch for coolant level
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/18 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/42/1 Weld point for engine wiring harness,
potential 31
X6/6 Plug connection for instruments wiring harness
*URXQGSRLQWV
X6/8 Plug connection for standard signal socket
[NORMS]
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/11 Plug connection for standard signal socket,
instruments wiring harness [NORMS]
X10/18 Plug connection for instruments wiring harness
- engine wiring harness [INSTR]
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
X29 Standard signal socket
Edition 01-2006
4010A-55
6KHHW 4010A-56
Sva 6-93360 EN
SS06A029
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
rear A60 ECCU2
B Switch for reducing speed B7 Rear PTO speed sensor
B8 Front PTO shaft speed sensor
C Switch for HTS
CN2/E ECCU2 plug connection
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
F32 Fuse for supply, PTO sensors, potential 15/2
S2/15/6 Switch for HTS [HTS]
S2/15/7 Switch for reducing speed
[DREHZAHLABSENKUNG]
X0/7/5 Weld point for wiring harness, cab, right,
potential 15
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
*URXQGSRLQWV potential 31
X0/27/5 Weld point for reverse travel equipment
wiring harness, setting off
X3/21 Plug connection for speed sensor, PTO, front
[PTO]
X24/2 Plug connection for cab wiring harness, right -
central print
X24/5 Plug connection for wiring harness, cab, right
- control panel
Edition 01-2006
4010A-57
6KHHW 4010A-58
Sva 6-93360 EN
SS06A030
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A16 EDC print
B Socket, mobile phone, left
E11 Cigarette lighter, right [E11]
C Cigarette lighter with socket on
E11/1 Mobile phone socket, left
right, 2-pin
F13 Fuse, cigarette lighter, 2-pin socket,
D Reserve, EDC print diagnosis socket, EDC print, potential 30
X0/7/17 Weld point for wiring harness, cab, right,
# Variant on sheet 31 handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X2/1 Socket, 2-pin 30/31 [2/1]
X2/4/1 Plug connection for central print,
potential 15/2
X2/6 Plug connection for lighting, potentiometer
EDC
X6/13 Plug connection for cigarette lighter and
socket, 2-pin
*URXQGSRLQWV X6/15 Plug connection for mobile phone socket, left
X14/4 Plug connection for EDC print - control panel
X24/2 Plug connection for cab wiring harness, right -
central print
Edition 01-2006
4010A-59
6KHHW 4010A-60
Sva 6-93360 EN
SS06A031
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A16 EDC print
B Socket, mobile phone, left for
reverse travel equipment E11 Cigarette lighter, right [E11]
E11/1 Mobile phone socket, left
D Cigarette lighter with socket on
F13 Fuse, cigarette lighter, 2-pin socket, diagnosis
right, 2-pin
socket, EDC print, potential 30
E Reserve, EDC print X0/7/17 Weld point for wiring harness, cab, right,
handbrake
# Variant on sheet 30 X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/28/8 Weld point for roof wiring harness, all-round
lights
X2/1 Socket, 2-pin 30/31 [2/1]
*URXQGSRLQWV X2/4/1 Plug connection for central print, potential 15/2
X2/6 Plug connection for lighting, potentiometer EDC
X6/13 Plug connection for cigarette lighter and socket,
2-pin
X6/15 Plug connection for mobile phone socket, left
X14/4 Plug connection for EDC print - control panel
X24/2 Plug connection for cab wiring harness, right -
central print
Edition 01-2006
4010A-61
6KHHW 4010A-62
Sva 6-93360 EN
SS06A032
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A14 Engine print
B# EDC without raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse for supply, potential 15/1 EDC box
lowering F210 Fuse for supply, EDC, potential 30
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
# Variant on sheet 33
X0/7/11 Weld point for cab wiring harness, right,
EDC GND
X0/7/12 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X2/12 Plug connection for raise/lower
X6/2 Plug connection for engine print, supply
*URXQGSRLQWV EDC [2]
X24/2 Plug connection for cab wiring harness, right -
central print
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]
Edition 01-2006
4010A-63
6KHHW 4010A-64
Sva 6-93360 EN
SS06A033
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A14 Engine print
B# EDC with raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse for supply, potential 15/1 EDC box
lowering F210 Fuse for supply, EDC, potential 30
S28 Changeover switch for raise/lower
X0/7/5 Weld point for wiring harness, cab, right,
# Variant on sheet 32
potential 31
X0/7/11 Weld point for wiring harness, cab, right,
EDC GND
X0/7/12 Weld point for cab wiring harness, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X2/12 Plug connection for raise/lower
*URXQGSRLQWV
X6/2 Plug connection for engine print, supply
EDC [2]
X24/2 Plug connection for cab wiring harness, right -
central print
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]
Edition 01-2006
4010A-65
6KHHW 4010A-66
Sva 6-93360 EN
GSV
EDC stop
Transport
lift RAISE
Transport/
lift LOWER
Controlling/
Potential 31
Potential 58
Front loader
Potential 15/1
Potential 15/1
Rapid retraction
Rapid retraction
Supply for EDC stop
SS06A034
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Switch for hydraulic master A12 Central print X0/25/5 Weld point for wiring harness, control panel,
Sva 6-93360 EN
A16 EDC print right GSV1
B Front power lift, Raise / Lower
A55 EDC box X1/FL Plug connection for front loader solenoid valve
C Armrest X10/4 Plug connection for EDC print armrest (GSV)
A60 ECCU2
CN3a ECCU2 plug connection X10/9 Plug connection for wiring harness, cab, right -
F19 Fuse for ARU supply, EDC potential 15/1 control panel
F20 Fuse for ARU supply, EDC potential 15/1 X18/4 Plug connection for cab wiring harness, right -
R3 2 kOhm resistance armrest
R4 2 kOhm resistance X24/2 Plug connection for cab wiring harness, right -
R5 2 kOhm resistance central print
R6 2 kOhm resistance X24/5 Plug connection for wiring harness, cab, right -
control panel
R7 2 kOhm resistance
X55 Plug connection for EDC box
R8 Potentiometer, accelerator pedal
R9 2 kOhm resistance Y60 Front loader solenoid valve
S2/7/3 Switch for hydraulic master [MASTER]
S18/1 External button for AUX BLUE, pressure in -
[ATS]
*URXQGSRLQWV S18/2 External button for AUX BLUE, pressure in +
[ATH]
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/7/11 Weld point for wiring harness, cab, right,
EDC GND
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/26 Weld point for wiring harness, cab, right,
transport/control signal
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Edition 01-2006
4010A-67
6KHHW 4010A-68
Sva 6-93360 EN
SS06A035
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2]
B Raise / Lower button EDC
A55 EDC box
C External button, EDC
S2/15/5 Raise / Lower button [INNEN]
S14/1 External button for LOWER, left [SENKEN]
S14/2 External button for LOWER, right [LOWER]
S15/1 External button for RAISE, left [RAISE]
S15/2 External button for RAISE, right [RAISE]
X0/7/4 Weld point for wiring harness, cab, right, supply
for external pushbutton on right
X0/7/6 Weld point for wiring harness, cab, right, supply
for external pushbutton on left
X0/7/10 Weld point for wiring harness, cab, right, radar
sensor
X0/7/16 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/21 Weld point for wiring harness, cab, right, RAISE
pushbutton
*URXQGSRLQWV X0/7/25 Weld point for wiring harness, cab, right,
LOWER
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X24/5 Plug connection for wiring harness, cab, right -
control panel
X55 Plug connection for EDC box
Edition 01-2006
4010A-69
6KHHW 4010A-70
Sva 6-93360 EN
transport
Ground during
SS06A036
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A EDC signal 50% A16 EDC print X3/18 Plug connection for EDC mixing
Sva 6-93360 EN
A55 EDC box potentiometer
B Indicator lights, EDC
A60 ECCU2 X3/19 Plug connection for slip control potentiometer
C Potentiometer, EDC X4/2 Plug connection for diagnosis LED, slip LED
CN3b ECCU2 plug connection
D1 Diode X4/3 Plug connection for raise LED, lower LED
E41 EDC lighting X5/6 Plug connection for nominal value
E42 EDC lighting potentiometer
E43 EDC lighting X10/4 Plug connection for EDC print armrest (GSV)
H2/1 Diagnosis LED X14/4 Plug connection for EDC print - control panel
H2/2 LED for slip
H2/3 LED for raise
H2/4 LED for lower
R1 2 kOhm resistance
R2 2 kOhm resistance
R6 2 kOhm resistance
R6/1 Setpoint potentiometer
R6/2 Lift limitation potentiometer
*URXQGSRLQWV R6/3 Mixing potentiometer
R6/4 Lowering speed potentiometer
R6/5 Slip control potentiometer
R12 0 kOhm resistance
R13 0 kOhm resistance
R14 6.2 kOhm resistance
R19 2 kOhm resistance
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X2/6 Plug connection for lighting, potentiometer EDC
X3/16 Plug connection for potentiometer, lowering
speed
X3/17 Plug connection for potentiometer, raising
speed
Edition 01-2006
4010A-71
6KHHW 4010A-72
Sva 6-93360 EN
Signal
Engine back
pressure brake
0.8V to 4.4V
0V to 5.8V
Signal
Handbrake
Signal
Seat switch
5.8 V
3V
Ground
5.8 V
Ground
5.6V
1.1V to 4V
4.4V to 0.8V
Ground
Potential 30
GSV3
Potential 31
Potential 15/1
Signal 80%
Accelerator
pedal signal
SS06A037
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Supply, FMGR A3 EEM3 control unit X24/2 Plug connection for cab wiring harness, right -
Sva 6-93360 EN
A4 FMGR central print
B# Clutch switch 80%
A4/1 FMGR plug connection (white) [1] X24/3 Plug connection for instruments wiring harness
C# Angle of rotation sensor, - cab wiring harness on right [3]
A4/2 FMGR plug connection - dark grey [2]
coupling X24/5 Plug connection for wiring harness, cab, right -
A4/3 FMGR plug connection (blue) [3]
D# Potentiometer, accelerator pedal A4/4 FMGR plug connection (grey) [4] control panel
E# Parking interlock switch A12 Central print X89/1 Plug connection for EEM3 engine control unit -
B17 Angle of rotation sensor, clutch engine wiring harness
F# Limit load potentiometer
F14 Fuse, FMGR, potential 30
G# Switch for engine back pressure
F51 Fuse, supply for potential 15/1 FMGR
brake
R8 Potentiometer, accelerator pedal
H# Switch for handbrake, seat
R23 Limit load potentiometer
switch
S2/61 Parking interlock switch [PARKBREMSE]
S8 Seat switch
# Variants on sheet 38, 39 S20 Engine back pressure brake switch
S21 Switch for handbrake
S46 Clutch switch 80%
*URXQGSRLQWV X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/24 Weld point for wiring harness, cab, right GSV3
X3/23 Plug connection for full-load potentiometer
X4/25 Plug connection for handbrake switch [25]
X4/61 Plug connection for Grammer seat
X4/70 Plug connection for accelerator pedal [70]
X10/18 Plug connection for instruments wiring harness
- engine wiring harness [INSTR]
Edition 01-2006
4010A-73
6KHHW 4010A-74
Sva 6-93360 EN
5.6V
Ground
1.1V to 4V
Potential 31
Signal 80%
Ground
0.8V to 4.4V
Potential 30
4.4V to 0.8V
Potential 15/1
5.8 V
signal
Accelerator pedal
SS06A038
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Supply, FMGR A3 EEM3 control unit X0/27/14 Weld point for reverse travel equipment wiring
Sva 6-93360 EN
A4 FMGR harness, coupling
B# Clutch switch 80% for reverse
A4/1 FMGR plug connection (white) [1] X4/70 Plug connection for accelerator pedal [70]
travel equipment
A4/3 FMGR plug connection (blue) [3] X4/70/1 Plug connection for accelerator pedal
C# Angle of rotation sensor, [FAHRPEDAL]
A4/4 FMGR plug connection (grey) [4]
coupling with reverse travel
A12 Central print X10/18 Plug connection for instruments wiring harness
equipment
B17 Angle of rotation sensor, clutch - engine wiring harness [INSTR]
D# Potentiometer, accelerator pedal B17/1 Angle of rotation sensor, clutch, reverse travel X24/2 Plug connection for cab wiring harness, right -
for reverse travel equipment equipment central print
F14 Fuse, FMGR, potential 30 X24/3 Plug connection for instruments wiring harness
# Variants on sheet 37, 39 F51 Fuse, supply for potential 15/1 FMGR - cab wiring harness on right [3]
K5/60 Relay for clutch [KUPPLUNG] X89/1 Plug connection for EEM3 engine control unit -
engine wiring harness
K5/61 Relay for front accelerator pedal
[FAHRPEDAL1]
K5/62 Relay for rear accelerator pedal
[FAHRPEDAL1]
R8 Potentiometer, accelerator pedal
R8/1 Potentiometer, accelerator pedal, reverse travel
*URXQGSRLQWV
equipment
S46 Clutch switch 80%
S46/1 Clutch switch 80% [KUPPL]
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/27/1 Weld point for seat R
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/10 Weld point for reverse travel equipment wiring
harness, accelerator pedal 2
X0/27/11 Weld point for reverse travel equipment wiring
harness, accelerator pedal 1
X0/27/13 Weld point for reverse travel equipment wiring
harness, coupling
Edition 01-2006
4010A-75
6KHHW 4010A-76
Sva 6-93360 EN
Signal
Handbrake
Signal
Seat switch
3V
Ground
0V to 5.8V
5.8 V
Signal
Engine back
pressure brake
GSV3
Signal for reverse
travel equipment
active
SS06A039
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A# Parking interlock switch A4 FMGR X6/23 Plug connection for rear wiper motor
Sva 6-93360 EN
A4/1 FMGR plug connection (white) [1] X6/27 Plug connection for seat switch, ARU console
B# Potentiometer, limit load for
A4/2 FMGR plug connection - dark grey [2] with reverse travel equipment
reverse travel equipment
A4/4 FMGR plug connection (grey) [4] X6/58 Plug connection for seat switch [SITZ RF]
C# Switch for engine back pressure
A70 Seat switch X24/3 Plug connection for instruments wiring harness
brake, handbrake for reverse
H1/1 Signal horn for reverse travel equipment - cab wiring harness on right [3]
travel equipment
R23 Limit load potentiometer X24/5 Plug connection for wiring harness, cab, right -
D# Seat switch for reverse travel S2/61 Parking interlock switch [PARKBREMSE] control panel
equipment
S2/61/1 Switch for parking interlock [PARK]
E# Horn for reverse travel S2/75 Button signal horn [HORN]
equipment S8 Seat switch
S8/1 Reversible seat switch
# Variants on sheet 37, 38 S8/2 Reversible seat switch
S20 Engine back pressure brake switch
S21 Switch for handbrake
X0/3/1 Weld point for instruments wiring harness,
potential 58L
*URXQGSRLQWV X0/3/3 Weld point for instruments wiring harness,
potential 15/2
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/24 Weld point for wiring harness, cab, right GSV3
X0/27/1 Weld point for seat R
X0/27/4 Weld point for parking interlock
X0/27/6 Weld point for GSV3
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point, potential 15
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X4/25 Plug connection for handbrake switch [25]
X4/25/1 Plug connection for handbrake switch
[HANDBREMSE]
Edition 01-2006
4010A-77
6KHHW 4010A-78
Sva 6-93360 EN
4WD
Management
All-wheel drive
ON
Brake oil
cooling valve 2
GSV1
Brake oil
cooling valve 1
Manual mode
0-14 km/h
0-25 km/h
Differential lock ON
Differential lock management
Differential lock solenoid valve
SS06A040
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
manual mode A4/1 FMGR plug connection (white) [1]
B# Switch for differential lock, all- A4/3 FMGR plug connection (blue) [3]
wheel drive management A16 EDC print
A60 ECCU2
C# Solenoid valves, brake oil
cooling CN3b ECCU2 plug connection
S2/56 Switch for differential lock management
[DIFF HI]
# Variant on sheet 41 S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
S2/59 Switch for 4-wheel drive management [4 WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/5 Weld point for wiring harness, control panel,
*URXQGSRLQWV right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control panel
X24/5 Plug connection for wiring harness, cab, right -
control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2
Edition 01-2006
4010A-79
6KHHW 4010A-80
Sva 6-93360 EN
All-wheel drive
ON
4WD
Management
Brake oil
cooling valve 2
GSV1
Brake oil
cooling valve 1
Manual mode
0-14 km/h
0-25 km/h
Differential lock ON
Differential lock management
Differential lock solenoid valve
SS06A041
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
manual mode for reverse travel A4/1 FMGR plug connection (white) [1]
equipment A4/3 FMGR plug connection (blue) [3]
B# Switch for differential lock, all- A16 EDC print
wheel drive management for A60 ECCU2
reverse travel equipment CN3b ECCU2 plug connection
C# Solenoid valves, brake oil S2/56 Switch for differential lock management
cooling [DIFF HI]
S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
# Variant on sheet 40 S2/59 Switch for 4-wheel drive management [4 WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/5 Weld point for wiring harness, control panel,
*URXQGSRLQWV right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control panel
X24/5 Plug connection for wiring harness, cab, right
- control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2
Edition 01-2006
4010A-81
6KHHW 4010A-82
Sva 6-93360 EN
Load ground for
reverse gear
with max.
200mA
Reverse
Forwards
Neutral
Dead man
Plug X4/59b in here in
an emergency
BUZZER
SS06A042
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2]
B Gearbox electronics
A12 Central print
C LIMP HOME plug connection
A13 Roof print
D# Shuttle lever A21 SGR transmission controller
E Preparation for buzzer, reverse A23 Linde electronics
gear A24 Hydrostat
F9 Fuse, SGR, potential 30
F18 Fuse, SGR, potential 15/1
# Variant on sheet 43
P8 ICU
S4/4 Shuttle lever
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/3 Weld point for roof wiring harness, potential 58
*URXQGSRLQWV
X0/28/12 Weld point for roof wiring harness, potential 31
X4/59/a Plug connection for LIMP HOME [A]
X4/59/b Plug connection for LIMP HOME [A]
X4/59/c Plug connection for LIMP HOME [B]
X6/1 Plug connection for Linde electronics
X6/3 Plug connection for instruments wiring harness
- steering column [3]
X6/9 Plug connection for Linde electronics -
hydrostat A24
X10/12 Plug connection for roof wiring harness
X16/21 SGR plug connection
X24/2 Plug connection for cab wiring harness, right -
central print
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
Edition 01-2006
4010A-83
6KHHW 4010A-84
Sva 6-93360 EN
Reverse
Forwards
Neutral
Dead man
In an emergency, plug
X4/59a here
SS06A043
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A ICU performance monitor A4 FMGR X4/59/a Plug connection for LIMP HOME [A]
Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2] X4/59/b Plug connection for LIMP HOME [A]
B Gearbox electronics
A12 Central print X4/59/c Plug connection for LIMP HOME [B]
C LIMP HOME plug connection
A13 Roof print X6/1 Plug connection for Linde electronics
D# Shuttle lever A21 SGR transmission controller X6/3 Plug connection for instruments wiring harness
E Display for reverse travel A23 Linde electronics - steering column [3]
equipment A24 Hydrostat X6/9 Plug connection for Linde electronics -
F9 Fuse, SGR, potential 30 hydrostat A24
F18 Fuse, SGR, potential 15/1 X10/12 Plug connection for roof wiring harness
# Variant on sheet 42 X16/21 SGR plug connection
P6 Display for reverse travel equipment
P8 ICU X24/2 Plug connection for cab wiring harness, right -
S4/4 Shuttle lever central print
S4/4/1 Forwards - reverse switch [V/R] X24/3 Plug connection for instruments wiring harness
X0/3/15 Weld point for instruments wiring harness, - cab wiring harness on right [3]
CAN H
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
*URXQGSRLQWV X0/27/2 Weld point for reverse travel equipment wiring
harness „V“
X0/27/3 Weld point for reverse travel equipment wiring
harness „R“
X0/27/5 Weld point for reverse travel equipment wiring
harness, setting off
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point, potential 15
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/12 Weld point for roof wiring harness, potential 31
Edition 01-2006
4010A-85
6KHHW 4010A-86
Sva 6-93360 EN
Ground
Ground
Ground
Ground
Ground
Ground
4V
Ground
4V
4V
4V
10V
10V
GND opens at a
difference in
pressure of
> 5 bar
4V
4V
4V
10 to 6000Hz
Ground
5V
PTC 1 kOhm to
4.4 kOhm
10 to 6000Hz
Ground
Ground
10 to 6000Hz
10 to 6000Hz
0.2V to 3.1V
0.2V to 1.2V
5V
10 to 6000Hz
SS06A044
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
B24 Speed sensor, cartridge input
B Speed sensors, cartridge
B25 Speed sensor, planetary carrier 3/4
C Sensors, cartridge switch
B26 Speed sensor, cartridge output
B26 Speed sensor, cartridge output
B32 Speed sensor, temperature sensor,
transmission oil
B35 Speed sensor, planetary carrier 1/2
B47 Pressure sensor for transmission system
pressure
B51 Pressure sensor for transmission lubricating
pressure
S49/1 Switch, pressure filter, 5bar
X5 Plug connection for pressure filter
X17 Plug connection for parking interlock ground
Y41 Solenoid valve, coupling 1
Y42 Solenoid valve, coupling 2
Y43 Solenoid valve, coupling 3
*URXQGSRLQWV
Y44 Solenoid valve, coupling 4
Y45 Solenoid valve, coupling, forward
Y46 Solenoid valve, coupling, reverse
Y57 Solenoid valve, parking interlock On
Y58 Solenoid valve, parking interlock Off
Y59 All-wheel solenoid valve
Edition 01-2006
4010A-87
6KHHW 4010A-88
Sva 6-93360 EN
12V for
PTO shaft
at rear active
12V for
PTO shaft
at front active
SS06A045
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
CN2/E ECCU2 plug connection
B Front PTO shaft
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
S2/70/1 Switch for front PTO [PTO VO]
S2/70/2 Switch for rear PTO [PTO HI]
S2/71 Switch for rear PTO, management [PTO M]
S17/1 External button for PTO, rear left
S17/2 External button for PTO, rear right
X0/7/9 Weld point for wiring harness, cab,
right GSV4
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X24/5 Plug connection for wiring harness, cab, right
*URXQGSRLQWV - control panel
Y4 Solenoid valve for front PTO [PTO VO]
Y5 Solenoid valve for rear PTO [PTO]
Edition 01-2006
4010A-89
6KHHW 4010A-90
Sva 6-93360 EN
Potential 15/2
12V
as of
during
locked
Ground
Ground
Potential 30
12V during
12V during
v< 14 km/h
12 V during
management
12V during UP
Check for
front axle 12V during UP /
ACTIVE 12V during UP DOWN
12V during
UP / DOWN
12 V
Signal flow
Signal flow
Ground
Ground
12 V
BLUE BLACK GREEN
SS06A046
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Spring-mounted front axle A12 Central print X12/20 Plug connection for control block, sprung front
Sva 6-93360 EN
A60 ECCU2 axle [VA]
B Supply, ECCU2
A61 Electronics, front axle with independent X24/2 Plug connection for cab wiring harness, right -
suspension central print
# Variant on sheet 47 B33/1 Angle of rotation sensor Y14 Solenoid valve for sprung front axle, UP/DOWN
B33/2 Angle of rotation sensor Y15 Solenoid valve for sprung front axle, left
CN1a ECCU2 plug connection Y16 Solenoid valve for sprung front axle, right
CN2/E ECCU2 plug connection
CN3b ECCU2 plug connection
F28 Fuse, sprung front axle, potential 15/2
F10 Fuse, supply, ECCU2, potential 30
F27 Fuse, sprung front axle, potential 30
F50 Switch for supply, potential 15/1 ECCU2
S2/15/1 Switch for sprung front axle UP/DOWN
S2/15/2 Switch for sprung front axle ON/OFF [VA ein]
X0/3/1 Weld point for instruments wiring harness,
potential 58L
*URXQGSRLQWV X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/45 Plug connection for wiring harness, cab, right -
sprung front axle [45]
X2/46 Plug connection for potential 58/31, sprung
front axle [GE.VA]
X4/45 Plug connection for sprung front axle [45]
Edition 01-2006
4010A-91
6KHHW 4010A-92
Sva 6-93360 EN
Potential 15/2
UP
12V
as of
during
locked
Ground
Ground
Potential 30
12V during
12V during
12V during
v< 14 km/h
12 V during
management
Check for
front axle 12V during UP /
ACTIVE 12V during UP DOWN
12V during UP /
DOWN
12 V
12 V
Signal flow
Signal flow
Ground
Ground
BLUE BLACK GREEN
SS06A047
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A Spring-mounted front axle A12 Central print X2/46 Plug connection for potential 58/31, sprung
Sva 6-93360 EN
A60 ECCU2 front axle [GE.VA]
B Supply, ECCU2 for ISO BUS
A61 Electronics, front axle with independent X2/87 Plug connection for cab wiring harness on
suspension right - instruments wiring harness ISO-BUS
# Variant on sheet 46 B33/1 Angle of rotation sensor X4/45 Plug connection for sprung front axle [45]
B33/2 Angle of rotation sensor X4/85/a Plug connection for cab wiring harness, right
CN1a ECCU2 plug connection - ISO BUS preparation
CN2/E ECCU2 plug connection X4/85/b Plug connection for cab wiring harness, right
CN3b ECCU2 plug connection - ISO BUS preparation
F10 Fuse, supply, ECCU2, potential 30 X12/20 Plug connection for control block, sprung
F27 Fuse for sprung front axle, potential 30 front axle [VA]
F28 Fuse for sprung front axle, potential 15/2 X24/2 Plug connection for cab wiring harness, right -
central print
F50 Switch for supply, potential 15/1 ECCU2
Y14 Solenoid valve for sprung front axle, UP/
S2/15/1 Switch for sprung front axle UP/DOWN
DOWN
S2/15/2 Switch for sprung front axle ON/OFF [VA ein]
Y15 Solenoid valve for sprung front axle, left
X0/3/1 Weld point for instruments wiring harness,
Y16 Solenoid valve for sprung front axle, right
potential 58L
*URXQGSRLQWV X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right
GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/45 Plug connection for wiring harness, cab, right
- sprung front axle [45]
Edition 01-2006
4010A-93
6KHHW 4010A-94
Sva 6-93360 EN
SS06A048
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
B19 Angle of rotation sensor [LAGESENSOR VO]
B Angle of rotation sensor, power
lift, front CN1a ECCU2 plug connection
CN3a ECCU2 plug connection
C External button, AUX, front
CN3b ECCU2 plug connection
D External button, power lift, front S14/3 External button for front power lift, LOWER
[Senken]
S15/3 External button for front power lift, RAISE
[Heben]
S19/1 External button for AUX BROWN, pressure in -
[Senken]
S19/2 External button for AUX BROWN, pressure in +
[Heben]
S28/1 Button for front power lift management
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/23/1 Weld point for additional line, external
pushbutton for front power lift GSV4
X3/22 Plug connection for angle of rotation sensor,
*URXQGSRLQWV front power lift [LAGE]
X4/69 Plug connection for external button, front power
lift [FHW]
X4/72 Plug connection for external button, front AUX
brown [EHS]
X18/4 Plug connection for cab wiring harness, right -
armrest
Edition 01-2006
4010A-95
6KHHW 4010A-96
Sva 6-93360 EN
SS06A049
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A3 EEM3 control unit
A65 KEY PADS
CN3 ADIC plug connection
P8 ICU
P8/1 Plug connection ICU CAN [DISP]
P8/2 Plug connection ICU CAN
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/3/7 Weld point for instruments wiring harness
CAN L
X0/3/8 Weld point for instruments wiring harness
CAN H
X0/3/9 Weld point for instruments wiring harness,
potential 30
X4/63 Plug connection for KEY PADS
X10/14 Plug connection for wiring harness for roof
supply
*URXQGSRLQWV X10/18 Plug connection for instruments wiring
harness - engine wiring harness [INSTR]
X14/14 Plug connection for roof supply [14]
X89/1 Plug connection for EEM3 engine control unit -
engine wiring harness
Edition 01-2006
4010A-97
6KHHW 4010A-98
Sva 6-93360 EN
Plug for service tool
SS06A050
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A4/4 FMGR plug connection (grey) [4]
A21 SGR transmission controller
A30 ARU print
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X0/7/32 Weld point for wiring harness, cab, right,
CAN H
X0/7/33 Weld point for wiring harness, cab, right, CAN L
X0/7/36 Weld point for wiring harness, cab, right,
CAN H
X0/7/37 Weld point for wiring harness, cab, right, CAN L
X0/7/52 Weld point for wiring harness, cab, right,
CAN H
X0/7/53 Weld point for wiring harness, cab, right, CAN L
X9/17 Socket for diagnosis service tool [DIAGNOSE]
*URXQGSRLQWV X16/21 SGR plug connection
X18/4 Plug connection for cab wiring harness, right -
armrest
Edition 01-2006
4010A-99
6KHHW 4010A-100
Sva 6-93360 EN
SS06A051
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A4/3 FMGR plug connection (blue) [3]
A12 Central print
A55 EDC box
A60 ECCU2
CN1a ECCU2 plug connection
F16 Fuse for reserve, potential 15/2
F47 Fuse for supply, AUX potential 15/1
X0/7/40 Weld point for wiring harness, cab, right,
CAN H
X0/7/41 Weld point for wiring harness, cab, right, CAN L
X0/7/44 Weld point for wiring harness, cab, right,
CAN H
X0/7/45 Weld point for wiring harness, cab, right, CAN L
X0/7/48 Weld point for cab wiring harness, right CAN H
X0/7/49 Weld point for cab wiring harness, right, CAN L
X24/2 Plug connection for cab wiring harness, right -
central print
*URXQGSRLQWV
X55 Plug connection for EDC box
Edition 01-2006
4010A-101
6KHHW 4010A-102
Sva 6-93360 EN
SS06A052
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
CN3b ECCU2 plug connection
B Heating valve for hydraulic oil
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/9/10 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/11 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/12 Weld point for wiring harness, AUX CAN H
X0/9/13 Weld point for wiring harness, AUX CAN L
X0/9/22 Weld point for wiring harness, AUX CAN H
X0/9/23 Weld point for wiring harness, AUX CAN L
X0/9/32 Weld point for wiring harness, AUX CAN H
X0/9/33 Weld point for wiring harness, AUX CAN L
X0/9/42 Weld point for wiring harness, AUX CAN H
X0/9/43 Weld point for wiring harness, AUX CAN L
X0/9/50 Weld point AUX CAN H
X0/9/51 Weld point for wiring harness, AUX CAN L
*URXQGSRLQWV
X3/10 Plug connection for terminating resistor
X4/83 Plug connection for remote control valves
[EHS]
X4/90 Plug connection AUX 1
X4/91 Plug connection AUX 2
X4/92 Plug connection AUX 3
X4/93 Plug connection AUX 4
X4/94 Plug connection AUX 5
Y8 Heating valve
Edition 01-2006
4010A-103
6KHHW 4010A-104
Sva 6-93360 EN
Supply for EDC stop
Transport
Lighting, potential 58
External button, power lift, front, raise
EDC stop
Potential 31
Potential 15
GSV
Controlling
Rapid retraction
Interface, wiring harness, cab, right
SS06A053
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
right C1 Condenser
B Armrest, electronics C2 Condenser
C3 Condenser
C4 Condenser
L1 Disturbance protection
L2 Disturbance protection
V1/1 Diode
V1/2 Z diode
V1/3 Protective diode CAN H
V1/4 Protective diode CAN L
X18/4 Plug connection for cab wiring harness, right -
armrest
X30/1 Plug connection for supply, armrest
X30/7 Plug connection for CAN BUS
*URXQGSRLQWV
Edition 01-2006
4010A-105
6KHHW 4010A-106
Sva 6-93360 EN
SS06A054
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A30 ARU print
B Control handle for AUX
B28 Manual accelerator slider
C Manual accelerator slider
B30 Longitudinal joystick
D Armrest, electronics B31 Transverse joystick
B52 Control lever
S35 Joystick button
X30/3 Plug connection for ARU - man. oper.
accelerator slider
X30/4 Plug connection for ARU - AUX control lever
X30/5 Plug connection for ARU - AUX joystick
*URXQGSRLQWV
Edition 01-2006
4010A-107
6KHHW 4010A-108
Sva 6-93360 EN
SS06A055
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
E28/1 Lighting ARU
B Reserve
R12 0 kOhm resistance
C Button, rapid retraction
R13 0 kOhm resistance
D Button, EDC - stop and lighting R14 6.2 kOhm resistance
E Armrest, electronics R15 1.2 kOhm resistance
R16 6.2 kOhm resistance
R17 2 kOhm resistance
S2/72 Rapid retraction button
S33 EDC stop button
S34 5th AUX button
X30/2 Plug connection for ARU - rapid retraction
button
X30/6 Plug connection for ARU - AUX button
X30/8 Plug connection for ARU reserve
X30/9 Plug connection for ARU - switch lighting
X30/13 Plug connection for ARU lighting
*URXQGSRLQWV X30/14 Plug connection for ARU button, EDC stop
Edition 01-2006
4010A-109
6KHHW 4010A-110
Sva 6-93360 EN
POTI_4 POTI_3 POTI_2 POTI_1 POTI_0
SS06A056
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
control valves R20/1 Potentiometer for 1st AUX
B Armrest, electronics R20/2 Potentiometer for 2nd AUX
R20/3 Potentiometer for 3rd AUX
R20/4 Potentiometer for 4th AUX
R20/5 Potentiometer for 5th AUX
R28/1 470 Ohm resistance
R28/2 560 Ohm resistance
R28/3 470 Ohm resistance
R28/4 560 Ohm resistance
R28/5 470 Ohm resistance
R28/6 560 Ohm resistance
R28/7 470 Ohm resistance
R28/8 560 Ohm resistance
R28/9 470 Ohm resistance
R28/10 560 Ohm resistance
X30/12 Plug connection for ARU - potentiometer
*URXQGSRLQWV AUX 5
X30/15 Plug connection for ARU - potentiometer
AUX 3 and AUX 4
X30/16 Plug connection for ARU - potentiometer
AUX 1 and AUX 2
Edition 01-2006
4010A-111
6KHHW 4010A-112
Sva 6-93360 EN
SS06A057
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
Sva 6-93360 EN
A31 Multicontroller II
B Armrest, electronics
S60/1 F/R button
S60/2 Cruise control button
S60/3 Speed button +
S60/4 Speed button -
S60/5 HTS button
S60/6 AUX blue button
S60/7 EDC Transport/control button
S60/8 Shift button (Schwimmstellung)
X4 Plug connection for ARU multicontroller II - print
X21 Plug connection for multicontroller II - print
X30/11 Plug connection for supply - multicontroller print
X30/19 Plug connection for shift button (float position)
*URXQGSRLQWV
Edition 01-2006
4010A-113
6KHHW 4010A-114
Sva 6-93360 EN
SS06A058
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
Edition 01-2006
'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW
A ISO-BUS A12 Central print X1/30/ISO Screw connection for engine print, potential 30
Sva 6-93360 EN
A14 Engine print X2/11 Plug connection for engine print ISO-BUS
B ISO-BUS
A60 ECCU2 X2/86 Plug connection for socket LBS ISO-BUS
CN1a ECCU2 plug connection X3/85 Plug connection for terminating resistor
CN3b ECCU2 plug connection ISO-BUS
CN4 Plug connection for ECCU2 ISO-BUS X4/85/a Plug connection for cab wiring harness, right -
F50 Switch for supply, potential 15/1 ECCU2 ISO BUS preparation
F219 Fuse for ISO-BUS, potential 30 X4/85/b Plug connection for cab wiring harness, right -
F220 Fuse for ISO-BUS, potential 30 ISO BUS preparation
F222 Fuse for ISO-BUS, potential 30 X9/17 Socket for diagnosis service tool [DIAGNOSE]
K5/80 Relay, potential 15, ISO-BUS X9/20 Socket for ISO-BUS
K5/81 Relay for ECU power, ISO-BUS X12/8 Plug connection for Virtual Terminal ISO-BUS
K5/82 Relay for power socket, ISO-BUS X24/2 Plug connection for cab wiring harness, right -
P9 Virtual terminal central print
V8/1 ISO-BUS diode group X85 Socket for LBS, ISO-BUS
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
*URXQGSRLQWV X0/32/1 Weld point for wiring harness, ISO-BUS
potential 31
X0/32/2 Weld point for wiring harness, ISO-BUS
potential 30
X0/32/3 Weld point for wiring harness ISO-BUS CAN H
X0/32/4 Weld point for wiring harness, ISO-BUS
potential 15/1
X0/32/5 Weld point for wiring harness, ISO-BUS
potential 15/1
X0/32/6 Weld point for wiring harness, ISO-BUS
potential 30
X0/32/7 Weld point for wiring harness ISO-BUS CAN L
X0/32/8 Weld point for wiring harness, ISO-BUS CAN L
X0/32/9 Weld point for wiring harness, ISO-BUS CAN H
X0/32/10 Weld point for wiring harness ISO-BUS,
potential 30
X0/32/12 Weld point for wiring harness, ISO-BUS CAN L
X0/32/13 Weld point for wiring harness, ISO-BUS CAN H
Edition 01-2006
4010A-115
Chapter
4011
4011
FAULTCODES
TABLE OF CONTENTS
BLANK PAGE
TEST ADAPTER
GENERAL
Handling Chapter 4011
The error descriptions are arranged by controller and in ascending error number order. The connector and compon-
ents are always shown at the end of the controller in question in the component overview. The function diagrams for
the error codes are located after the component overview.
The technical data of the individual components can be obtained from Chapter 4009 (up to DBD100000) or 4009A
(from DBD100001).
General advise
The connector module A28 and the can module A27 was fitted in tractors up to chassis number DBD094270.
From DBD094271 the two modules are replaced by one module A30. The new module has no influence in function
and has the same connectors like the two old modules. On the new modul A30 the two connectors YA1 and YB1 will
be dropped (no more needed).
Abbreviations
ADIC................................................................................................................................ Analogue / digital instrument
ARU...................................................................................................................................................................Armrest
AUX ..............................................................................................................................................Remote control valve
BB light ........................................................................................................................... Turn signal / side marker light
DMM...................................................................................................................................................Digital multimeter
DZG................................................................................................... Signal of crankshaft position (upper dead point)
ECCU2 ............................................................................................................................................ Central control unit
EDC.................................................................................................................................... Electronic power lift control
EEM2................................................................................................................................................Engine control unit
EEM3................................................................................................................................................Engine control unit
FMGR................................................................................................................. Vehicle/engine/transmissioncontroller
GSV.......................................................................................................................................................... Cyclic supply
HTS .................................................................................................. Field end management (headland management)
ICU ...............................................................................................................................................Performance monitor
ID module .................................................................................................. Identification module for engine electronics
KEY PAD´S ............................................................................................ Function keys for analogue/digital instrument
NTC ............................................................................................................................Negative temperature coefficient
PCB .................................................................................... Printed circuit board (relay switching, terminal resistance)
PCU............................................................................................................................... Electronic pumps - control unit
PTC ............................................................................................................................ Positive temperature coefficient
SBB light........................................................................................................... Tail light, turn signal / side marker light
SGR.......................................................................................................................................... Transmission controller
NOTE: The name in the square brackets [xx] is inscribed on the plug.
SS05F003
SS05F004
SS05F005
Only the terminating resistor in the vehicle connected to the CAN data bus:
CANH to CANL: 120 ohms +/- 10 %.
Only the terminating resistor in the ISO bus socket connected to the ISO data bus:
CANH to CANL: 150 ohms +/- 10 %.
SS06F006
SS06F007
SS06E002
BLANK PAGE
SS06F008
SS06E003
BLANK PAGE
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The EEPROM is defective.
2. The controller is defective.
3. The connections between EEPROM and controller on the printed board are faulty.
Remedy:
Cancel fault. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds and check whether
the fault is no longer displayed.
Should the fault still occur, there is a defect in the ADIC electronics.
The ADIC must be replaced.
0 10 ±2.5
1/2 95 ±5
1 180 ±12
2. Disconnect plugs CN3 and CN1 from the ADIC. Measure the resistance between lines CN3 PIN14 (signal) and
CN1 PIN22 (GND - sensor). If the value is < 7.5 ohms or > 192 ohms and if the sensor itself is ok (determined by
the measurement in step 1), the fault is caused by the wiring.
3. If you cannot detect a fault in steps 1 to 2, the fault is caused by the ADIC. In this case, the ADIC must be replaced.
0 10 ±2.5
½ 95 ±5
1 180 ±12
2. With the ADIC disconnected, measure the resistance between the two lines CN3 PIN14 (signal) and CN1 PIN22
(sensor GND). If the value is < 10 ohms and if the sensor itself is ok (determined by the measurement in step 1),
the fault is caused by the wiring.
3. If you cannot detect a fault in steps 1 - 2, the fault is caused by the ADIC. In this case, the ADIC must be replaced.
0 10
2 52
4 88
6 124
8 155
10 184
2. Disconnect plugs CN3 and CN1 from the ADIC. Measure the voltage between the following lines (CN3 PIN15
(signal) against CN1 PIN22 (GND - sensor). If a voltage is present here, the fault is caused by the wiring.
3. Measure the resistance between the following lines (CN3 PIN15 (signal) against CN1 PIN22 (GND - sensor). If
the value is > 184 ohms and if the sensor itself is ok (determined by the measurement in step 1), the fault is
caused by the wiring.
4. If you cannot detect a fault in steps 1 to 2, the fault is caused by the ADIC. In this case, the ADIC must be replaced.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ADIC is faulty.
2. Interruption or contact fault on the CAN BUS (vehicle bus), e.g. in the line to the ADIC.
3. Conductive connection or short-circuit between the data lines (terminating resistors excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective.
5. The screening of the CAN wiring is faulty.
6. The ADIC is defective.
Remedy:
Use the "CONTROL modulE status" Service Tool to check whether other users of the vehicle bus are also offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whe-
ther fault 250 is active again.
If fault ADIC 250 is active again or if other bus users on the vehicle bus are signalling faults in connection with
the CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17con).
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to a plus supply or to plus 1, plus 2 or plus 3 (12 V screening). Go to step c.
c) Check resistances - CAN H against CAN L at diagnosis socket (X9/17con).
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check the supply (12V) to the ADIC.
e) Check the voltages CANH (yellow) and CANL (green) at the ADIC, plug CN3 (setpoints see step 2b).
Turn ignition switch to ON position. PIN26 (CANH, yellow) and PIN25 (CANL, green) against (GND).
f) Check the screening of the data lines:
Red line (12V) against black line (GND).
NOTE: The screening and the data lines are twisted together. It ends freely in front of the ADIC. It is therefore not
routed up to the ADIC.
If the power supply, the voltage values of CANH and CANL at plug CN3 of the ADIC and the screening are ok,
the ADIC must be replaced.
3. Voltages - CANH and CANL at the ADIC not ok: Carry out a continuity check at the data lines.
a) Disconnect plug CN3 from the ADIC, plug X70 from the EEM2 and plug X10/14. Use an ohmmeter to check
the line from one plug to the next (setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
b) Short-circuit check between the data lines:
At plug X10/14, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ADIC is faulty.
2. Interruption or contact fault on the CAN BUS (vehicle bus), e.g. in the line to the ADIC.
3. Conductive connection or short-circuit between the data lines (terminating resistors excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective.
5. The ADIC is defective.
Remedy:
Use the "CONTROL modulE status" Service Tool to check whether other users of the vehicle bus are also offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whe-
ther fault 250 is active again.
If fault ADIC 250 is active again or if other bus users on the vehicle bus are signalling faults in connection with
the CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con).
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND, nor to
a plus supply. Go to step c.
c) Check resistances - CAN H against CAN L at diagnosis socket (X9/17 con).
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check the supply (12V) to the ADIC.
e) Check the voltages CAN H (yellow) and CAN L(green) at the ADIC, plug CN3 (setpoints see step 2b).
Turn ignition switch to ON position. PIN26 (CANH, yellow) and PIN25 (CANL, green) against (GND).
If the power supply, the voltage values of CANH and CANL at plug CN3 of the ADIC are ok, the ADIC must be
replaced.
3. Voltages - CANH and CANL at the ADIC not ok: Carry out a continuity check at the data lines.
a) Disconnect plug CN3 from the ADIC, plug X89/1 from the EEM3 and plug X10/14. Use an ohmmeter to check
the line from one plug to the next (setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
b) Short-circuit check between the data lines:
At plug X10/14, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
4. Check the terminating resistors (for configuration see diagram of CAN bus).
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM3 and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms. Check the resistance at the following measuring points:
Diagnosis socket X9/17 and plug CN3 on the ADIC. If the setpoint is not met, check the terminating resistors one
by one. Go to step b.
COMPONENTS SUMMARY
A1 ADIC ................................................................................................................................................. Fig. 1
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 2
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 3
B2/1 Sensor for tank content, left .............................................................................................................. Fig. 4
B3 Sensor for compressed air................................................................................................................ Fig. 5
CN1 Plug connection, ADIC...................................................................................................................... Fig. 6
CN3 Plug connection, ADIC...................................................................................................................... Fig. 7
P8 ICU ................................................................................................................................................... Fig. 1
P8 Plug connection, ICU ........................................................................................................................ Fig. 8
P8/1 Plug connection, ICU CAN [DISP] .................................................................................................... Fig. 9
P8/2 Plug connection, ICU CAN ............................................................................................................... Fig. 8
S31 Changeover switch for CAN SGR/FMGR up to DBD100000 ......................................................... Fig. 10
X3/10 Plug connection, terminal resistance ...............................................................................................Fig. 11
X9/17 Socket for diagnosis service tool .................................................................................................... Fig. 12
X10/14 Plug connection, instruments wiring harness - supply for roof wiring harness [14] ........................ Fig. 13
X10/18 Plug connection, instruments wiring harness -
engine wiring harness [INSTR] from DBD100001 .......................................................................... Fig. 14
X14/14 Plug connection, roof supply [14].................................................................................................... Fig. 15
X23/1 Plug connection, instruments wiring harness - engine wiring harness up to DBD100000.............. Fig. 16
X70 Plug connection, EEM2 engine control unit up to DBD100000 ...................................................... Fig. 17
X89/1 Plug connection, engine - EEM3 engine control unit wiring harness from DBD100001 ................. Fig. 18
Fig. 8 Fig. 11
Fig. 13 up to DBD100000
BLANK PAGE
CN1 26 16 24 23
A1 ADIC
Supply
A4/3 17 18 CN1a 15 16
X70 CN3
CAN H Pilot lamps and displays controlled
18 26
CAN L via CAN BUS
42 25
X6/11 X6/8 X29
Pilot lamps and displays 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
A61 A12 CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 rpm = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 15 Lighting ON = 12V
BLANK PAGE
CN1 26 16 24 23
A1 ADIC
Supply
A4/3 17 18 CN1a 15 16
X89/1 CN3
CAN H Pilot lamps and displays controlled
35 26
CAN L via CAN BUS
34 25
X6/11 X6/8 X29
Pilot lamps and displays 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
A61 A12 CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 min-1 = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 15 Lighting ON = 12V
BLANK PAGE
BLANK PAGE
If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS scheme).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
e) Repeat the check using the Service Tool.
Possible causes:
1. Contact resistance at electrical connections too high:
a) Plug-in contacts, screwed / crimped connections oxidized.
b) Contacts loose, bent or pushed back (not engaged) in the plug housing.
c) The CAN module is defective.
2. Voltage drop too high during the starting procedure:
a) Battery charge is insufficient or the battery is defective.
b) Plug module in the armrest is defective (buffer capacity too small).
Remedy:
General:
Once the ignition switch is turned to the ON position, the CAN module is supplied with 12V (nominal) via the plug
module for fuse F20, 5A (15/1), on central print A12.
The voltage should be 12.5 to 14 V when the engine is running and the charging indicator has gone out.
In order to ensure a reliable supply to the CAN module under all operating conditions, the plug module is equipped
with the following safety components:
Safety diode V1/1, overload protection V1/2, capacities C1 and C2 as a buffer against short dips in the supply voltage
(caused by operating loads outside the armrest).
For voltage measurements, the ignition switch must be turned to the ON position.
1. Cancel the fault. Turn the ignition switch to the ON position.
a) If fault ARU 20 is activated again, go to step 2.
b) If fault ARU 20 is not activated, start the engine. If fault ARU 20 is activated again, go to step 2.
2. Check the supply voltage (12V nominal):
Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
a) Check the voltage between PIN9 (12V) and PIN8 (GND) on plug X28/1 of the plug module (at least 12V). If
there is no voltage, go to step b.
NOTE: When checking the voltage at plug X28/1, load the supply with a 12V 21W bulb (during operation there is an
additional load due to the switching of the front loader switch.
If a voltage of 12V is available, go to step c.
c) Check the supply voltage at plug YB1 on the CAN module and on plug YA1 on the plug module (ribbon cable
connection):
PIN1 and PIN3 (12V) to PIN2 and PIN4 (GND).
If the voltage drop between plugs X28/1 and YA1 on the plug module is > 0.2V, check the continuity using an
ohmmeter (setpoint value < 1 ohm). Replace the faulty plug module. The same applies to the ribbon cable con-
nection.
d) If a supply voltage of 12V is available at plug YB1 on the CAN module, cancel the fault. Then turn the ignition
switch to the OFF position. After waiting for at least 5 secs., start the engine. If fault ARU 20 is activated again,
then the CAN module must be replaced (see fault code ARU 1, steps 1 to 4).
e) Refit the lower armrest cover. Fit the armrest. Start the engine and check that fault ARU 20 is no longer acti-
vated.
Possible causes:
1. The alternator voltage regulator is defective.
2. Ground connection between the alternator / battery and CAN module faulty.
3. CAN module defective.
Remedy:
With the engine running (charging indicator lamp has gone out), check the charge voltage of the alternator
(G2/2, G2/3, G2/2/2) and the battery voltage. The charge voltage should be 13.8 to 14.5 V at various engine speeds.
If the charge voltage is much higher, go to step 2.
1. If the charge voltage is ok, check the ground connection from the generator via the battery to the CAN module,
plug YB1, PIN1 and 3 (12V) to PIN2 and 4 (GND); repair if necessary. With the engine running (charging indicator
lamp has gone out), check the supply voltage at the CAN module, plug YB1, PIN1 and 3 (12V) to PIN2 and 4
(GND) (12.5 to 14.5 V). If the cabling and supply voltage at the CAN module are ok, but fault 21 is activated again
after starting the engine once again, then the CAN module must be replaced (see fault code ARU 1, steps 1 to 4).
2. If the charge voltage is not within the specified value limits, then the alternator voltage regulator must be replaced.
Then start the engine. When the charging indicator lamp has gone out, check the charge voltage at various engine
speeds and check whether fault 21 is still activated.
ARU - 30 Signal from AUX stick with latch (AUX1) below valid range
Cause:
The signal voltage from the AUX stick B30 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the plug module up to the CAN module (re-
sistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the AUX stick (resistance too
high), thus voltage at AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 30 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the plug module, plug X28/5:
PIN1 (5V) to PIN3 (GND): Supply voltage approx. 5.0V (plug X28/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X28/5 connected).
PIN2 (signal) to PIN3 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X28/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B30 is in the Neutral position (plug
X28/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X28/5 on the plug module are ok. Go to step 5.
If the signal voltage at plug X28/5 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN3 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/5 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/5 is ok with PIN2 detached, go to step 4.
4. Check the signal voltage at plug YB1 on the ribbon cable connection at the CAN module:
PIN37 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.
ARU - 31 Signal from AUX stick with latch (AUX1) above valid range
Cause:
The signal voltage from the AUX stick B30 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8 V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the AUX
stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 31 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/5 PIN1 (5V) to PIN3 (GND).
At CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B30 is in the Neutral position:
At the plug module, plug X28/5 PIN2 (signal) to PIN3 (GND).
At CAN module, plug YB1 PIN37 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/5 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/5 at the plug module. Cancel fault 31. Turn the ignition switch to the ON position.
If fault 31 is no longer activated, check plug X28/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.
ARU - 32 Signal from AUX stick without latch (AUX2) below valid
range
Cause:
The signal voltage from the AUX stick B31 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the plug module up to the CAN module (re-
sistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the AUX stick (resistance too
high), thus voltage at AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 32 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at plug module, plug X28/5:
PIN5 (5V) to PIN7 (GND): Supply voltage approx. 5.0V (plug X28/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X28/5 connected).
PIN6 (signal) to PIN7 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X28/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B31 is in the Neutral position (plug
X28/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X28/5 on the plug module are ok. Go to step 5.
If the signal voltage at plug X28/5 PIN6 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN6 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN6 to PIN7 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/5 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/5 is ok with PIN6 detached, go to step 4.
4. Check the signal voltage at plug YB1 on the CAN module:
PIN29 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.
ARU - 33 Signal from AUX stick without latch (AUX2) above valid
range
Cause:
The signal voltage from the AUX stick B31 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the AUX
stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 33 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/5 PIN5 (5V) to PIN7 (GND).
At the CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B31 is in the Neutral position:
At the plug module, plug X28/5 PIN6 (signal) to PIN7 (GND).
At the CAN module, plug YB1 PIN29 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/5 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/5 at the plug module. Cancel fault 33. Turn the ignition switch to the ON position.
If fault 33 is no longer activated, check plug X28/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the plug module up to the CAN module (re-
sistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the AUX stick (resistance too
high), thus voltage at AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 34 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the plug module, plug X28/4:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X28/4 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X28/4 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X28/4 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B52 is in the Neutral position (plug
X28/4 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X28/4 on the plug module are ok. Go to step 5.
If the signal voltage at plug X28/4 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/4 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/4 is ok with PIN2 detached, go to step 4.
4. Check the signal voltage at plug YB1 on the CAN module:
PIN27 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.
The signal voltage from the AUX stick B52 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the AUX
stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 35 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/4 PIN1 (5V) to PIN4 (GND).
At the CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B52 is in the Neutral position:
At the plug module, plug X28/4 PIN2 (signal) to PIN4 (GND).
At the CAN module, plug YB1 PIN27 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/4 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/4 at the plug module. Cancel fault 35. Turn the ignition switch to the ON position.
If fault 35 is no longer activated, check plug X28/4 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the throttle lever via the plug module up to the CAN module
(resistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the throttle lever (resistance
too high), thus voltage at the throttle lever < 5V.
4. Throttle lever defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 4.5k ohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 36 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the plug module, plug X28/3:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X28/3 disconnected; the throttle lever supply is thus
not on-load).
The throttle lever has a maximum power consumption of 15 mA.
Supply voltage approx. 5.0V (plug X28/3 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must not be < 0.2V and > 4.8V when the throttle lever is moved
from limit to limit (plug X28/3 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the throttle lever and the cabling
between the throttle lever and plug X28/3 on the plug module is ok. Go to step 5.
If the signal voltage at plug X28/3 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the throttle lever. Detach PIN2 (signal) from the plug housing (it is thus
not on-load). Check the throttle lever signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is
still < 0.2V in this state, then the throttle lever must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/3 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/3 is ok with PIN2 detached, go to step 4.
4. Check the signal voltage at plug YB1on the CAN module:
PIN25 (signal) to PIN39 and 40 (GND for "hall elements" such as throttle lever, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the throttle
lever (resistance too high).
3. Throttle lever defective (mechanical or electrical fault).
4. Supply voltage < 5V >12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 37 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/3 PIN1 (5V) to PIN4 (GND).
At the CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the throttle lever B28 from limit to limit when doing
so):
At the plug module, plug X28/3 PIN2 (signal) to PIN4 (GND).
At the CAN module, plug YB1 PIN25 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/3 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/3 at the plug module. Cancel fault 37. Turn the ignition switch to the ON position.
If fault 37 is no longer activated, check plug X28/3 and the cabling to the throttle lever.
If the check does not reveal a fault, then the throttle lever must be replaced.
6. Attach the lower armrest cover and fit the armrest.
If the signal voltage at plug X28/11 PIN12 is ok, but < 0.2V at plug YB1 PIN15, check the individual sections in
between. If the signal voltage at plug X28/11 is already < 0.2V, go to step 4.
4. Disconnect plug X28/11. Measure the resistance at the plug connection to the multi-controller II (from PIN12 to
PIN1).
a) Button not depressed: Setpoint value approx. 8.2 kohms,
b) Button depressed: Setpoint value approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
If the setpoint values are not attained, go to step 5.
5. Unscrew the screw on the grip housing on the multi-controller II. Carefully detach the keyboard from the grip hou-
sing. Disconnect plug X21 at the keyboard (14-pole) and measure the resistance at the plug connection on the
keyboard (from PIN10 to PIN1):
a) Button not depressed, approx. 8.2 kohms.
b) Button depressed, approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace the keyboard. If the setpoint values
are attained, the fault in the line between plug X28/11 and plug X21 must be rectified or the line replaced.
If the resistance setpoint values are now attained at plug X28/11, reconnect the plug. Turn the ignition switch to
the ON position and check whether the signal voltage reaches the setpoint values at plug YB1 on the CAN mo-
dule.
Cancel fault 40 and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.
Possible causes:
1. Signal voltage too high due to a short-circuit to another signal in the armrest or to the 5V or 12V supply.
2. Fault in the resistor circuit of the multi-controller II pushbutton function. Supply voltage to the keyboard too high
(> 5V) due to:
3. Faulty ground supply (GND) to the CAN module.
4. CAN module defective.
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"MULTI-CONTROLLER II + BUTTON" to check the pushbutton function.
If fault 41 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V)
Plug X28/11 on the plug module, PIN1 (5V) to PIN9 (GND).
Plug YB1 in the CAN module, PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the supply voltage of 5V is exceeded, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is not exceeded, go to step 3.
3. Check the signal voltage (from pushbutton function to CAN module) at the following points:
Plug X28/11 on plug module, PIN12 to PIN9 (GND) and
plug YB1, ribbon cable connection on CAN module, PIN15 to PIN2 and PIN4 (GND).
Button not depressed: 0.2 - 2.3V, button depressed: 2.4 - 4.8V. If the signal voltage at plug YB1 is ok, the ground
line (GND) and plug-in connections from plug X18/4 to plug YB1 on the CAN module still have to be checked.
If the ground line is ok and the signal voltage too high, go to step 4.
4. Turn the ignition switch to the OFF position and disconnect plug X28/11 at the plug module.
Measure the resistance at the plug connection to the multi-controller II (from PIN12 to PIN1). Button not depres-
sed: approx. 8.2 kohms, button depressed: approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
The next step is to check whether the signal line between plug X28/11 and plug YB1 has a short-circuit to another
signal line or to a supply (+).
If the setpoint values are not attained (e.g. the resistance is much lower), continue troubleshooting as follows:
Unscrew the screw on the grip housing on the multi-controller II and carefully detach the pushbutton function unit
from the grip housing. Disconnect plug X21 (14-pole) at the keyboard and measure the resistance from PIN1 to
PIN10 on the keyboard:
a) Button not depressed: approx. 8.2 kohms,
b) Button depressed: approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace it. If the setpoint values are attained,
the fault in the line between plug X28/11 and plug X21 must be rectified or the line replaced.
5. Cancel the fault, start the engine again and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.
Possible causes:
1. Contact fault in the signal line between potentiometer R20/1 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. The potentiometer R20/1 is defective.
6. Plug module is defective (e.g. resistors R28/7 or R28/8 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 50 is activated again.
Use the Service Tool monitor:
"AUX1 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module.
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/1 at the plug module (after resistor R28/7). When doing so, plug
X28/16 (potentiometer R20/1) must be connected to the plug module.
Plug X28/16 PIN4 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/1 at the plug module (before resistor R28/8):
Plug X28/16 PIN6 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/16, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/16, go to step 5.
4. Check the signal voltage at the CAN module:
Plug YB1 PIN24 to PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1,
steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/16 at the plug module.
Plug X28/11 PIN1 to plug X28/16 PIN4, setpoint value 470 ohms.
Plug X28/16 PIN6 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.
Possible causes:
1. Contact fault in the signal line between potentiometer R20/2 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/2 is defective.
6. Plug module is defective (e.g. resistors R28/5 or R28/6 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 52 is activated again.
Use the Service Tool monitor: "AUX2 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module. Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/2 at the plug module (after resistor R28/5). When doing so, plug
X28/16 (potentiometer R20/2) must be connected to the plug module.
Plug X28/16 PIN1 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/2 at the plug module (before resistor R28/6).
Plug X28/16 PIN3 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/16, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/16, go to step 5.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).
Possible causes:
1. Contact fault in the signal line between potentiometer R20/3 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/3is defective.
6. Plug module is defective (e.g. resistors R28/3 or R28/4 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 54 is activated again.
Use the Service Tool monitor:
"AUX3 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/3 at the plug module (after resistor R28/3). When doing so, plug
X28/15 (potentiometer R20/3) must be connected to the plug module.
Plug X28/15 PIN4 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/3 at the plug module (before resistor R28/4):
Plug X28/15 PIN6 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/15, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/15, go to step 5.
4. Check the signal voltage at the CAN module:
Plug YB1 PIN28 to plug PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/15 at the plug module.
Plug X28/11 PIN1 to plug X28/15 PIN4, setpoint value 470 ohms.
Plug X28/15 PIN6 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.
Possible causes:
1. Contact fault in the signal line between potentiometer R20/4 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/4 is defective.
6. Plug module is defective (e.g. resistors R28/1 or R28/2 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 56 is activated again.
Use the Service Tool monitor: "AUX4 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/4 at the plug module (after resistor R28/1).
When doing so, plug X28/15 (potentiometer R20/4) must be connected to the plug module.
Plug X28/15 PIN1 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/4 at the plug module (before resistor R28/2):
Plug X28/15 PIN3 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/15, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/15, go to step 5.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).
Possible causes:
1. Contact fault in the signal line between the potentiometer R20/5 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/5 is defective.
6. Plug module is defective (e.g. resistors R28/9 or R28/10 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 58 is activated again.
Use the Service Tool monitor:
"AUX5 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 IN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If a
voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for the potentiometer R20/5 on the plug module (after resistor R28/9). When doing so,
plug X28/12 must be connected to the plug module.
Plug X28/12 PIN1 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for the potentiometer R20/5 at the plug module (before resistor R28/10):
Plug X28/12 PIN4 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/12, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/12, go to step 5.
4. Check the signal voltage at the CAN module:
Plug YB1 PIN32 to plug PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/12 at the plug module.
Plug X28/11 PIN1 to plug X28/12 PIN1, setpoint value 470 ohms.
Plug X28/12 PIN4 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to CAN module A27 in the armrest is faulty.
2. Interruption or contact fault on the CAN (vehicle bus), e.g. in the spur line to the CAN module.
3. Conductive connection or short-circuit between the data lines (terminating resistances excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective or plug-in contacts at X3/10 are faulty.
5. The screening of the CAN wiring is faulty.
6. The CAN module is defective.
Remedy:
Use Service Tool "CONTROL modulE status" to check whether other bus users are also offline.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whether
the fault is active again.
1. If fault ARU 71 is active again or if other bus users on the vehicle bus are signalling faults in connection with the
CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin ) .
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to a plus supply or to plus 1, plus 2 or plus 3 (12 V screening). Go to step c.
c) Check resistance values - CAN H against CAN L at diagnosis socket .
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check supply voltage (12V) to the CAN module in the armrest:
Turn ignition switch to ON position.
Plug YB1 PIN1 and 3 (12V) against PIN2 and PIN4 (GND).
If the voltage is >12V (<8V), it is faulty and must be repaired. For details on fault rectification, refer to fault code
ARU 20 (this fault code is active as soon as the supply voltage is < 8V).
e) Check supply (5V) to CAN module A27:
NOTE: A voltage regulator at the CAN module is supplied with 12 V. This supplies 5V to specific components on the
CAN module and to specific control elements.
Turn ignition switch to ON position.
Plug YB1 PIN6, 8 and 10 (5V) against PIN2 and PIN4 (GND).
If the voltage (5V) is not present, detach the plugs to the multi-controller II and to the other control elements at
plug module A28. If the supply (5V) is present, there is a short-circuit in the control elements or in their wiring. If
the supply (5V) is not present, there could be other faults: CAN module defective or short-circuit at the plug mo-
dule or short-circuit in the ribbon cable connection between YA1 and YB1.
f) Check the voltages - CANH and CANL at CAN module plug YB1:
Turn ignition switch to ON position. PIN5 (CANH) and PIN7 (CANL) against PIN2 and PIN4 (GND).
g) Check the screening of the data lines:
Violet line (12V) against black line (GND).
NOTE: The screening and the data lines are twisted together. It ends freely in front of plug X28/7 on the plug
module. It is therefore not routed up to the CAN module.
If the power supply, the voltage values of CAN H and CAN L at plug YB1 of the CAN module and the screening
are ok, the CAN module must be replaced (see fault code ARU 1, steps 1 to 4).
Sva 6-52632 EN Edition 06-2006
4011-72
3. Voltages - CANH and CANL at the CAN module not ok:
a) Carry out a voltage check at the plugs in the following sequence:
Plug X28/7 at the plug module:
PIN3 (CANH) and PIN4 (CANL) against plug X28/1 PIN8 (GND).
If voltages are not ok, detach plug X28/7. Check voltages at the plug part of the CAN wiring. If voltages are not
ok, check data lines between plug X28/7 and the weld points of the spur line (measure e.g. against diagnosis
socket X9/17). If the voltages at plug X28/7 are ok, check the voltages at plug YA1 on the plug module:
PIN5 (CANH) and PIN7 (CANL) against PIN2 and PIN4 (GND). Check faulty sections of the data line. Replace
plug module or ribbon cable connection if necessary.
b) Continuity check at data lines:
Detach the plugs on the line section concerned. Use an ohmmeter to check the line from one plug to the next
(setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
c) Short-circuit check between the data lines:
Disconnect plugs X18/4 and YB1.
At plug YB1, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
4. Check the terminating resistors in accordance with the CAN bus diagram
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM2and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms at the following measuring points:
Diagnosis socket X9/17, X18/4 (armrest), X28/7 and YA1 (plug module A28) as well as YB1 (CAN module A27).
b) Check of the individual terminating resistors:
Turn ignition switch to OFF position. Disconnect plug X3/10. Check resistance between PINA and PINB:
Setpoint 120 ohms. At the plug part of the cable harness also check the resistance between PINA and PINB:
Setpoint 120 ohms.
If the setpoint of approx. 120 ohms is also reached with this measurement, the terminating resistor in the EEM2
and the lines CANH and CANL between the terminating resistors are ok. If the resistance considerably deviates
from the setpoint, the terminating resistor in the EEM2 and each data line must be checked separately.
Detach plug X70 from the EEM2. Check the terminating resistance between PIN18 (CANH) and PIN42 (CANL)
at the EEM2. Setpoint 120 ohms.
BLANK PAGE
COMPONENTS SUMMARY
ARU Armrest ............................................................................................................................................. Fig. 1
AUX1 1st remote control valve.................................................................................................................... Fig. 1
AUX2 2nd remote control valve .................................................................................................................. Fig. 1
AUX3 3rd remote control valve ................................................................................................................... Fig. 1
AUX4 4th remote control valve ................................................................................................................... Fig. 1
AUX5 5th remote control valve ................................................................................................................... Fig. 1
A2 EEM2 control unit ............................................................................................................................. Fig. 1
B28 Manual accelerator slider ................................................................................................................. Fig. 2
B30 Longitudinal joystick.......................................................................................................................... Fig. 2
B31 Transverse joystick ........................................................................................................................... Fig. 2
B52 Shift lever for AUX (black)................................................................................................................. Fig. 2
G2/2 Generator Magneton 120A .............................................................................................................. Fig. 3
G2/2/2 2nd generator Magneton 95A ........................................................................................................... Fig. 4
G2/3 Generator Denso 140A..................................................................................................................... Fig. 5
R20/1 Potentiometer 1st AUX ..................................................................................................................... Fig. 2
R20/2 Potentiometer 2nd AUX .................................................................................................................... Fig. 2
R20/3 Potentiometer 3rd AUX..................................................................................................................... Fig. 2
R20/4 Potentiometer 4th AUX ..................................................................................................................... Fig. 2
R20/5 Potentiometer 5th AUX ..................................................................................................................... Fig. 2
S31 Changeover switch for CAN SGR/FMGR ......................................................................................... Fig. 6
S60/2 Cruise control button......................................................................................................................... Fig. 7
S60/3 Speed button +.................................................................................................................................. Fig. 7
X3/10 Plug connection, terminal resistance ................................................................................................ Fig. 8
X18/4 Plug connection, wiring harness, cab right - armrest ........................................................................ Fig. 9
X21 Plug connection, multicontroller II - print......................................................................................... Fig. 10
X28/1 Plug connection, ARU - wiring harness, cab right ...........................................................................Fig. 11
X28/3 Plug connection, ARU - manual accelerator slider ......................................................................... Fig. 12
X28/4 Plug connection, ARU - AUX control lever ..................................................................................... Fig. 13
X28/5 Plug connection, ARU - AUX joystick ............................................................................................. Fig. 14
X28/7 Plug connection, ARU CAN - BUS ................................................................................................. Fig. 15
X28/11 Plug connection, ARU - multicontroller II ....................................................................................... Fig. 16
X28/12 Plug connection, ARU - potentiometer R20/5 ................................................................................. Fig. 17
X28/15 Plug connection, ARU - potentiometer R20/3 and R20/4 ............................................................... Fig. 18
X28/16 Plug connection, ARU - potentiometer R20/1 and R20/2 ............................................................... Fig. 19
X70 Plug connection, engine control unit EEM2 .................................................................................... Fig. 20
YA1 Plug connection, ARU connector module - CAN module ................................................................ Fig. 7
YB1 Plug connection, ARU CAN module - connector module ................................................................ Fig. 7
Fig. 1 Fig. 5
Fig. 2 Fig. 6
Fig. 3 Fig. 7
Fig. 4 Fig. 8
Fig. 9 Fig. 12
Fig. 13
Fig. 10
Fig. 14
Fig. 11
Fig. 15
Fig. 16 Fig. 20
Fig. 17
Fig. 18
Fig. 19
BLANK PAGE
5V CAN -
B30 1 4
0
2 1
GND 3
7 3 X4/92 AUX 3
X
B31 5V CAN H
5 6 1 3
GSV4 CAN L
6 8 2 2
5V CAN +
4 1
S35 CAN -
8 X10/9 2 X10/9 6 8 4
X4 CN1a 10
GND
4 CAN - X4/93 AUX 4
17 A60 ECCU2
X
5V 5V CN3a CAN H
3
1 CAN +
6.4 V with EDC and AUX ON 4 CAN L
B52 2 CAN L 2
16 6.4 V with EDC ON 1 CAN +
X16 CAN H 1
R20/1 0.5 V 560Ω
GND
15 CAN -
6 4
470Ω
4.7 V
4 X10/11 X14/15 A12
A13 F45 5A
5 7 12 +15/1
X4/94 AUX 5
R20/2 0.5 V
560Ω CAN H
3 P8/1 3 4 1 2 3
4.7 V 470Ω X10/12 6 CAN L
1 P8 ICU P8 2
CAN +
2 7 X14/14 X10/14 1
CAN -
X15 5 4 7 4
R20/3 0.5 V 560Ω
6 3
4.7 V
470Ω
(7)
A X3/10 B
4 A14 X20/1 X23/1
(8) F93 5A
5 +30 8 Q
R20/4 0.5 V 560Ω 120 Ω
3
470Ω
4.7 V A12 Central print R20/5 Potentiometer AUX5 X10/14 10-pin plug connection
1 A13 Roof print S2/7/3 Switch, hydraulic master X11 16-pin plug connection
2 A14 Engine print S34 Switch AUX5 X12 4-pin plug connection
X12 A27 CAN module ---> DBD..... S35 Joystick pushbutton X14/14 14-pin plug connection
R20/5 0.5 V 560Ω A28 Plug module ---> DBD..... S60/6 AUX blue pushbutton X14/15 14-pin plug connection
4 A30 Print ARU DBD..... ---> S60/8 Shift pushbutton X15 6-pin plug connection
4.7 V
1 A29 Joystick (float position) X16 6-pin plug connection
A31 Multi controller X1 14-pin plug connection X18/4 18-pin plug connection
2 A60 ECCU2 X3/10 3-pin plug connection X19 2-pin plug connection
X6 0Ω B30 Joystick X4 4-pin plug connection X20/1 20-pin plug connection
longitudinal direction AUX1 X4/83 4-pin plug connection X21 14-pin plug connection
8
5V
6k2 B31 Joystick X4/90 4-pin plug connection X23/1 23-pin plug connection
2 transverse direction AUX2 X4/91 4-pin plug connection X24/2 24-pin plug connection
S34 1k2
B52 Selector lever AUX4 X4/92 4-pin plug connection YA1 44-pin plug connection
3
6k2 CN1a 26-pin plug connection X4/93 4-pin plug connection ---> DBD.....
2
7 CN3a 26-pin plug connection X4/94 4-pin plug connection YB1 44-pin plug connection
0
15/1
1
4 0Ω
5V GND 15/1 GND P8 ICU X5 2-pin plug connection ---> DBD.....
2 P8 10-pin plug connection X5/1 Plug connection (7) Ground point, roof hood, left
4 P8/1 4-pin plug connection X6 8-pin plug connection (8) Ground point, roof hood,
8 *YA1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7 R20/1 Potentiometer AUX1 X7 4-pin plug connection right
1 R20/2 Potentiometer AUX2 X10/9 10-pin plug connection (16) Ground, starter
5 *YB1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7
7 R20/3 Potentiometer AUX3 X10/11 10-pin plug connection
* A27 CAN MODULE R20/4 Potentiometer AUX4 X10/12 10-pin plug connection
BLANK PAGE
F20 5A
X20/1 F97 10A
+15/1 7 +15/2
ARMREST F16 5A
F94 25A
+15/2 X1/14
(16) 31
*A28 PLUG MODULE X1/10 F92 10A
+30
X1 X18/4
*A30 PRINT ARU X24/2 17 18 2 X5/1
8 10
X3 7 13
B28 5V X70 21 48 70 46 69
1 9 9 (11)
CAN H A14
CAN + 18 A2 EEM2 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
X 2 2 16 Supply
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 Pre-glowing and
+15
1 2
X20/1 (11)
12V
CN3 17
* A27 CAN MODULE A1 ADIC 12V
26 16
M13 (11)
25 Emergency signal
X70
3 M 1
36 0.8 to 4.4 V
A2/2 PCU 2
X70 X9/7 (11)
12V
R8 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
PCU activation 20 2 2.5 V
CAN L
44 1 2.5 V
S6
43 5 Emergency shut-down
130 Hz at 900 rpm
B21 X1/3 p 19 8 DZG
335 Hz at 2300 rpm
1 X70
p 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
n 1 62 A12 Central print X1/12 Plug connection
B20 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
f 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
Switches and A30 Print ARU DBD..... ---> X3 4-pin plug connection
sensors A50/1 Power module X3/12 3-pin plug connection
t X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
B22 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
R 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
R A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
B23 B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
U C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
p,t 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
B29 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
U,R 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure
BLANK PAGE
GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4
0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6
X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1
CAN H
CAN +
CAN L
12 4
CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H
A2 EEM2
CAN L
B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U
BLANK PAGE
BLANK PAGE
If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS scheme).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.
If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".
a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
e) Repeat the check using the Service Tool.
Possible causes:
1. Contact resistance at electrical connections too high:
a) Plug-in contacts, screwed / crimped connections oxidized.
b) Contacts loose, bent or pushed back (not engaged) in the plug housing.
c) The Print ARU is defective.
2. Voltage drop too high during the starting procedure:
a) Battery charge is insufficient or the battery is defective.
b) Print ARU in the armrest is defective (buffer capacity too small).
Remedy:
General:
Once the ignition switch is turned to the ON position, the Print ARU is supplied with 12V (nominal) for fuse F20, 5A
(15/1), on central print A12.
The voltage should be 12.5 to 14 V when the engine is running and the charging indicator has gone out.
In order to ensure a reliable supply to the Print ARU under all operating conditions, the following safety components
are ordered:
Safety diode V1/1, overload protection V1/2, capacities C1 and C2 as a buffer against short dips in the supply voltage
(caused by operating loads outside the armrest).
For voltage measurements, the ignition switch must be turned to the ON position.
1. Cancel the fault. Turn the ignition switch to the ON position.
a) If fault ARU 20 is activated again, go to step 2.
b) If fault ARU 20 is not activated, start the engine. If fault ARU 20 is activated again, go to step 2.
2. Check the supply voltage (12V nominal):
Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
a) Check the voltage between PIN9 (12V) and PIN8 (GND) on plug X30/1 of the Print ARU (at least 12V). If there
is no voltage, go to step b.
NOTE: When checking the voltage at plug X30/1, load the supply with a 12V 21W bulb (during operation there is an
additional load due to the switching of the front loader switch.
If a voltage of 12V is available, go to step c.
c) Cancel the fault. Then turn the ignition switch to the OFF position. After waiting for at least 5 secs., start the
engine. If fault ARU 20 is activated again, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 to 4).
d) Refit the lower armrest cover. Fit the armrest. Start the engine and check that fault ARU 20 is no longer acti-
vated.
Possible causes:
1. The alternator voltage regulator is defective.
2. Ground connection between the alternator / battery and Print ARU faulty.
3. Print ARU defective.
Remedy:
With the engine running (charging indicator lamp has gone out), check the charge voltage of the alternator and the
battery voltage. The charge voltage should be 13.8 to 14.5 V at various engine speeds. If the charge voltage is much
higher, go to step 2.
1. If the charge voltage is ok, check the ground connection from the generator via the battery to the Print ARU, plug
X30/1, PIN4 (12V) to PIN8 (GND); repair if necessary. With the engine running (charging indicator lamp has gone
out), check the supply voltage at the Print ARU, plug X30/1, PIN9 (12V) to PIN8 (GND) (12.5 to 14.5 V). If the
cabling and supply voltage at the Print ARU are ok, but fault 21 is activated again after starting the engine once
again, then the Print ARU must be replaced (see fault code ARU 1, steps 1 to 4).
2. If the charge voltage is not within the specified value limits, then the alternator voltage regulator must be replaced.
Then start the engine. When the charging indicator lamp has gone out, check the charge voltage at various engine
speeds and check whether fault 21 is still activated.
ARU - 30 Signal from AUX stick with latch (AUX1) below valid range
Cause:
The signal voltage from the AUX stick B30 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the AUX stick (resistance too high), thus voltage at
AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 30 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the Print ARU , plug X30/5:
PIN1 (5V) to PIN3 (GND): Supply voltage approx. 5.0V (plug X30/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X30/5 connected).
PIN2 (signal) to PIN3 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X30/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B30 is in the Neutral position (plug
X30/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X30/5 on the plug module are ok. Go to step 4.
If the signal voltage at plug X30/5 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN3 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/5 is ok with PIN2 detached, set in PIN2
again.
4. Attach the lower armrest cover and fit the armrest.
ARU - 31 Signal from AUX stick with latch (AUX1) above valid range
Cause:
The signal voltage from the AUX stick B30 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range (0.2 to 4.8 V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU up to the AUX stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 31 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At Print ARU , plug X30/5 PIN1 (5V) to PIN3 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B30 is in the Neutral position:
At Print ARU, plug X30/5 PIN2 (signal) to PIN3 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective. Repla-
ce the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug 30/5. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/5 at the Print ARU. Cancel fault 31. Turn the ignition switch to the ON position.
If fault 31 is no longer activated, check plug X30/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the AUX stick (resistance too high), thus voltage at
AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 32 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at Print ARU , plug X30/5:
PIN5 (5V) to PIN7 (GND): Supply voltage approx. 5.0V (plug X30/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X30/5 connected).
PIN6 (signal) to PIN7 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X30/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B31 is in the Neutral position (plug
X30/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X30/5 on the Print ARU are ok. Go to step 4.
If the signal voltage at plug X30/5 PIN6 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN6 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN6 to PIN7 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/5 is ok with PIN6 detached, set in PIN6
again.
4. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU up to the AUX stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 33 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the Print ARU, plug X30/5 PIN5 (5V) to PIN7 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B31 is in the Neutral position:
At the Print ARU, plug X30/5 PIN6 (signal) to PIN7 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective. Repla-
ce the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug X30/5. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/5 at the Print ARU. Cancel fault 33. Turn the ignition switch to the ON position.
If fault 33 is no longer activated, check plug X30/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the AUX stick (resistance too high), thus voltage at
AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 34 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the Print ARU, plug X30/4:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X30/4 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X30/4 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X30/4 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B52 is in the Neutral position (plug
X30/4 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X30/4 on the Print ARU are ok. Go to step 4.
If the signal voltage at plug X30/4 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/4 is ok with PIN2 detached, set in PIN2
again.
4. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU up to the AUX stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 35 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the Print ARU, plug X30/4 PIN1 (5V) to PIN4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B52 is in the Neutral position:
At thePrint ARU, plug X30/4 PIN2 (signal) to PIN4 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective.
Replace the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug X30/4. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/4 at the Print ARU. Cancel fault 35. Turn the ignition switch to the ON position.
If fault 35 is no longer activated, check plug X30/4 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the throttle lever via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the throttle lever (resistance too high), thus voltage
at the throttle lever < 5V.
4. Throttle lever defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 4.5k ohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 36 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the Print ARU, plug X30/3:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X30/3 disconnected; the throttle lever supply is thus
not on-load).
The throttle lever has a maximum power consumption of 15 mA.
Supply voltage approx. 5.0V (plug X30/3 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must not be < 0.2V and > 4.8V when the throttle lever is moved
from limit to limit (plug X30/3 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the throttle lever and the cabling
between the throttle lever and plug X30/3 on the Print ARU is ok. Go to step 4.
If the signal voltage at plug X30/3 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the throttle lever. Detach PIN2 (signal) from the plug housing (it is thus
not on-load). Check the throttle lever signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is
still < 0.2V in this state, then the throttle lever must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/3 is ok with PIN2 detached, set in PIN2
again.
4. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.
Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU to the throttle lever (resistance too high).
3. Throttle lever defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 37 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the Print ARU, plug X30/3 PIN1 (5V) to PIN4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the throttle lever B28 from limit to limit when doing
so):
At the Print ARU, plug X30/3 PIN2 (signal) to PIN4 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective.
Replace the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug X30/3. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/3 at the Print ARU. Cancel fault 37. Turn the ignition switch to the ON position.
If fault 37 is no longer activated, check plug X30/3 and the cabling to the throttle lever.
If the check does not reveal a fault, then the throttle lever must be replaced.
6. Attach the lower armrest cover and fit the armrest.
If the signal voltage at plug X30/11 PIN12 is not ok (< 0.2V). Go to step 4.
4. Disconnect plug X30/11. Measure the resistance at the plug connection to the multi-controller II (from PIN12 to
PIN1).
a) Button not depressed: Setpoint value approx. 8.2 kohms,
b) Button depressed: Setpoint value approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
If the setpoint values are not attained, go to step 5.
5. Unscrew the screw on the grip housing on the multi-controller II. Carefully detach the keyboard from the grip hou-
sing. Disconnect plug X21 at the keyboard (14-pole) and measure the resistance at the plug connection on the
keyboard (from PIN1 to PIN10):
a) Button not depressed, approx. 8.2 kohms.
b) Button depressed, approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace the keyboard. If the setpoint values
are attained, the fault in the line between plug X30/11 and plug X21 must be rectified or the line replaced.
If the resistance setpoint values are now attained at plug X30/11, reconnect the plug.
Turn the ignition switch to the ON position. Cancel fault 40 and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.
Possible causes:
1. Signal voltage too high due to a short-circuit to another signal in the armrest or to the 5V or 12V supply.
2. Fault in the resistor circuit of the multi-controller II pushbutton function. Supply voltage to the keyboard too high
(> 5V) due to:
3. Faulty ground supply (GND) to the Print ARU.
4. Print ARU defective.
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"MULTI-CONTROLLER II + BUTTON" to check the pushbutton function.
If fault 41 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug X30/11 on the Print ARU, PIN1 (5V) to PIN9 (GND).
If the supply voltage of 5V is exceeded, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is not exceeded, go to step 3.
3. Check the signal voltage (from pushbutton function to Print ARU) at the following points:
Plug X30/11 on Print ARU, PIN12 to PIN9 (GND).
Button not depressed: 0.2 - 2.3V, button depressed: 2.4 - 4.8V. If the signal voltage at plug X30/11 is ok, the
ground line (GND) and plug-in connections from plug X18/4 to plug X30/11 on the Print ARU still have to
be checked.
If the ground line is ok and the signal voltage too high, go to step 4.
4. Turn the ignition switch to the OFF position and disconnect plug X30/11 at the Print ARU.
Measure the resistance at the plug connection to the multi-controller II from (PIN12 to PIN1). Button not depres-
sed: approx. 8.2 kohms, button depressed: approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
The next step is to check whether the signal line at plug X30/11 has a short-circuit to another signal line or to a
supply (+).
If the setpoint values are not attained (e.g. the resistance is much lower), continue troubleshooting as follows:
Unscrew the screw on the grip housing on the multi-controller II and carefully detach the pushbutton function unit
from the grip housing. Disconnect plug X21 (14-pole) at the keyboard and measure the resistance from PIN1 to
PIN10 on the keyboard:
a) Button not depressed: approx. 8.2 kohms,
b) Button depressed: approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace it. If the setpoint values are attained,
the fault in the line between plug X30/11 and plug X21 must be rectified or the line replaced.
5. Cancel the fault, start the engine again and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).
Possible causes:
1. Contact fault in the signal line between potentiometer R20/1 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/1 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/1.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/1.
5. The potentiometer R20/1 is defective.
6. Print ARU is defective (e.g. resistors R28/7 or R28/8 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 50 is activated again.
Use the Service Tool monitor:
"AUX1 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU :
Plug X30/11 PIN1 (5V) to PIN9 (GND).
Setpoint value approx. 5V. If a voltage of 5V is not available, check the supply voltage at plug X30/1 PIN9 (12 V)
to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced (see fault
code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for potentiometer R20/1 at the Print ARU (after resistor R28/7). When doing so, plug
X30/16 (potentiometer R20/1) must be connected to the plug module.
Plug X30/16 PIN4 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/1 at the Print ARU (after resistor R28/8):
Plug X30/16 PIN6 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/16, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/16, go to step 5.
4. Check the signal voltage at the Print ARU:
Plug X30/16 PIN5 to plug X30/11 PIN9 (GND):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU :
Turn the ignition switch to the OFF position and disconnect plug X30/16 at the Print ARU.
Plug X30/11 PIN1 to plug X30/16 PIN4, setpoint value 470 ohms.
Plug X30/16 PIN6 to plug X30/11 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the Print ARU are in the specified range, go to step 6.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).
Possible causes:
1. Contact fault in the signal line between potentiometer R20/2 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/2 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/2.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/2.
5. Potentiometer R20/2 is defective.
6. Print ARU is defective (e.g. resistors R28/5 or R28/6 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 52 is activated again.
Use the Service Tool monitor:
"AUX2 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND.
Setpoint value approx. 5V. If a voltage of 5V is not available, check the supply voltage at plug X30/1 PIN9 (12V)
to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage already deviates substantially from 5V at plug 30/11, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for potentiometer R20/2 at the Print ARU (after resistor R28/5). When doing so, plug
X30/16 (potentiometer R20/2) must be connected to the Print ARU.
Plug X30/16 PIN1 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/2 at the Print ARU (after resistor R28/6).
Plug X30/16 PIN3 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/16, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/16, go to step 5.
Possible causes:
1. Contact fault in the signal line between potentiometer R20/3 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/3 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/3.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/3.
5. Potentiometer R20/3is defective.
6. Print ARU is defective (e.g. resistors R28/3 or R28/4 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 54 is activated again.
Use the Service Tool monitor:
"AUX3 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND)
Setpoint value approx. 5V. If a voltage of 5V is not available, check the supply voltage at plug X30/1 PIN9 (12V)
to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced (see fault
code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).
Possible causes:
1. Contact fault in the signal line between potentiometer R20/4 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/4 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/4.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/4.
5. Potentiometer R20/4 is defective.
6. Print ARU is defective (e.g. resistors R28/1 or R28/2 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 56 is activated again.
Use the Service Tool monitor:
"AUX4 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND). Setpoint value approx. 5V. If a voltage of 5V is not available, check the
supply voltage at plug X30/1 PIN9 (12V) to PIN8 (GND) at the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage already deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for potentiometer R20/4 at the Print ARU (after resistor R28/1). When doing so, plug
X30/15 (potentiometer R20/4) must be connected to the Print ARU.
Plug X30/15 PIN1 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/4 at the Print ARU (after resistor R28/2):
Plug X30/15 PIN3 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/15, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/15, go to step 5.
4. Check the signal voltage at the Print ARU:
Plug X30/15 PIN2 to plug X30/11 PIN9 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced (see fault code ARU 1,
steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU:
Turn the ignition switch to the OFF position and disconnect plug X30/15 at the Print ARU.
Plug X30/11 PIN1 to plug X30/15 PIN1, setpoint value 470 ohms.
Plug X30/15 PIN3 to plug X30/11 PIN9, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at thePrint ARU are in the specified range, go to step 6.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).
Possible causes:
1. Contact fault in the signal line between the potentiometer R20/5 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/5 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/5.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/5.
5. Potentiometer R20/5 is defective.
6. Print ARU is defective (e.g. resistors R28/9 or R28/10 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 58 is activated again.
Use the Service Tool monitor:
"AUX5 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND). Setpoint value approx. 5V. If a voltage of 5V is not available, check the
supply voltage at plug X30/1 PIN9 (12V) to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced (see fault
code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for the potentiometer R20/5 on the Print ARU (after resistor R28/9). When doing so,
plug X30/12 must be connected to the Print ARU.
Plug X30/12 PIN1 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for the potentiometer R20/5 at the Print ARU (after resistor R28/10):
Plug X30/12 PIN4 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/12, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/12, go to step 5.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to Print ARU in the armrest is faulty.
2. Interruption or contact fault on the CAN bus (vehicle bus), e.g. in the spur line to the Print ARU.
3. Conductive connection or short-circuit between the data lines (terminating resistances excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective or plug-in contacts at X3/10 are faulty.
5. The screening of the CAN wiring is faulty.
6. The Print ARU is defective.
Remedy:
Use Service Tool "CONTROL modulE status" to check whether other bus users are also offline.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whether
the fault is active again.
1. If fault ARU 71 is active again or if other bus users on the vehicle bus are signalling faults in connection with the
CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin ) .
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to a plus supply or to plus 1, plus 2 or plus 3 (12 V screening). Go to step c.
c) Check resistance values - CAN H against CAN L at diagnosis socket .
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check supply voltage (12V) to the Print ARU in the armrest:
Turn ignition switch to ON position.
If the voltage is >12V (<8V), it is faulty and must be repaired. For details on fault rectification, refer to fault code
ARU 20 (this fault code is active as soon as the supply voltage is < 8V).
e) Check supply (5V) to Print ARU:
NOTE: A voltage regulator at the Print ARU is supplied with 12 V. This supplies 5V to specific components on the
Print ARU and to specific control elements.
Turn ignition switch to ON position.
If the voltage (5V) is not present, detach the plugs to the multi-controller II and to the other control elements at
Print ARU A30. If the supply (5V) is present, there is a short-circuit in the control elements or in their wiring. If the
supply (5V) is not present, there could be other faults: Print ARU defective or short-circuit at the Print ARU.
f) Check the voltages - CANH and CANL at Print ARU plug X30/7:
Turn ignition switch to ON position. PIN3 (CANH) and PIN4 (CANL) against PIN2.
g) Check the screening of the data lines:
Violet line (12V) against black line (GND).
NOTE: The screening and the data lines are twisted together. It ends freely in front of plug X30/7 on the Print ARU.
If the power supply, the voltage values of CAN H and CAN L at plug X30/7 of the Print ARU and the screening
are ok, the Print ARU must be replaced (see fault code ARU 1, steps 1 to 4).
COMPONENTS SUMMARY
ARU Armrest ............................................................................................................................................. Fig. 1
AUX1 1st remote control valve.................................................................................................................... Fig. 1
AUX2 2nd remote control valve .................................................................................................................. Fig. 1
AUX3 3rd remote control valve ................................................................................................................... Fig. 1
AUX4 4th remote control valve ................................................................................................................... Fig. 1
AUX5 5th remote control valve ................................................................................................................... Fig. 1
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 2
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 3
B28 Manual accelerator slider ................................................................................................................. Fig. 4
B30 Longitudinal joystick.......................................................................................................................... Fig. 4
B31 Transverse joystick ........................................................................................................................... Fig. 4
B52 Shift lever for AUX (black)................................................................................................................. Fig. 4
G2/2 Generator Magneton 120A up to DBD100000.................................................................................. Fig. 5
G2/2 Generator Bosch 120A from DBD100001 ........................................................................................ Fig. 5
G2/2/2 2nd generator Magneton 95A ........................................................................................................... Fig. 6
G2/3 Generator Denso 140A up to DBD100000 ....................................................................................... Fig. 6
R20/1 Potentiometer 1st AUX ..................................................................................................................... Fig. 4
R20/2 Potentiometer 2nd AUX .................................................................................................................... Fig. 4
R20/3 Potentiometer 3rd AUX..................................................................................................................... Fig. 4
R20/4 Potentiometer 4th AUX ..................................................................................................................... Fig. 4
R20/5 Potentiometer 5th AUX ..................................................................................................................... Fig. 4
S31 Changeover switch for CAN SGR/FMGR up to DBD100000 ........................................................... Fig. 7
S60/2 Cruise control button......................................................................................................................... Fig. 8
S60/3 Speed button +.................................................................................................................................. Fig. 8
X3/10 Plug connection, terminal resistance ................................................................................................ Fig. 9
X9/17 Socket for diagnosis service tool .................................................................................................... Fig. 10
X18/4 Plug connection, wiring harness, cab right - armrest .......................................................................Fig. 11
X21 Plug connection, multicontroller II - print......................................................................................... Fig. 12
X30/1 Plug connection, supply armrest .................................................................................................... Fig. 13
X30/3 Plug connection, ARU - manual accelerator slider ......................................................................... Fig. 14
X30/4 Plug connection, ARU - AUX control lever ..................................................................................... Fig. 15
X30/5 Plug connection, ARU - AUX joystick ............................................................................................. Fig. 16
X30/7 Plug connection, ARU CAN BUS.................................................................................................... Fig. 17
X30/11 Plug connection, supply - multicontroller print ............................................................................... Fig. 18
X30/12 Plug connection, ARU - potentiometer R20/5 ................................................................................. Fig. 19
X30/15 Plug connection, ARU - potentiometer R20/3 and R20/4 ............................................................... Fig. 20
X30/16 Plug connection, ARU - potentiometer R20/1 and R20/2 ............................................................... Fig. 21
X70 Plug connection, engine control unit EEM2 up to DBD100000 ...................................................... Fig. 22
X89/1 Plug connection for EEM3 engine control unit - engine wiring harness from DBD100001 ............. Fig. 23
Fig. 1 Fig. 5
Fig. 4 Fig. 8
Fig. 10 up to DBD100000
Fig. 12 Fig. 16
Fig. 13 Fig. 17
Fig. 14 Fig. 18
Fig. 15 Fig. 19
Fig. 21
Fig. 22 up to DBD100000
*) see Note page 8 ARMREST FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL
S60/6
A31
X21
*A28 PLUG MODULE
X11 *A30 PRINT ARU
X24/2 VALVES UP TO DBD100000
F19 5A
17 A12 X4/83 X4/90 AUX 1
8 6 F20 5A CAN H
18 +15/1 3 3
7 13 X1 X18/4 F16 5A CAN L
5V 2 +15/2
X24/2 4 2
1 1 7 13 F47 5A CAN +
+15/1 24 1 1
6 10 9 9 CAN -
GND 2 4
X19 2 1 8 10 (16)
CAN +
X7 15 X5/1
S60/8 CAN - X4/91 AUX 2
2 16 CAN H
CAN H 3
3 17 CAN L
A29 X5 CAN L 2
GND GND 4 18 CAN +
3 1
S2/7/3
X
5V CAN -
B30 1 4
0
2 1
GND 3
7 3 X4/92 AUX 3
X
B31 5V CAN H
5 6 1 3
GSV4 CAN L
6 8 2 2
5V CAN +
4 1
S35 CAN -
8 X10/9 2 X10/9 6 8 4
X4 CN1a 10
GND
4 CAN - X4/93 AUX 4
17 A60 ECCU2
X
5V 5V CN3a CAN H
3
1 CAN +
6.4 V with EDC and AUX ON 4 CAN L
B52 2 CAN L 2
16 6.4 V with EDC ON 1 CAN +
X16 CAN H 1
R20/1 0.5 V 560Ω
GND
15 CAN -
6 4
470Ω
4.7 V
4 X10/11 X14/15 A12
A13 F45 5A
5 7 12 +15/1
X4/94 AUX 5
R20/2 0.5 V
560Ω CAN H
3 P8/1 3 4 1 2 3
4.7 V 470Ω X10/12 6 CAN L
1 P8 ICU P8 2
CAN +
2 7 X14/14 X10/14 1
CAN -
X15 5 4 7 4
R20/3 0.5 V 560Ω
6 3
4.7 V
470Ω
(7)
A X3/10 B
4 A14 X20/1 X23/1
(8) F93 5A
5 +30 8 Q
R20/4 0.5 V 560Ω 120 Ω
3
470Ω
4.7 V A12 Central print R20/5 Potentiometer AUX5 X10/14 10-pin plug connection
1 A13 Roof print S2/7/3 Switch, hydraulic master X11 16-pin plug connection
2 A14 Engine print S34 Switch AUX5 X12 4-pin plug connection
X12 A27 CAN module ---> DBD..... S35 Joystick pushbutton X14/14 14-pin plug connection
R20/5 0.5 V 560Ω A28 Plug module ---> DBD..... S60/6 AUX blue pushbutton X14/15 14-pin plug connection
4 A30 Print ARU DBD..... ---> S60/8 Shift pushbutton X15 6-pin plug connection
4.7 V
1 A29 Joystick (float position) X16 6-pin plug connection
A31 Multi controller X1 14-pin plug connection X18/4 18-pin plug connection
2 A60 ECCU2 X3/10 3-pin plug connection X19 2-pin plug connection
X6 0Ω B30 Joystick X4 4-pin plug connection X20/1 20-pin plug connection
longitudinal direction AUX1 X4/83 4-pin plug connection X21 14-pin plug connection
8
5V
6k2 B31 Joystick X4/90 4-pin plug connection X23/1 23-pin plug connection
2 transverse direction AUX2 X4/91 4-pin plug connection X24/2 24-pin plug connection
S34 1k2
B52 Selector lever AUX4 X4/92 4-pin plug connection YA1 44-pin plug connection
3
6k2 CN1a 26-pin plug connection X4/93 4-pin plug connection ---> DBD.....
2
7 CN3a 26-pin plug connection X4/94 4-pin plug connection YB1 44-pin plug connection
0
15/1
1
4 0Ω
5V GND 15/1 GND P8 ICU X5 2-pin plug connection ---> DBD.....
2 P8 10-pin plug connection X5/1 Plug connection (7) Ground point, roof hood, left
4 P8/1 4-pin plug connection X6 8-pin plug connection (8) Ground point, roof hood,
8 *YA1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7 R20/1 Potentiometer AUX1 X7 4-pin plug connection right
1 R20/2 Potentiometer AUX2 X10/9 10-pin plug connection (16) Ground, starter
5 *YB1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7
7 R20/3 Potentiometer AUX3 X10/11 10-pin plug connection
* A27 CAN MODULE R20/4 Potentiometer AUX4 X10/12 10-pin plug connection
BLANK PAGE
A31
ARMREST FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE
S60/6 X21 X30/11 A30 PRINT ARU X30/1 X18/4 X24/2
A12
CONTROL VALVES FROM DBD100001
F19 5A
8 6 7 13 17 X4/83 X4/90 AUX 1
F20 5A CAN H
7 13 9 9 18 +15/1 3 3
5V F47 5A CAN L
1 1 8 10 24 +15/1 4 2
CAN +
6 10 1 1
CAN -
X30/19 2 1 X30/7 (11)
2 4
2 16
S60/8 CAN H
3 17 X4/91 AUX 2
CAN L CAN H
4 18 (11) 3
A29 X30/5 CAN L
GND GND
S2/7/3 2
3 CAN +
1
X
5V
B30 1 0
CAN -
1
4
2 3
GND 3
7
6 1 AUX 3
X
B31 5V X4/92
5 GSV4 CAN H
8 2 3
6 CAN L
5V 2
S35
4 2 X10/9 X10/9 6 8 CAN +
1
8 CAN -
4
X30/4 CN1a A60 ECCU2 CN3a
GND
4 10 6.4 V with EDC and AUX ON 4
AUX 4
X
5V 5V CAN L X4/93
1 16 6.4 V with EDC ON 1 CAN H
CAN H 3
B52 2 15 CAN L
2
X30/16 A12 CAN +
R20/1 0.5 V 560Ω
GND A13 X10/11 X14/15 1
6 F45 5A CAN -
4.7 V 470Ω 7 12 +15/1 4
4
5 X10/12 6 A14
R20/2 0.5 V
560Ω X10/14 X10/3 X4/94 AUX 5
3 F212 5A CAN H
4.7 V
470Ω 7 6 +30 3
1 CAN L
2
2 X14/14 CAN +
1
X30/15 4 CAN -
R20/3 0.5 V 560Ω 4
6
4.7 V
470Ω (7)
4 P8 7 5 3 (8)
A X3/10 B
5 P8/1 P8 ICU
R20/4 0.5 V 560Ω CAN L
3 4 120 Ω
4.7 V
470Ω CAN H
1 3
2
X30/12 A12 Central print R20/4 Potentiometer AUX4 X14/14 14-pin plug connection
R20/5 0.5 V
560Ω
A13 Roof print R20/5 Potentiometer AUX5 X14/15 14-pin plug connection
4
4.7 V 470Ω A14 Engine print S2/7/3 Switch, hydraulic master X18/4 18-pin plug connection
1 A30 Print ARU S34 Switch AUX5 X21 14-pin plug connection
2 A29 Joystick S35 Joystick pushbutton X24/2 24-pin plug connection
0Ω A31 Multi controller S60/6 AUX blue pushbutton X30/1 14-pin plug connection
X30/6 A60 ECCU2 S60/8 Shift pushbutton X30/4 4-pin plug connection
8 B30 Joystick (float position) X30/5 2-pin plug connection
5V
6k2 longitudinal direction AUX1 X3/10 3-pin plug connection X30/6 8-pin plug connection
2 B31 Joystick X4/83 4-pin plug connection X30/7 4-pin plug connection
S34 1k2
transverse direction AUX2 X4/90 4-pin plug connection
3 X30/11 16-pin plug connection
6k2 B52 Selector lever AUX4 X4/91 4-pin plug connection X30/12 4-pin plug connection
2
7 CN1a 26-pin plug connection X4/92 4-pin plug connection X30/15 6-pin plug connection
0
1
4 0Ω CN3a 26-pin plug connection X4/93 4-pin plug connection X30/16 6-pin plug connection
2 P8 ICU X4/94 4-pin plug connection X30/19 2-pin plug connection
4 P8 10-pin plug connection X10/3 10-pin plug connection (7) Ground point, roof hood, left
8 P8/1 4-pin plug connection X10/9 10-pin plug connection (8) Ground point, roof hood, right
1 R20/1 Potentiometer AUX1 X10/11 10-pin plug connection (11) Ground point,
5 R20/2 Potentiometer AUX2 X10/12 10-pin plug connection engine cable carrier, rear
7
R20/3 Potentiometer AUX3 X10/14 10-pin plug connection
BLANK PAGE
F20 5A
X20/1 F97 10A
+15/1 7 +15/2
ARMREST F16 5A
F94 25A
+15/2 X1/14
(16) 31
*A28 PLUG MODULE X1/10 F92 10A
+30
X1 X18/4
*A30 PRINT ARU X24/2 17 18 2 X5/1
8 10
X3 7 13
B28 5V X70 21 48 70 46 69
1 9 9 (11)
CAN H A14
CAN + 18 A2 EEM2 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
X 2 2 16 Supply
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 Pre-glowing and
+15
1 2
X20/1 (11)
12V
CN3 17
* A27 CAN MODULE A1 ADIC 12V
26 16
M13 (11)
25 Emergency signal
X70
3 M 1
36 0.8 to 4.4 V
A2/2 PCU 2
X70 X9/7 (11)
12V
R8 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
PCU activation 20 2 2.5 V
CAN L
44 1 2.5 V
S6
43 5 Emergency shut-down
130 Hz at 900 rpm
B21 X1/3 p 19 8 DZG
335 Hz at 2300 rpm
1 X70
p 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
n 1 62 A12 Central print X1/12 Plug connection
B20 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
f 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
Switches and A30 Print ARU DBD..... ---> X3 4-pin plug connection
sensors A50/1 Power module X3/12 3-pin plug connection
t X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
B22 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
R 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
R A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
B23 B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
U C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
p,t 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
B29 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
U,R 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure
BLANK PAGE
F20 5A
+15/1
ARMREST X89/1 40 9 8 3 2 11 10 5 6
17 18 X24/2 A3 EEM3
(11) CAN H (2)
A30 PRINT ARU 35
X30/1 X18/4 CAN L Supply F208 10A
34 +30
8 10 (11)
X30/3 7 13
B28 M13
1 9 9 X12/1
5V 12V
X30/7 Pre-glowing and K5/LP 9 3 M 1
0.4V to 4.7V fuel delivery pump 4
X 2 2 16 3 5
3
CAN H X89/1
17 1 2
CAN L 55 4 GND
GND 4 4 18 X12/1
(11)
X1/30/1 E10/1
+30
P8/1 4 3
P8 ICU + -
P8/2
3 K8/2
4 3 5
(12)
1 2
X36/1 X2/19 X2/19
4
A1 ADIC CN3 5
26
25
A1 ADIC X4/4 4-pin plug connection
A3 EEM3 X4/70 4-pin plug connection
A7 ID module X10/18 10-pin plug connection
A12 Central print X12/1 12-pin plug connection
Emergency signal A14 Engine print X18/4 18-pin plug connection
R8 X4/70 X24/3 X10/18 X89/1 A30 Print ARU X24/2 24-pin plug connection
4 16 10 79 0.8 to 4.4 V B28 Manual throttle X24/3 24-pin plug connection
CN3 26-pin plug connection X30/1 14-pin plug connection
E10/1 Heating flange X30/3 4-pin plug connection
K5/LP Relay, fuel delivery pump X30/7 4-pin plug connection
K8/2 Relay, heating flange X36/1 36-pin plug connection
M13 Fuel delivery pump X89/1 89-pin plug connection
P8 ICU (2) Ground point, EEM3 control unit
A7 ID module Engine identification P8/1 4-pin plug connection (11) Ground point, engine cable carrier,
X4/4 X89/1
12V P8/2 4-pin plug connection rear
4 21 R8 Potentiometer, accelerator pedal (12) Ground point, engine cable carrier,
GND front
120 Ω 1 29 120 Ω
X1/30/1 Screw connection
CAN L X1/30/EEM Screw connection
2 52
CAN H X2/19 2-pin plug connection
3 53
BLANK PAGE
GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4
0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6
X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1
CAN H
CAN +
CAN L
12 4
CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H
A2 EEM2
CAN L
B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U
BLANK PAGE
X30/11
F19 5A F51 10A F18 5A
+15/1 +15/1
A30 PRINT ARU 3R7
(11) F20 5A F14 7.5A F9 10A
X21 X30/1 X18/4 +15/1 +30 +30
M
A31 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 3R7
S60/1 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
S60/2 2 16 A4 FMGR 17 1 A21 SGR
GND
CAN H CAN L
11 V
11 11 3 17 3 18 2 Supply
CAN L Supply
4 18 2
S60/3
A23 1 12 2 11 9 10 3
10 12 S4/4
0 V or 5 V
X6/3 X24/3 A4/2 LIMP HOME circuit
S60/4 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE A23 ELECTRONICS
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)
X4/59/b
X4/59/a
plug connection is linked.
A21/4 X6/1
11 4
CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 3 20 9 2
F45 5A
+15/1 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 Brake A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
S25 3.9 Ω
3 4 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
A14 X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
F212 5A S5 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
+30 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 Clutch A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
3.9 Ω A21 SGR transmission controller X6/9 7-pin plug connection
S46 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
CAN H
CAN L
BLANK PAGE
FAULTCODES AUX
AUX1 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 137
AUX1 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 137
AUX1 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 138
AUX1 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 138
AUX1 - 16 Controller fault (EEPROM inconsistent) .......................................................................................... 139
AUX1 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 139
AUX1 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 139
AUX1 - 23 Spool deflection too short ................................................................................................................ 140
AUX1 - 24 Spool deflection excessive .............................................................................................................. 140
AUX1 - 25 Float position not reached ............................................................................................................... 140
AUX1 - 26 Manual operation ............................................................................................................................. 141
AUX1 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 141
AUX1 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 142
AUX1 - 41 High Overvoltage - supply voltage above 45 VDC .......................................................................... 142
AUX1 - 42 Output stage fault ............................................................................................................................ 143
AUX1 - 43 Position transducer fault .................................................................................................................. 143
AUX1 - 81 Valve spool cannot brought back to neutral position ....................................................................... 144
AUX1 - 82 Valve spool not in neutral when switched on ................................................................................... 144
AUX2 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 145
AUX2 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 145
AUX2 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 146
AUX2 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 146
AUX2 - 16 Controller Fault (EEPROM inconsistent) ......................................................................................... 147
AUX2 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 147
AUX2 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 147
AUX2 - 23 Spool deflection too short ................................................................................................................ 148
AUX2 - 24 Spool deflection excessive .............................................................................................................. 148
AUX2 - 25 Float position not reached ............................................................................................................... 148
AUX2 - 26 Manual operation ............................................................................................................................. 149
AUX2 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 149
AUX2 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 150
AUX2 - 41 High overvoltage - supply voltage above 45 VDC ........................................................................... 150
AUX2 - 42 Output stage fault ............................................................................................................................ 151
AUX2 - 43 Position transducer fault .................................................................................................................. 151
AUX2 - 81 Valve spool cannot brought back to neutral position ....................................................................... 152
AUX2 - 82 Valve spool not in neutral when switched on ................................................................................... 152
AUX3 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 153
AUX3 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 153
AUX3 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 154
AUX3 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 154
AUX3 - 16 Controller Fault (EEPROM inconsistent) ......................................................................................... 155
AUX3 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 155
AUX3 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 155
AUX3 - 23 Spool deflection too short ................................................................................................................ 156
AUX3 - 24 Spool deflection excessive .............................................................................................................. 156
AUX3 - 25 Float position not reached ............................................................................................................... 156
AUX3 - 26 Manual operation ............................................................................................................................. 157
AUX3 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 157
AUX3 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 158
AUX3 - 41 High Overvoltage - supply voltage above 45 VDC .......................................................................... 158
Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch off and back on - if fault code 42 re-occurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch on, if fault code 81 re-occurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch on, if fault code 82 re-occurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch off and back on - if fault code 42 re-occurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 re-occurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch off and back on. If fault code 42 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 reoccurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch off and back on. If fault code 42 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 reoccurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch off and back on - if fault code 42 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 reoccurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".
BLANK PAGE
COMPONENTS SUMMARY
(11) Ground point engine device carrier up to DBD100000 ..................................................................... Fig. 1
(11) Ground point engine cable carrier, rear from DBD100001 ............................................................... Fig. 2
AUX1 1st remote control valve.................................................................................................................... Fig. 3
AUX2 2nd remote control valve .................................................................................................................. Fig. 3
AUX3 3rd remote control valve ................................................................................................................... Fig. 3
AUX4 4th remote control valve ................................................................................................................... Fig. 3
AUX5 5th remote control valve ................................................................................................................... Fig. 3
B30 Longitudinal joystick ......................................................................................................................... Fig. 3
B31 Transverse joystick ........................................................................................................................... Fig. 3
B52 Shift lever for AUX (black)................................................................................................................. Fig. 3
S34 5th AUX button ................................................................................................................................ Fig. 3
S60/6 AUX blue button ............................................................................................................................... Fig. 3
X4/90 Plug connection AUX1...................................................................................................................... Fig. 4
X4/91 Plug connection AUX2...................................................................................................................... Fig. 4
X4/92 Plug connection AUX3...................................................................................................................... Fig. 4
X4/93 Plug connection AUX4...................................................................................................................... Fig. 5
X4/94 Plug connection AUX5...................................................................................................................... Fig. 5
Fig. 3
Fig. 5 up to DBD100000
FAULTCODES ECCU2
ECCU2 - 1 Processor memory fault .................................................................................................................. 183
ECCU2 - 2 Processor fault ................................................................................................................................ 183
ECCU2 - 3 Processor fault ................................................................................................................................ 183
ECCU2 - 4 Processor fault ................................................................................................................................ 184
ECCU2 - 5 Processor fault ................................................................................................................................ 184
ECCU2 - 14 Differential lock switch in ON position - signal permanently at + .................................................. 184
ECCU2 - 15 Hydraulic Master switch: EHS position - signal permanently at + ................................................ 185
ECCU2 - 20 Rear PTO shaft - signal from left-hand external button is permanently at + ................................. 185
ECCU2 - 22 Rear PTO shaft - signal from right-hand external button is permanently at + .............................. 186
ECCU2 - 26 Rear PTO shaft - signal from button in ON position is permanently at + ...................................... 186
ECCU2 - 27 Rear PTO shaft - signal from button in OFF position is permanently at + .................................... 187
ECCU2 - 28 Front PTO shaft - signal from button in ON position is permanently at + ..................................... 187
ECCU2 - 29 Front PTO shaft - signal from button in OFF position is permanently at + ................................... 188
ECCU2 - 31 Rear PTO shaft - signal from Management button in ON position is permanently at + ................ 188
ECCU2 - 34 Differential lock switch in MANAGEMENT position - signal permanently at + .............................. 189
ECCU2 - 35 Front hitch - signal from LOWER button is permanently at + ....................................................... 189
ECCU2 - 36 Front hitch - signal from RAISE button is permanently at + .......................................................... 190
ECCU2 - 37 Field end management (HTS) button in RECORD position - signal permanently at + ................. 190
ECCU2 - 38 Field end management button in PLAY position - signal permanently at + .................................. 191
ECCU2 - 41 Front PTO shaft - slip too high ...................................................................................................... 191
ECCU2 - 43 Rear PTO shaft - slip too high ...................................................................................................... 191
ECCU2 - 44 Front PTO shaft - speed was detected although PTO shaft is off ................................................ 192
ECCU2 - 45 Rear PTO shaft - speed was detected although PTO shaft is off ................................................. 192
ECCU2 - 46 Front PTO speed - no signal from speed sensor .......................................................................... 192
ECCU2 - 47 PTO shaft speed rear - no signal from speed sensor ................................................................... 193
ECCU2 - 48 Front PTO shaft - ON button pressed for too long ........................................................................ 193
ECCU2 - 49 Rear PTO shaft - ON button pressed for too long ........................................................................ 194
ECCU2 - 50 Differential lock does not switch ON ............................................................................................. 194
ECCU2 - 51 Front PTO shaft does not switch ON ............................................................................................ 195
ECCU2 - 52 Rear PTO shaft does not switch ON ............................................................................................. 195
ECCU2 - 53 Reversing fan does not switch ON up to DBD100000 .................................................................. 196
ECCU2 - 53 Reversing fan does not switch ON from DBD100001 ................................................................... 196
ECCU2 - 54 Oil preheating does not switch ON ............................................................................................... 197
ECCU2 - 55 Differential lock - output stage temperature too high .................................................................... 197
ECCU2 - 56 Front PTO shaft - output stage temperature too high ................................................................... 198
ECCU2 - 57 Rear PTO shaft - output stage temperature too high .................................................................... 198
ECCU2 - 58 Reversing fan - overtemperature of power stage up to DBD100000 ............................................ 199
ECCU2 - 58 Reversing fan - overtemperature of power stage from DBD100001 ............................................. 199
ECCU2 - 59 Oil preheating - output stage temperature too high ...................................................................... 200
ECCU2 - 65 Front PTO shaft - current was measured although PTO shaft is off ............................................. 200
ECCU2 - 66 Front PTO shaft - no current was measured although PTO shaft is on ........................................ 201
ECCU2 - 67 Rear PTO shaft - current was measured although PTO shaft is off ............................................. 201
ECCU2 - 68 Rear PTO shaft - no current was measured although PTO shaft is on ........................................ 202
ECCU2 - 72 Front hitch position sensor - value exceeds permissible range .................................................... 202
ECCU2 - 73 Front hitch position sensor - value below permissible range ........................................................ 203
ECCU2 - 85 AUX 1 switched off because temperature is too high ................................................................... 203
ECCU2 - 86 AUX 2 switched off because temperature is too high ................................................................... 204
ECCU2 - 87 AUX 3 switched off because temperature is too high ................................................................... 204
ECCU2 - 88 AUX 4 switched off because temperature is too high ................................................................... 205
ECCU2 - 89 AUX 5 switched off because temperature is too high ................................................................... 205
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3a PIN21 to button
S17/1 and repair if necessary.
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3a PIN22 to button
S17/2 and repair if necessary.
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN33 via
X24/5 PIN14 to button S2/70/2 and repair if necessary.
a) If the data value remains OFF, ECCU2 has an internal defect and must be replaced.
b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN32 via
X24/5 PIN15 to button S2/70/2 and repair if necessary.
b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN31 via
X24/5 PIN17 to button S2/70/1 and repair if necessary.
b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN30 via
X24/5 PIN18 to button S2/70/1 and repair if necessary.
a) If the fault is activated again, the signal line is shorted to plus or ground or is interrupted. Check signal line from
CN3b PIN22 X3/21 PIN2 to sensor B8 PINB and repair if necessary.
b) If a frequency of > 100 Hz is measured and the fault is activated again, the fault is caused by ECCU2. Replace
ECCU2.
a) If the data value is still "ON", there is a short-circuit in the wiring. (see step 2)
b) If the data value changes when the plug is disconnected, replace the button.
2. Check signal line from S2/70/1 via X24/5 PIN17 to CN3b PIN31 and repair if necessary.
a) If the data value is still "ON", there is a short-circuit in the wiring. (see step 2)
b) If the data value changes when the plug is disconnected, replace the button.
2. Check signal line from S2/70/2 via X24/5 PIN14 to CN3b PIN33 and repair if necessary.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and
solenoid valve Y10.
Check wiring from Y10 PIN1 to CN3b PIN5 and Y10 PIN2 to grounding point 16 and repair if necessary.
3. If the fault is still active, replace ECCU2.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 1 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (> 5 secs) (RESET).
Remedy:
Faults ECCU2 86, 87, 88 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. Afterwards turn ignition switch back to the ON
position and check whether 85 is still active. If the fault is active again, read off the temperature of all AUX units.
If the value of AUX 1 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 1 is defective. Replace AUX 1.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 85 is still active.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 2 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 87, 88 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 86 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 2 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 2 is defective. Replace AUX 2.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 86 is still active.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 3 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 86, 88 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 87 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 3 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 3 is defective. Replace AUX 3.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 87 is still active.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 4 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 86, 87 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 88 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 4 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 4 is defective. Replace AUX 4.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 88 is still active.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 5 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 86, 87 and 88 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 89 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 5 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 5 is defective. Replace AUX 5.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 89 is still active.
a) If the charging voltage is outside the specified range, the voltage regulator of the alternator must be replaced.
b) If the charging voltage is in the specified range, cancel the fault and switch the engine off. Start the engine
again after approx. 5 seconds. If the fault is activated again, replace ECCU2.
a) If the charging voltage is outside the specified range, the voltage regulator of the alternator must be replaced.
b) If the charging voltage is in the specified range, cancel the fault and switch the engine off. Start the engine
again after approx. 5 seconds. If the fault is activated again, replace ECCU2.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault on the CAN bus lines CANH or CANL between ECCU2 and other bus users.
2. Short-circuit between CANH and CANL.
3. One of the CAN bus lines is shorted to plus or GND.
4. Bus termination fault (contact fault or terminating resistor defective).
5. Fault in the screening of the bus line.
6. Fault in the supply to ECCU2.
7. Hardware fault of ECCU2 or another bus user.
Remedy:
Use CONTROL modulE status Service Tool to check whether other bus users are offline, too.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether the
fault is still active.
NOTE: If only fault 110 is active, the fault is probably caused by ECCU2 or the CAN bus wiring (including screening)
between ECCU2 and the weld points to the vehicle bus.
1. Check the plus supply of ECCU2 (fuses at print A12). Also check the ground supply to ECCU2. See fault codes
ECCU2 99 and ECCU2 101. Afterwards, turn ignition switch to ON position. If only fault 110 is active, go to step 3.
If other CAN bus faults are also active or if other bus users are OFFLINE, check all CAN bus fuses. Go to step 2.
2. If other bus users on the vehicle bus are also OFFLINE, check the entire vehicle bus for short-circuits, interrupti-
ons or defective terminating resistors. In the event of a short-circuit, all bus users are OFFLINE.
In this case, disconnect one bus user after the other, starting with ECCU2. If the other bus users go ONLINE when
the bus user to be tested is disconnected, this bus user must be replaced.
3. Carry out checks (by measuring) at the vehicle bus:
Disconnect the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(switch in upper position). Turn ignition switch to ON position.
b) Check resistance values - CAN H against CAN L at diagnosis socket X9/17con. To do so, turn ignition switch
to OFF position.
PINC (CANH, yellow ) against PIND (CANL, green). Setpoint: 60 ohms +/- 10%.
c) Check the terminating resistor in plug housing X3/10. (Plug of the CAN wiring disconnected) PINA against
PINB = 120 ohms +/- 10%.
d) Check the resistance of the CAN lines including the terminating resistor in the EEM, at X3/10: (Terminating
resistor at X3/10 disconnected)
PINA against PINB = 120 ohms +/- 10%.
If the resistance strongly deviates from the setpoint, disconnect plug X70 from the EEM and check the terminating
resistor at the EEM, PIN18 against PIN42. (120 ohms +/- 10%)
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault on the CAN bus lines CANH or CANL between ECCU2 and other bus users.
2. Short-circuit between CANH and CANL.
3. One of the CAN bus lines is shorted to plus or GND.
4. Bus termination fault (contact fault or terminating resistor defective).
5. Fault in the supply to ECCU2.
6. Hardware fault of ECCU2 or another bus user.
Remedy:
Use "CONTROL module status" Service Tool to check whether other bus users are offline, too.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether the
fault is still active.
NOTE: If only fault 110 is active, the fault is probably caused by ECCU2 or the CAN bus wiring between ECCU2
and the weld points to the vehicle bus.
1. Check the plus supply of ECCU2 (fuses at print A12). Also check the ground supply to ECCU2. See fault codes
ECCU2 99 and ECCU2 101. Afterwards, turn ignition switch to ON position. If only fault 110 is active, go to step 3.
If other CAN bus faults are also active or if other bus users are OFFLINE, check all CAN bus fuses. Go to step 2.
2. If other bus users on the vehicle bus are also OFFLINE, check the entire vehicle bus for short-circuits, interrupti-
ons or defective terminating resistors. In the event of a short-circuit, all bus users are OFFLINE.
In this case, disconnect one bus user after the other, starting with ECCU2. If the other bus users go ONLINE when
the bus user to be tested is disconnected, this bus user must be replaced.
3. Carry out checks (by measuring) at the vehicle bus:
Disconnect the plug of Service Tool DPA from diagnosis socket X9/17. Turn ignition switch to ON position.
b) Check resistance values - CAN H against CAN L at diagnosis socket X9/17con. To do so, turn ignition switch
to OFF position.
PINC (CANH) against PIND (CANL). Setpoint: 60 ohms +/- 10%.
c) Check the terminating resistor in plug housing X3/10. (Plug of the CAN wiring disconnected) PINA against
PINB = 120 ohms +/- 10%.
e) If the terminating resistor in the EEM is also ok, check the CAN lines. Connect the terminating resistor to
X3/10. Measure the resistance at plug X89/1 between PIN34 and PIN35. (120 ohms +/- 10%) If the resistance
strongly deviates, check and repair the CAN wiring.
4. Disconnect plug CN1a from ECCU2 and also measure resistances and voltages at the spur line (PIN15 against
PIN16). Localize the interruption or contact fault and repair the spur line.
b) Check the resistance values CAN H to CAN L at diagnosis socket X9/17 con. To do so, turn the ignition switch
to the OFF position.
PINH (CANH) to PINJ (CANL). Setpoint: 60 ohms + / -10%.
If the resistance deviates substantially from the setpoint value when checking CANH to CANL, then both termi-
nating resistors must then be checked individually.
c) One terminating resistor is located in plug X3/85 (German, 4-pole), the other one is integrated in the ISO bus
socket. Disconnect the terminating resistor in plug X4/86. Repeat the resistance measurement as described in
step b. Setpoint: 120 ohms +/-10%. If the setpoint value is attained, then the terminating resistor in the ISO bus
socket is ok. If not, then the ISO bus socket must be replaced.
d) Check plug X3/85 and the terminating resistor: Pin assignment: see ISO bus schematic, setpoint = 120 ohms
+/- 10%. If the resistance deviates from the setpoint value, then the terminating resistor is defective. Replace the
terminating resistor in plug X3/85.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse defective.
2. Bulb defective.
3. Interruption or contact fault in the lamp circuit.
4. Data communication on the bus was disturbed by electromagnetic interference.
Remedy:
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If the fault is no longer active, data communication on the ISO bus was disturbed by electromagnetic interference.
2. Check fuse and replace if required. Check bulb and replace if required. If neither fuse nor bulb is defective, then
check that the bulb has good contact to the lamp socket and check the wiring for interruptions or contact faults.
Repair if necessary.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Supply to CAN module in the armrest faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the armrest is "OFFLINE" go to fault code ARU 71. If the armrest is ONLINE, however, this was only a temporary
fault.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Supply to AUX 1 faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If AUX 1 is "ONLINE", however, this was only a temporary fault.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If AUX 1 is "OFFLINE", use the CAN BUS diagram to check the supply and the data lines to AUX 1. Repair if
necessary.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Supply to EDC is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. Check supply to EDC. For details, refer to fault code EDC 33.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Supply to EEM is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Fault in the screening of the bus line.
5. Data communication on the bus was disturbed by electromagnetic interference.
6. Another bus user is faulty.
Remedy:
Use "CONTROL module status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the EEM is "OFFLINE" go to fault code EEM 141. If the EEM is "ONLINE", however, this was only a temporary
fault.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Supply to EEM is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the EEM is "OFFLINE" go to fault code EEM 141. If the EEM is "ONLINE", however, this was only a temporary
fault.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the FMGR is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the FMGR is "OFFLINE" go to fault code FMGR 255. If the FMGR is ONLINE, however, this was only a tem-
porary fault.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ICU is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the ICU is "OFFLINE" go to fault code ICU 2. If the ICU is "ONLINE", however, this was only a temporary fault.
BLANK PAGE
COMPONENTS SUMMARY
(11) Ground point engine device carrier, rear up to DBD100000..............................................................Fig. 1
(11) Ground point engine cable carrier, rear from DBD100001 ................................................................Fig. 2
(16) Ground point starter...........................................................................................................................Fig. 3
ARU Armrest ..............................................................................................................................................Fig. 4
AUX1 1st remote control valve ....................................................................................................................Fig. 4
AUX2 2nd remote control valve ...................................................................................................................Fig. 4
AUX3 3rd remote control valve ....................................................................................................................Fig. 4
AUX4 4th remote control valve ....................................................................................................................Fig. 4
AUX5 5th remote control valve ....................................................................................................................Fig. 4
A2 EEM2 control unit up to DBD100000.................................................................................................Fig. 5
A3 EEM3 control unit from DBD100001 .................................................................................................Fig. 6
A4 FMGR ................................................................................................................................................Fig. 7
A55 EDC control unit ................................................................................................................................Fig. 8
A60 ECCU2 ..............................................................................................................................................Fig. 9
B7 Rear PTO speed sensor .................................................................................................................Fig. 10
B8 Front PTO speed sensor ................................................................................................................. Fig. 11
B19 Angle of rotation sensor [LAGESENSOR VO]..................................................................................Fig. 12
CN1a ECCU2 plug connection ..................................................................................................................Fig. 13
CN2/E ECCU2 plug connection ..................................................................................................................Fig. 13
CN3a ECCU2 plug connection ..................................................................................................................Fig. 14
CN3b ECCU2 plug connection ..................................................................................................................Fig. 14
G2/2 Generator, Magneton 120A up to DBD100000................................................................................Fig. 15
G2/2 Generator, Bosch 120A from DBD100001 ......................................................................................Fig. 15
G2/2/2 2nd Generator, Magneton 95A ........................................................................................................Fig. 16
G2/3 Generator, Denso 140A up to DBD100000 .....................................................................................Fig. 16
K5/16 Relay, reverse fan up to DBD100000 ..............................................................................................Fig. 17
P8 ICU ..................................................................................................................................................Fig. 18
P8 Plug connection ICU........................................................................................................................Fig. 19
S2/7/3 Switch, hydraulic master [MASTER]................................................................................................Fig. 20
S2/15/6 Switch, HTS [HTS]...........................................................................................................................Fig. 21
S2/15/7 Switch, reducing speed [DREHZAHLABSENKUNG] ......................................................................Fig. 21
S2/56 Switch, differential lock management [DIFF HI]...............................................................................Fig. 22
S2/70/1 Switch, front PTO [PTO VO] ............................................................................................................Fig. 23
S2/70/2 Switch, rear PTO [PTO HI]...............................................................................................................Fig. 23
S2/71 Switch, rear PTO management [PTO M] .........................................................................................Fig. 23
S14/3 External button, front power lift, LOWER.........................................................................................Fig. 24
S15/3 External button, front power lift, RAISE ...........................................................................................Fig. 24
S17/1 External button, PTO rear left .........................................................................................................Fig. 25
S17/2 External button, PTO rear right........................................................................................................Fig. 26
Fig. 3 Fig. 7
Fig. 4 Fig. 8
Fig. 11 up to DBD100000
Fig. 13 up to DBD100000
Fig. 14 up to DBD100000
Fig. 15 Fig. 19
Fig. 16 Fig. 20
Fig. 18
Fig. 24 up to DBD100000
Fig. 26
Fig. 34 up to DBD100000
Fig. 35 up to DBD100000
Fig. 37
Fig. 41 up to DBD100000
Fig. 47 up to DBD100000
Fig. 49 up to DBD100000
Fig. 50 up to DBD100000
Fig. 53
Fig. 54
Fig. 55 up to DBD100000
CN1a
15 3 P8/2 CN3 A1 ADIC
CAN L CAN H
16 4 3 26
CAN L
4 25
X10/9 CN1a
GSV4
2 10
S2/56 Y10
CN3b
Differential lock 12 V
0 5 1
1
2
X24/5 CN3b
5 2 24 Management
3 2
1 1 23 Differential lock ON
S2/15/6
(16)
0
1
X24/5 CN3a HTS
2
7 22 18 RECORD
3
1 24 19 PLAY
S2/15/7
OFF
ON A62
Speed reduction
X24/5 CN3a
X4/66
2 1 7 24
3 M
A14
S2/74
F95 15A
X1/17
+30
A12 Reversible fan
OFF
X24/1 ON
X24/3 CN3a 1
F29 10A K5/16
+15/2 4 1 3 22 3 12 V 4
3 5 2
CN3b X24/3 X23/1 X2/25
12 V 1 2
8 16 H 1 4
X1/17 Plug connection X23/1 23-pin plug connection
X2/25 2-pin plug connection X24/1 24-pin plug connection
X4/66 4-pin plug connection X24/2 24-pin plug connection X2/25 2
X4/85a 4-pin plug connection X24/3 24-pin plug connection
X4/85b 4-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
X10/12 10-pin plug connection (7) Ground point, roof hood, left 16 1
X10/14 10-pin plug connection (8) Ground point, roof hood, right (11)
Heating valve Y8
X14/14 14-pin plug connection (11) Ground point, engine device carrier
X14/15 14-pin plug connection (16) Ground point, starter 2
X20/1 20-pin plug connection
(16)
BLANK PAGE
A60 ECCU2
X10/9 CN1a
GSV4
2 10
S2/70/1
Front PTO
ON
OFF
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E Y4
12 V**
7 1
X3/21 CN3b
(11) GND
n C 3 X23/2 CN3b 225 Hz at 900 rpm 6 2
B8 B 2 N 22 490 Hz at 1900 rpm
f A 1 570 Hz at 2300 rpm
A12
F32 10A
X24/2 **) Activation for approx. 6 sec. with 3 V, then 12 V
+15/2 7
GND
S2/70/2 18 2
(16)
ON
OFF
X24/5 CN3b
1 A12 Central print
14 33 6.4 V when ON A60 ECCU2
3
7 15 32 6.4 V when OFF B7 Rear PTO speed sensor
B8 Front PTO speed sensor
S2/71 CN1a 26-pin plug connection
Rear PTO CN2/E 26-pin plug connection
OFF
CN3a 26-pin plug connection
ON
CN3b 34-pin plug connection
S2/70/1 Switch for front PTO
X24/5 CN3a S2/70/2 Switch for rear PTO
5 1 16 20 6.4 V with management ON S2/71 Switch for rear PTO, management
S17/1 External pushbutton, PTO shaft, rear left
S17/1 S17/2 External pushbutton, PTO shaft, rear right
X3/21 3-pin plug connection
OFF
X10/9 10-pin plug connection
ON X23/2 23-pin plug connection
CN3a X24/2 24-pin plug connection
1 2 21 6.4 V with pushbutton pressed X24/5 24-pin plug connection
22 Ω Y4 Solenoid valve, front PTO
S17/2 Y5 Solenoid valve, rear PTO
(11) Ground point, engine device carrier
OFF
(16) Ground point, starter
ON
CN3a
1 2 22 6.4 V with pushbutton pressed
22 Ω
BLANK PAGE
CN1a
15
S2/74 Reverse fan pushbutton CAN L (7)
X1/31/1 Screw connection 16 P8 7 5 3 (8)
X4/64 4-pin plug connection P8 ICU A1 ADIC
X10/9 CN1a P8/1 P8/2 CN3
GSV4 CAN H
2 10 3 3 26
CAN L
4 4 25
S2/56
0 Differential lock
1
X24/5 CN3b
2
1 2 3
CN3b 1
S2/74 X6/2
12 V 2
Reverse fan 8 3 1
A12
OFF
F29 10A
X24/1 ON
X24/3 CN3a X1/31/1
+15/2 4 1 3 22 3 12 V 2
GND
4
(11)
X4/66 4-pin plug connection X14/15 14-pin plug connection
X4/85/a 4-pin plug connection X24/1 24-pin plug connection
X4/85/b 4-pin plug connection X24/2 24-pin plug connection
X6/2 6-pin plug connection X24/3 24-pin plug connection
X10/3 10-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
16 1
X10/12 10-pin plug connection (7) Ground point, roof hood, left
X10/14 10-pin plug connection (8) Ground point, roof hood, right
Y8
Heating valve
X14/14 14-pin plug connection (11) Ground point, engine cable carrier, rear 2
(11)
BLANK PAGE
A60 ECCU2
X10/9 CN1a
GSV4
2 10
S2/70/1
Front PTO
ON
OFF
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E Y4
12 V**
7 1
X3/21 CN3b
(11) GND
n C 3 CN3b 225 Hz at 900 rmp 6 2
B8 B 2 22 490 Hz at 1900 rmp
f A 1 570 Hz at 2300 rmp
A12
F32 10A
X24/2 **) Activation approx. 6 sec. with 3 V, then 12 V
+15/2 7
GND
S2/70/2 18 2
(11)
ON
OFF
X24/5 CN3b
1 14 33 6.4 V when ON
3
7 15 32 6.4 V when OFF A12 Central print
S2/71 A60 ECCU2
Rear PTO B7 Rear PTO speed sensor
B8 Front PTO speed sensor
OFF
ON
CN1a 26-pin plug connection
CN2/E 26-pin plug connection
X24/5 CN3a CN3a 26-pin plug connection
5 1 16 20 6.4 V with management ON CN3b 34-pin plug connection
S17/1 S2/70/1 Switch for front PTO
S2/70/2 Switch for rear PTO
S2/71 Switch for rear PTO, management
OFF
S17/1 External pushbutton for PTO, rear left
ON
CN3a S17/2 External pushbutton for PTO, rear right
1 2 21 6.4 V with pushbutton pressed X3/21 3-pin plug connection
22 Ω X10/9 10-pin plug connection
S17/2 X24/2 24-pin plug connection
X24/5 24-pin plug connection
OFF Y4 Solenoid valve, front PTO
ON
CN3a Y5 Solenoid valve, rear PTO
(11) Ground point, engine cable carrier, rear
1 2 22 6.4 V with pushbutton pressed
22 Ω
BLANK PAGE
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS UP TO DBD100000
3 X10/9 CN3a
X4/91 AUX 2
X10/9 6 1 8 1 6.4 V with EDC ON CAN H
3
2 8 2 6 4 6.4 V with EDC and AUX ON CAN L
2
A12 CAN +
X24/2 1
ARMREST F47 5A CAN -
+15/1 24 4
2
X5/1
S28/1 0
X18/4 CN3a 31
X4/92 AUX 3
X18/4 1
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER X14/15 CAN L
7 7 16 6.4 V with pushbutton pressed F45 5A 2
+15/1 12 CAN +
1
S18/1 CAN -
4
CAN H
CAN +
CAN L
CAN -
OFF
ON CN3a X4/93 AUX 4
1 2 A13 X10/11 CAN H
3
12 6.4 V with pushbutton pressed
22 Ω 7 CAN L
S18/2 2
CAN +
X10/12 6 1
CAN -
P8/1 3 4 1 2 4
OFF
ON
P8 ICU P8
1 2 13 6.4 V with pushbutton pressed
22 Ω 7 X14/14 X10/14 X4/94 AUX 5
S19/1 CAN H
5 4 7 3
CAN L
OFF
3 2
(7) CAN +
X23/2 X4/72 ON
X4/72 X23/2 1
(8) CAN -
K 3 1 2 2 F 10 6.4 V with pushbutton pressed 4
22 Ω
S19/2 A14 X20/1 X23/1
F93 5A A X3/10 B
+30 8 Q
OFF
X4/72 ON
X4/72 X23/2 120 Ω
4 1 2 1 G 11 6.4 V with pushbutton pressed A12 Central print X4/72 4-pin plug connection
A X23/2 22 Ω
A13 Roof print X4/83 4-pin plug connection
S14/3
A14 Engine print X4/90 4-pin plug connection
A60 ECCU2 X4/91 4-pin plug connection
2 X4/69 X4/92 4-pin plug connection
OFF B19 Angle of rotation sensor for front power lift
ON
X4/69 CN1a 26-pin plug connection X4/93 4-pin plug connection
X23/2 X4/94 4-pin plug connection
CN3a 26-pin plug connection
1 2 2 D 23 6.4 V with pushbutton pressed
CN3b 34-pin plug connection X5/1 Plug connection
22 Ω
S15/3 P8 ICU X10/9 10-pin plug connection
P8 10-pin plug connection X10/11 10-pin plug connection
P8/1 4-pin plug connection X10/12 10-pin plug connection
OFF S2/7/3 Switch, hydraulic master X10/14 10-pin plug connection
ON
X4/69 X23/2 S14/3 External pushbutton, front power lift LOWER X14/14 14-pin plug connection
S15/3 External pushbutton, front power lift RAISE X14/15 14-pin plug connection
1 2 1 C 26 6.4 V with pushbutton pressed S18/1 External push button, AUX BLUE pressure in - X18/4 18-pin plug connection
22 Ω
S18/2 External push button, AUX BLUE pressure in + X20/1 20-pin plug connection
CN3b S19/1 External push button, AUX BROWN X23/1 23-pin plug connection
X3/22 X23/2 12 (up to DBD... YELOW) pressure in - X23/2 23-pin plug connection
8V S19/2 External push button, AUX BROWN X24/2 24-pin plug connection
3 3 S CN3a (7) Ground point, roof hood, left
(up to DBD... YELOW) pressure in +
B19 2 2 T 8 2.5 to 4.7 V S28/1 Switch, front power lift management (8) Ground point, roof hood, right
U GND X3/10 3-pin plug connection
1 1 R CN1a X3/22 3-pin plug connection
23 X4/69 4-pin plug connection
BLANK PAGE
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS FROM DBD100001
3 X10/9 CN3a
X4/91 AUX 2
X10/9 6 1 8 1 6.4 V with EDC ON
A12 CAN H
X24/2 3
2 8 2 6 4 6.4 V with EDC and AUX ON F47 5A CAN L
+15/1 24 (11) 2
CAN +
1
ARMREST X14/15 CAN -
F45 5A 4
+15/1 12
2
S28/1 0
X18/4 CN3a X4/92 AUX 3
X18/4 1
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER CAN L
7 7 16 6.4 V with pushbutton pressed 2
A13 X10/11 CAN +
1
S18/1 7 CAN -
4
OFF
X10/12 6 A14
CN3a X10/14 X10/3
ON
F212 5A X4/93 AUX 4
7 6 +30
CAN H
1 2 12 6.4 V with pushbutton pressed 3
22 Ω CAN L
S18/2 2
CAN +
4 X14/14 1
CAN -
OFF
ON
4
X4/72 ON
X4/72 120 Ω
4 1 2 1 11 6.4 V with pushbutton pressed
22 Ω
A12 Central print X4/69 4-pin plug connection
S14/3 A13 Roof print X4/72 4-pin plug connection
A14 Engine print X4/83 4-pin plug connection
2 X4/69 OFF A60 ECCU2 X4/90 4-pin plug connection
ON
X4/69 B19 Angle of rotation sensor for front power lift X4/91 4-pin plug connection
CN1a 26-pin plug connection X4/92 4-pin plug connection
1 2 3 23 6.4 V with pushbutton pressed CN3a 26-pin plug connection X4/93 4-pin plug connection
22 Ω
S15/3 CN3b 34-pin plug connection X4/94 4-pin plug connection
P8 ICU X10/3 10-pin plug connection
P8 10-pin plug connection X10/9 10-pin plug connection
OFF P8/1 4-pin plug connection X10/11 10-pin plug connection
ON
X4/69 S2/7/3 Switch, hydraulic master X10/12 10-pin plug connection
1 2 1 26 6.4 V with pushbutton pressed S14/3 External pushbutton, front power lift LOWER X10/14 10-pin plug connection
22 Ω S15/3 External pushbutton, front power lift, RAISE X14/14 14-pin plug connection
CN3b S18/1 External pushbutton, AUX BLUE pressure in - X14/15 14-pin plug connection
12 S18/2 External pushbutton, AUX BLUE pressure in + X18/4 18-pin plug connection
X3/22 S19/1 External pushbutton, AUX BROWN pressure in - X24/2 24-pin plug connection
8V
3 3 CN3a S19/2 External pushbutton, AUX BROWN pressure in + (7) Ground point, roof hood, left
B19 2 2 8 2.5 to 4.7 V S28/1 Switch for front power lift management (8) Ground point, roof hood, right
GND X3/10 3-pin plug connection (11) Ground point, engine cable carrier, rear
U 1 1 CN1a X3/22 3-pin plug connection
23
BLANK PAGE
FAULTCODES EDC
EDC - 11 Valve solenoid Y6 RAISE is not activated ......................................................................................... 255
EDC - 12 Valve solenoid Y7 LOWER is not activated ...................................................................................... 256
EDC - 15 The signal of the RAISE/LOWER buttons is outside the permissible range ..................................... 257
EDC - 16 Stabilised supply voltage for sensors and control elements is faulty ................................................ 259
EDC - 17 Supply voltage too high (> 18 V) ....................................................................................................... 260
EDC - 18 The signal of the TRANSPORT, CONTROL and QUICK-DROPkey functions is outside
the permissible range up to DBD094270 .......................................................................................................... 261
EDC - 18 The signal of the TRANSPORT, CONTROL and QUICK-DROP key functions is outside
the permissible range from DBD094271 ........................................................................................................... 263
EDC - 21 The signal of the EMERGENCY-STOP key is outside the permissible range up to DBD094270 ..... 265
EDC - 21 The signal of the EMERGENCY-STOP key is outside the permissible range from DBD094271 ...... 266
EDC - 22 Angle of rotation sensor signal is faulty ............................................................................................. 268
EDC - 23 The signal of SETPOINT potentiometer R6/1 is outside the permissible range ................................ 269
EDC - 24 The signal of LIFT LIMITER potentiometer R6/2 is outside the permissible range ........................... 270
EDC - 31 Signal from force sensor, right, B10/2 is faulty .................................................................................. 272
EDC - 32 Signal from force sensor, left, B10/1 is faulty .................................................................................... 273
EDC - 33 Supply voltage too low (< 11.5 V) ..................................................................................................... 275
EDC - 34 The signal of LOWERING SPEED potentiometer R6/4 is outside the permissible range ................. 276
EDC - 36 The signal of MIXED CONTROL potentiometer R6/3 is outside the permissible range .................... 277
EDC - 41 Signal of radar sensor B16 is faulty or not present up to DBD100000 .............................................. 279
EDC - 41 Signal of radar sensor B16 is faulty or not present from DBD100001 ............................................... 280
EDC - 42 Theoretical driving speed signal is faulty or not present ................................................................... 282
EDC - 44 The signal of SLIP LIMIT potentiometer R6/5 is outside the permissible range ................................ 283
COMPONENTS SUMMARY ............................................................................................................................. 285
FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC UP TO DBD100000 ......................................................... 295
FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC FROM DBD100001 .......................................................... 299
BLANK PAGE
b) If the voltage does not change although all buttons are disconnected, the wiring between EDC Box and buttons
must be checked. The wiring must not be shorted to other lines (plus or ground, or to components). The two signal
lines (RAISE and LOWER) and the supply line must not be shorted. Repair the wiring if necessary.
c) If the supply is ok and if the voltage does not change when a button is operated, the button is defective or the
supply or signal line to the next weld point is defective. Replace the button or repair the line.
d) Press the QUICK-DROP button S2/72 on the armrest and hold it down.
Monitor display: "QUICK-DROP".
e) Release the QUICK-DROP button.
Monitor display: "NONE".
NOTE: If a fault is active, the EDC control valve is not activated. As a result, the lifting cylinders do not move.
If the engine function does not change from step b) to e) and if the fault is active, go to step 2.
2. Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Start the engine.
3. Check the signal voltage at the EDC Box: PIN21 (signal) against PIN28 (GND).
TRANSPORT mode. Setpoint: 6.7V +/- 0.5V.
CONTROL mode. Setpoint 5.1V +/- 0.5V.
QUICK-DROP mode. Setpoint: 3.4V +/- 0.5V.
a) If the signal voltage is 10.5V +/- 0.4V, the signal line is interrupted. Go to step 4.
b) If the signal voltage is > 9.5V (up to 14V), the signal line is shorted to plus. Go to step 5.
c) If the signal voltage is < 0.5V, the signal line is shorted to GND or is interrupted.
Go to step 6.
4. Check signal line between plug X55 PIN 21 and plug X10/4 PIN8 at print A16 for correct continuity
(resistance < 1 ohm). Repair if necessary.
Connect both plugs and check the signal voltage as described in step 3.
d) Press the QUICK-DROP button S2/72 on the armrest and hold it down.
Monitor display: "QUICK-DROP".
e) Release the QUICK-DROP button.
Monitor display: "NONE".
NOTE: If a fault is active, the EDC control valve is not activated. As a result, the lifting cylinders do not move.
If the engine function does not change from step b) to e) and if the fault is active, go to step 2.
2. Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Start the engine.
3. Check the signal voltage at the EDC Box: PIN21 (signal) against PIN28 (GND).
TRANSPORT mode. Setpoint: 6.7V +/- 0.5V.
CONTROL mode. Setpoint 5.1V +/- 0.5V.
QUICK-DROP mode. Setpoint: 3.4V +/- 0.5V.
a) If the signal voltage is 10.5V +/- 0.4V, the signal line is interrupted. Go to step 4.
b) If the signal voltage is > 9.5V (up to 14V), the signal line is shorted to plus. Go to step 5.
c) If the signal voltage is < 0.5V, the signal line is shorted to GND or is interrupted.
Go to step 6.
4. Check signal line between plug X55 PIN21 and plug X10/4 PIN8 at print A16 for correct continuity
(resistance < 1 ohm). Repair if necessary.
Connect both plugs and check the signal voltage as described in step 3.
The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/1 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/1 in position "10": Monitor display "95%" = 10 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/1 and check whether the percentage in the monitor function has
changed.
If fault 23 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/1 at EDC Box A55:
PIN22 (signal) against PIN28 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step b.
b) Check the signal voltage of potentiometer R6/1 at the output of print A16:
X14/4 PIN13 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).
c) Check the signal voltage of potentiometer R6/1 at the input of print A16:
To do so, disconnect plug X5/6.
X5/6 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X5/6 PIN3 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X5/6 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/1 at print A16.
X5/6 PIN2 (plus) against X14/4 PIN12 (GND): Setpoint 10V +/- 0.25V.
X5/6 PIN1 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage does not meet the setpoint, the faulty print A16 must be replaced. If, subsequently, the supply volta-
ge is ok, repeatedly check the signal voltage at plug X5/6 (see step 2c).
If the signal voltage at plug X5/6 does not meet the setpoint, go to step b):
The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/2 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/2 in position "10": Monitor display "95%" = 9.5 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/2 and check whether the percentage in the monitor function has
changed.
If fault 24 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Turn ignition switch to ON position.
b) Check the signal voltage of potentiometer R6/2 at the output of print A16:
X14/4 PIN6 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 9.5V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).
c) Check the signal voltage of potentiometer R6/2 at the input of print A16:
To do so, disconnect plug X3/17.
X5/17 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 9.5V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X3/17 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/17 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/2 at print A16.
X3/17 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 9.5V +/- 0.25V.
X3/17 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage is outside the setpoint range, go to step b.
The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/4 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/4 in position "10": Monitor display "95%" = 10 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/4 and check whether the percentage in the monitor function has
changed.
If fault 34 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/4 at EDC Box A55:
PIN23 (signal) against PIN28 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect measuring adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step b.
b) Check the signal voltage of potentiometer R6/4 at the output of print A16:
X14/4 PIN4 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).
c) Check the signal voltage of potentiometer R6/4 at the input of print A16:
To do so, disconnect plug X3/16.
X5/16 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X3/16 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/16 does not meet the setpoint, go to step 3.
The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/3 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/3 in position "10": Monitor display "95%" = 10 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/3 and check whether the percentage in the monitor function has
changed.
If fault 36 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/3 at EDC Box A55:
PIN4 (signal) against PIN28 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
b) Check the signal voltage of potentiometer R6/3 at the output of print A16:
X14/4 PIN11 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).
c) Check the signal voltage of potentiometer R6/3 at the input of print A16:
To do so, disconnect plug X3/18.
X3/18 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X3/18 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/18 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/3 at print A16.
X3/18 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 10V +/- 0.25V.
X3/18 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage does not meet the setpoint, the faulty print A16 must be replaced. If, subsequently, the supply volta-
ge is ok, repeatedly check the signal voltage at plug X3/18 (see step 2c).
If the signal voltage at plug X3/18 does not meet the setpoint, go to step b):
c) Measure the signal frequency: Setpoint: approx. 180 Hz (standard: 130 pulses/metre or 505 Hz/14 km/h).
NOTE: The voltage remains constant, irrespective of the driving speed.
If the frequency is not displayed while driving, the supply to radar sensor B16 must be checked. Go to step 3.
If the signal at plug X4/12 is ok, continue checking the signal at the input of EDC Box A55. Go to step d).
d) Detach plug X55 from EDC Box A55 and
connect adapter 380000074 in between. Connect a multi-meter between PIN10 (signal) and PIN28 (ground EDC
Box). Check as described in steps 2b and 2c.
If the signal is not ok, check the signal line between radar sensor and EDC Box, repair if necessary.
3. Check the supply to radar sensor B16.
a) Check the plus supply: Start the engine.
At plug X4/12 PIN1 (12.5V to 14V), measure against ground. If the setpoint is not reached, subsequently check
the voltage at plug X3/1 at print A12, and if necessary also at the output of the fuse (supply +15/2). Check plug-
in contacts and line, repair if necessary. If necessary, replace damaged print A12.
c) At ECCU2, plug CN3b, PIN21, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty ECCU. If the signal is not ok, go to step d).
d) At the EDC Box, plug X55, PIN10, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty EDC Box.
5. Delete fault 41 and turn ignition switch to OFF position. After at least 5 seconds, start engine, drive tractor and
check that fault 41 is no longer active.
c) Measure the signal frequency: Setpoint: approx. 180 Hz (standard: 130 pulses/metre or 505 Hz/14 km/h).
NOTE: The voltage remains constant, irrespective of the driving speed.
If the frequency is not displayed while driving, the supply to radar sensor B16 must be checked. Go to step 3.
If the signal at plug X3/2 is ok, continue checking the signal at the input of EDC Box A55. Go to step d).
d) Detach plug X55 from EDC Box A55 and
connect adapter 380000074 in between. Connect a multi-meter between PIN10 (signal) and PIN28 (ground EDC
Box). Check as described in steps 2b and 2c.
If the signal is not ok, check the signal line between radar sensor and EDC Box, repair if necessary.
3. Check the supply to radar sensor B16.
a) Check the plus supply: Start the engine.
At plug X3/2 PIN1 (12.5V to 14V), measure against ground. If the setpoint is not reached, subsequently check
the voltage at plug X3/1 at print A12, and if necessary also at the output of the fuse (supply +15/2). Check plug-
in contacts and line, repair if necessary. If necessary, replace damaged print A12.
b) Check the signal line to the EDC Box and to the ECCU for interruptions or short-circuits to other lines or ground.
If the signal line is ok (also via print A12, plug X3/1, PIN2), go to step c).
c) At ECCU2, plug CN3b, PIN21, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty ECCU. If the signal is not ok, go to step d).
d) At the EDC Box, plug X55, PIN10, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty EDC Box.
5. Delete fault 41 and turn ignition switch to OFF position. After at least 5 seconds, start engine, drive tractor and
check that fault 41 is no longer active.
b) Check the signal voltage of potentiometer R6/5 at the output of print A16:
X14/4 PIN1 (signal) against X14/4 PIN12 (GND).
Setpoint 2.5V to 7.4V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).
c) Check the signal voltage of potentiometer R6/5 at the input of print A16:
To do so, disconnect plug X3/19.
X3/19 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 2.5V to 7.4V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X3/19 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/19 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/5 at print A16.
X3/19 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 7.4V +/- 0.25V.
X3/19 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 2.5V +/- 0.1V.
If the voltage is outside the setpoint range, go to step 3b.
c) Check series resistors R14 and R13 of the potentiometer supply at print A16.
Turn ignition switch to OFF position.
Disconnect plug X3/19 (wiring to pot R6/5) from print A16.
Resistance measurement (R14) at plug X14/4 PIN14 against plug X3/19 PIN1:
Setpoint 2.5 kOhms +/- 10 %.
Resistance measurement (R13) at plug X14/4 PIN12 against plug X3/19 PIN2:
Setpoint 2.5 kOhms +/- 10 %.
If one of the setpoints is not met, the faulty print A16 must be replaced.
If, subsequently, the supply voltage to the potentiometer is ok, repeatedly check the signal voltage at plug X3/19
(see step 2c).
4. Delete fault 44. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 44 is not displayed any longer.
COMPONENTS SUMMARY
ARU Armrest ..............................................................................................................................................Fig. 1
A4 FMGR ................................................................................................................................................Fig. 2
A4/2 FMGR plug connection - dark grey [2]...............................................................................................Fig. 3
A55 EDC control unit ................................................................................................................................Fig. 4
A60 ECCU2 ..............................................................................................................................................Fig. 5
B9/1 Rotary angle sensor EDC [LAGES] ...................................................................................................Fig. 6
B10/1 Power sensor, left ..............................................................................................................................Fig. 7
B10/2 Power sensor, right ...........................................................................................................................Fig. 8
B16 Radar sensor ....................................................................................................................................Fig. 9
CN2/E ECCU2 plug connection ..................................................................................................................Fig. 10
CN3b ECCU2 plug connection .................................................................................................................. Fig. 11
R6/1 Setpoint potentiometer ....................................................................................................................Fig. 12
R6/2 Lift limitation potentiometer..............................................................................................................Fig. 12
R6/3 Mixing potentiometer .......................................................................................................................Fig. 12
R6/4 Lowering speed potentiometer .......................................................................................................Fig. 12
R6/5 Slip control potentiometer ................................................................................................................Fig. 12
S2/15/5 Raise / Lower button [INNEN] .........................................................................................................Fig. 13
S2/72 Rapid retraction button .....................................................................................................................Fig. 9
S14/1 External button for LOWER, left [SENKEN].....................................................................................Fig. 14
S14/2 External button for LOWER, right [SENKEN] ..................................................................................Fig. 15
S15/1 External button for RAISE, left [HEBEN] .........................................................................................Fig. 14
S15/2 External button for RAISE, right [HEBEN] .......................................................................................Fig. 15
S33 EDC stop button ................................................................................................................................Fig. 9
S60/7 EDC Transport/control button ...........................................................................................................Fig. 1
X3/1 Plug connection, radar sensor ........................................................................................................Fig. 16
X3/2 Plug connection, radar sensor from DBD100001 ............................................................................Fig. 17
X3/16 Plug connection, potentiometer, lowering speed .............................................................................Fig. 18
X3/17 Plug connection, potentiometer, raising speed ...............................................................................Fig. 19
X3/18 Plug connection, EDC mixing potentiometer ..................................................................................Fig. 20
X3/19 Plug connection, slip control potentiometer ....................................................................................Fig. 21
X4/12 Plug connection, radar sensor up to DBD100000 ...........................................................................Fig. 22
X5/6 Plug connection, nominal value potentiometer ...............................................................................Fig. 23
Fig. 1
Fig. 2
Fig. 4
Fig. 7
Fig. 8
Fig. 9
Fig. 12
Fig. 11 up to DBD100000
Fig. 13
Fig. 14 up to DBD100000
Fig. 15 Fig. 18
Fig. 23
Fig. 26 up to DBD100000
Fig. 24 up to DBD100000
Fig. 29 up to DBD094270
Fig. 33
BLANK PAGE
F16 5A 6 1
2 7 13 2 +15/2
X18/1 54c
5V (16) 1 O P X23/2 8 2
9 9 16
GSV4
1 GND D+
S2/72 X2 8 10
ARU + X5/1
2 X7 15 X24/3 1 54c
5V ARU - X2/12
1 2 16 1 X10/9 2 X10/9 6 8
CAN H (16)
A31 3 17
S60/7 X4 X11 CAN L CN3a 2 X55 13 24 29 47 28 46
12V 4 18 CAN H CN1a 10 CN3a 4 1
1 16 A60 ECCU2 15 A55 EDC
A60 ECCU2
BLANK PAGE
A55 EDC
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
A16 EDC print B9/1 2 6 2.5 to 7.5 V X55 Y6
A55 EDC box U GND
1 35 1
A60 ECCU2
B9/1 Angle of rotation sensor Sensors and
B10/1 Power sensor, left solenoid valves 0 to 5 V
B10/2 Power sensor, right F 3 55 2
B16 Radar sensor B10/1 2 7 approx. 5 V not loaded
CN2/E 26-pin plug connection U
CN3b 34-pin plug connection 1
H2/1 Diagnosis LED
H2/2 Slip LED
H2/3 RAISE LED F 3
H2/4 LOWER LED B10/2 2 26 approx. 5 V not loaded Y7
S2/15/5 RAISE/LOWER pushbutton GND GND
S2/73 Switch, slip control U 1 38 53 1
S14/1 External pushbutton, LOWER, left
S14/2 External pushbutton, LOWER, right 41
S15/1 External pushbutton, RAISE, left 0 to 5 V
19 2
S15/2 External pushbutton, RAISE, right
X3/1 3-pin plug connection 5V
X4/2 4-pin plug connection 9
X4/3 4-pin plug connection S14/1 S15/1
X4/12 4-pin plug connection
X10/4 10-pin plug connection
X10/9 10-pin plug connection OFF OFF
X14/4 1k
X4/2
S2/15/5 H2/2
12 2 4
2 3
0
X24/5 31 7
1k
2
X24/5 1
1 20
LOWER
36 5 V with pushbutton pressed
19 3 RAISE 1
S2/73 7 21 17 5 V with pushbutton pressed H2/1
0
1
14 GND
X14/4 9 X10/4 4
Slip control
X4/12 X3/1 A12 CN2/E A60 A4
F31 5A
1 1 +15/2 8 Potentiometer R6/5 is shown
v X24/2 on the previous page
B16 GND
2 3 5 CN3b (16)
f 3 2 15 21 9 A4/2 X24/2 19
Theoretical speed A12
11 505 Hz at 14 km/h F13 7.5A
+30
Real speed
10 505 Hz at 14 km/h
A60
Standard signal CN3b
Ground during transport
15 11
BLANK PAGE
ARMREST F19 5A 3
17 1
A30 PRINT ARU
F20 5A ON
F210 7.5A 6 1
18 +15/1
X18/1
OFF
4 +30
S33 X30/14 8 2
X30/1 X18/4 D+ 16 54c
GSV4
2 1
5V 7 13
1 X24/3 1
9 9
S2/72 X30/2 (11) 1 54c
8 10 A60 ECCU2 CN3a
2 X2/12 X10/9 2 6 8
5V X30/7 2
1 X55 13 24 29 47 28 46 (11)
2 16 CAN H
CAN H 50 A55 EDC
A31 3 17 CAN L
X4 X30/11 CAN L 52 Supply 10 4 1 CN3a
S60/7 4 18 CN1a
A60
BLANK PAGE
A55 EDC
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
B9/1 2 6 2.5 to 7.5 V X55 Y6
A16 EDC print
A55 EDC box U GND
1 35 1
A60 ECCU2 Sensors and
B9/1 Angle of rotation sensor
B10/1 Power sensor, left solenoid valves 0 to 5 V
F 3 55 2
B10/2 Power sensor, right
B10/1 2 7 approx. 5 V not loaded
B16 Radar sensor
CN2/E 26-pin plug connection U 1
CN3b 34-pin plug connection
H2/1 Diagnosis LED
H2/2 Slip LED 3 Y7
H2/3 RAISE LED
F
B10/2 GND
H2/4 LOWER LED 2 26 approx. 5 V not loaded 53 1
S2/15/5 RAISE/LOWER pushbutton U GND
1 38
S2/73 Switch, slip control 0 to 5 V
S14/1 External pushbutton, LOWER, left 41 19 2
S14/2 External pushbutton, LOWER, right
S15/1 External pushbutton, RAISE, left
S15/2 External pushbutton, RAISE, right 5V
9
X3/1 3-pin plug connection
X3/2 3-pin plug connection S14/1 S15/1
X4/2 4-pin plug connection
X4/3 4-pin plug connection
OFF OFF
X10/4 10-pin plug connection ON ON A16
X10/9 10-pin plug connection
X14/4 X4/3
X14/4 14-pin plug connection 1 2 1 2 1k H2/4
X24/2 24-pin plug connection 22 Ω 22 Ω 5 1
X24/5 24-pin plug connection S14/2 2
S15/2
X55 55-pin plug connection 1k
Y6 Solenoid valve, EDC RAISE 37 3 4
Y7 Solenoid valve, EDC LOWER OFF OFF
3
(11) Ground point, engine cable carrier, rear ON ON External pushbuttons H2/3
and LEDs
1 2 1 2
22 Ω 22 Ω
X14/4 1k
X4/2
S2/15/5 H2/2
12 2 4
2 3
0
X24/5 1k
X24/5 1
DOWN 31 7 2
1 20 36 5 V with pushbutton pressed
19 3 RAISE 1
7 21 17 5 V with pushbutton pressed H2/1
S2/73
0
1
14 GND
X14/4 9 X10/4 4
Slip control
X3/2 X3/1 A12 CN2/E A60 A4
F31 5A
v 1 1 +15/2
X24/2 8 Potentiometer R6/5 is shown (11)
B16 GND
2 3 5 CN3b on the previous page X24/2 19
f 3 2 15 21 9 A4/2 A12
F13 7.5A
+30
Theoretical speed
11 505 Hz at 14 km/h
Real speed
10 505 Hz at 14 km/h
A60
Standard signal CN3b
Ground during transport
15 11
BLANK PAGE
EEM2 - 114 Intake air temperature signal out of range (too low)
Description:
The measured signal by the temperature sensor (integrated in the boost pressure sensor) lies below the normal ope-
rating range. Reason could be a defective boost pressure sensor, or a problem in the wiring between boost pressure
sensor B29 and EEM2-controller, or defective EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Functions by the intake manifold temperature are not active.
Solution:
1. Check contact surfaces of connector X4/71 (all pins) and EEM2 controller pins 59, 12, 11, 35 of connector X70.
(oxidation)
2. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
3. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
4. Check the temperature signal wiring from the boost pressure sensor connector X4/71 PIN2 to the EEM2 controller
PIN12 of connector X70.
5. Intake manifold temperature can be monitored with CNH service tool via CAN bus monitoring function (Intake ma-
nifold temperature). Present temperature can be compared to resistance of boost pressure sensor connector
X4/71 between PIN2 (temperature output) and PIN1 (GND). (see resistance of boost pressure sensor values)
If the intake manifold temperature signal is present on EEM2 controller connector X70, PIN12, then test current EEM2
controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 114 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.
EEM2 - 115 Intake air temperature signal out of range (too high)
Description:
The measured signal by the temperature sensor (integrated in the boost pressure sensor) lies above the normal ope-
rating range. Reason could be a defective boost pressure sensor B29, or a problem in the wiring between boost pres-
sure sensor and EEM2-controller, or defective EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Functions by the intake manifold temperature are not active.
Solution:
1. Check the wiring from the EEM2 controller to the boost pressure sensor B29.
2. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
3. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
4. Check the temperature signal wiring from the boost pressure sensor connector X4/71 PIN2 to the EEM2 controller
PIN12 of connector X70.
5. Intake manifold temperature can be monitored with CNH service tool via CAN bus monitoring function
(Intake manifold temperature). Present temperature can be compared to resistance of boost pressure sensor con-
nector X4/71 between PIN2(temperature output) and PIN1 (GND)
(see resistance of boost pressure sensor values).
If the intake manifold temperature signal is present on EEM2 controller connector X70, PIN12, then test current EEM2
controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 114 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.
Disconnect the EEM2 control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 ohms +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistance in EEM box
A2 between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
If the connection is ok, check the EEM2 controller plug X70 for bent, broken or corroded contacts and repair them
if required.
Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
COMPONENTS SUMMARY
(11) Ground point engine device carrier................................................................................................... Fig. 1
A2 EEM2 control unit ............................................................................................................................. Fig. 2
A2/2 PCU electronic pumps - control unit ................................................................................................. Fig. 3
A4 FMGR .............................................................................................................................................. Fig. 4
B20 Engine speed sensor ....................................................................................................................... Fig. 5
B21 Test switch, fuel delivery pressure ................................................................................................... Fig. 5
B22 Engine temperature sensor ............................................................................................................. Fig. 6
B23 ’Water in fuel’ sensor ........................................................................................................................ Fig. 6
B29 Charge-air pressure / temperature sensor........................................................................................ Fig. 7
F200 Main fuse .......................................................................................................................................... Fig. 7
M13 Fuel delivery pump ........................................................................................................................... Fig. 8
S6 Engine oil pressure switch ............................................................................................................... Fig. 9
X1/3 Plug connection, fuel filter pressure sensor .................................................................................... Fig. 8
X1/12 Plug connection, engine print, potential 30.................................................................................... Fig. 10
X2/22 Plug connection, temperature sensor EEM2 [22] ..........................................................................Fig. 11
X3/10 Plug connection, terminal resistance ............................................................................................. Fig. 12
X3/12 Plug connection, “Water in fuel” sensor .......................................................................................... Fig. 13
X3/13 Plug connection, sensor B23 ......................................................................................................... Fig. 14
X3/20 Plug connection, engine speed sensor .......................................................................................... Fig. 15
X4/71 Plug connection, charger pressure / charged air temperature sensor ........................................... Fig. 16
X9/7 Plug connection, fuel injection pump [7] .......................................................................................... Fig. 3
X18/1 Plug connection, instruments wiring harness - central print [1] ...................................................... Fig. 17
X20/1 Plug connection, engine wiring harness (Würth) ............................................................................ Fig. 18
X23/1 Plug connection, instruments wiring harness - engine wiring harness .......................................... Fig. 19
X24/12 Plug connection, engine wiring harness (Berifors) ......................................................................... Fig. 18
X70 Plug connection, engine control unit EEM2 .................................................................................... Fig. 20
Fig. 1 Fig. 5
Fig. 2 Fig. 6
Fig. 3 Fig. 7
Fig. 4
Fig. 8 Fig. 11
Fig. 12
Fig. 9
Fig. 13
Fig. 10
Fig. 14 Fig. 18
Fig. 15 Fig. 19
Fig. 16
Fig. 17
Fig. 20
F20 5A
X20/1 F97 10A
+15/1 7 +15/2
ARMREST F16 5A
F94 25A
+15/2 X1/14
(16) 31
*A28 PLUG MODULE X1/10 F92 10A
+30
X1 X18/4
*A30 PRINT ARU X24/2 17 18 2 X5/1
8 10
X3 7 13
B28 5V X70 21 48 70 46 69
1 9 9 (11)
CAN H A14
CAN + 18 A2 EEM2 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
X 2 2 16 Supply
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 Pre-glowing and
+15
1 2
X20/1 (11)
12V
CN3 17
* A27 CAN MODULE A1 ADIC 12V
26 16
M13 (11)
25 Emergency signal
X70
3 M 1
36 0.8 to 4.4 V
A2/2 PCU 2
X70 X9/7 (11)
12V
R8 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
PCU activation 20 2 2.5 V
CAN L
44 1 2.5 V
S6
43 5 Emergency shut-down
130 Hz at 900 rpm
B21 X1/3 p 19 8 DZG
335 Hz at 2300 rpm
1 X70
p 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
n 1 62 A12 Central print X1/12 Plug connection
B20 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
f 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
Switches and A30 Print ARU DBD..... ---> X3 4-pin plug connection
sensors A50/1 Power module X3/12 3-pin plug connection
t X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
B22 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
R 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
R A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
B23 B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
U C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
p,t 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
B29 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
U,R 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure
BLANK PAGE
BLANK PAGE
EEM3 - 94 Overspeed
Description:
The error code becomes active if the engine speed exceeds 3,000 rpm in operation.
NOTE: Exceeding the highest permitted engine speed leads to damage to the engine and the gearbox.
Reaction:
EC is stored and the warning lamp is activated. The injection is set to zero.
Solution:
Return the engine to the normal operating condition. Select an appropriate gear ratio.
EEM3 - 114 Charge air temperature sensor, signal voltage too low
Description:
The signal voltage of the charge air temperature sensor B29 is under the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty charge air temperature sensor
3. Supply voltage to charge air temperature sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Tyrn the starter switch to the "ON" posi-
tion and measure the supply voltage between connector:
X4/29 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X4/29 PIN1 and ground
X4/29 PIN2 and ground
X4/29 PIN1 and X36/1 PIN25
X4/29 PIN2 and X36/1 PIN29
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)
EEM3 - 115 Charge air temperature sensor, signal voltage too high
Description:
The signal voltage of the charge air temperature sensor B29 is above the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty charge air temperature sensor
3. Supply voltage to charge air temperature sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the signal cable for short-circuit against +supply. Use test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X4/29 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)
EEM3 - 233 Engine controller switch-off did not function the last
time
Description:
After the starter switch is turned to the "OFF" position, the engine controller is switched off in a controlled manner. If
the switch-off did not function the last time, the error becomes active when the starter switch is turned to the "ON"
position again.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then to "ON" again. If the error code continues active,
the cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)
EEM3 - 276 Pressure drop in intake system too high during engine
start-up
Description:
The pressure in the intake system (boost pressure sensor signal voltage) falls below ther warning limit during engine
start-up.
Possible causes:
1. Blockage in intake system
2. Faulty connector or wiring
3. Faulty boost pressure sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine runs noisily or does not start.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the mechanical components of the intake system for proper functioning. (air filter, boost air cooler, hoses
and pipes of the complete intake and boost air system, turbocharger)
a) If the cause of the pressure drop lies in mechanical component, remedy the fault. (see chapter 2002A)
b) If the mechanical components are OK, the error is in the electrical system. Go to step 2
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X4/29 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit to ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X4/29 PIN3 and ground
X4/29 PIN4 and ground
X4/29 PIN3 and X36/1 PIN33
X4/29 PIN4 and X36/1 PIN34
X4/29 PIN1 and X36/1 PIN25
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X4/29 PIN4 and PIN1
The displayed signal voltage must be 1.07 volt (at 1 bar atmospheric pressure). If the voltage is not reached, re-
place the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)
EEM3 - 291 Fuel delivery pressure sensor, signal voltage too low
Description:
The signal voltage of the fuel delivery pressure sensor is under the permitted range (< 0.2 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty fuel delivery pressure sensor
3. Supply voltage to the fuel delivery pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/39 of the fuel delivery pressure sensor B39 and the connector X36/1 of the engine con-
troller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the sensor X3/39. (sensor unplugged) Turn the starter switch to the "ON" position
and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit to ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X3/39 PIN2 and ground
X3/39 PIN3 and ground
X3/39 PIN1 and X36/1 PIN17
X3/39 PIN2 and X36/1 PIN21
X3/39 PIN3 and X36/1 PIN31
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be 0.5 volt. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)
EEM3 - 292 Fuel delivery pressure sensor, signal voltage too high
Description:
The signal voltage of the fuel delivery pressure sensor is over the permitted range 4.7 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty fuel delivery pressure sensor
3. Supply voltage to rail pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/39 of the fuel delivery pressure sensor B39 and the connector X36/1 of the engine con-
troller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/39. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
5. a) Check between connector:
X3/39 PIN2 and PIN1
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
6. Check the sensor.
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be 0.5 volt. If a higher voltage is displayed, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A).
COMPONENTS SUMMARY
(2) Screw connection for ground point, engine control unit.....................................................................Fig. 1
(11) Ground point engine cable carrier, rear ............................................................................................Fig. 2
A3 EEM3 control unit ..............................................................................................................................Fig. 3
A7 ID module ..........................................................................................................................................Fig. 4
B20 Engine speed sensor .........................................................................................................................Fig. 4
B22 Engine temperature sensor ...............................................................................................................Fig. 5
B23 ’Water in fuel’ sensor ........................................................................................................................Fig. 5
B29 Charge-air pressure / temperature sensor ........................................................................................Fig. 6
B36 Fuel temperatur sensor .....................................................................................................................Fig. 6
B37 Oil pressure sensor ..........................................................................................................................Fig. 7
B38 Rail pressure sensor..........................................................................................................................Fig. 7
B39 Fuel delivery pressure sensor ...........................................................................................................Fig. 8
B40 Camshaft position sensor ..................................................................................................................Fig. 8
G2/2 Generator, Bosch, 120A ....................................................................................................................Fig. 9
G2/2/2 2nd Generator Magneton 95A ...........................................................................................................Fig. 9
R8 Potentiometer, accelerator pedal ....................................................................................................Fig. 10
X1/30/EEMScrew connection, engine print potential 30 ............................................................................... Fig. 11
X2/21 Plug connection, solenoid valve, high-pressure pump ...................................................................Fig. 12
X2/22 Plug connection, coolant temperature sensor .................................................................................Fig. 13
X2/28 Plug connection, engine speed sensor............................................................................................Fig. 14
X2/36 Plug connection, fuel temperature sensor .......................................................................................Fig. 15
X3/10 Plug connection, terminating resistor ..............................................................................................Fig. 16
X3/12 Plug connection, ’Water in fuel’ sensor............................................................................................Fig. 17
X3/37 Plug connection, oil pressure sensor ..............................................................................................Fig. 18
X3/38 Plug connection, rail pressure sensor .............................................................................................Fig. 19
X3/39 Plug connection, fuel delivery pressure sensor ...............................................................................Fig. 20
X3/40 Plug connection, camshaft position sensor .....................................................................................Fig. 21
X4/4 Plug connection, ID module ............................................................................................................Fig. 22
X4/29 Plug connection, charge-air pressure/charge-air temperature sensor ...........................................Fig. 23
X4/70 Plug connection, accelerator pedal [70] .........................................................................................Fig. 24
X12/1 Plug connection, engine wiring harness - engine print ..................................................................Fig. 25
X16/1 Plug connection, EEM3 engine control unit - engine injection nozzles wiring harness .................. Fig. 26
X36/1 Plug connection, EEM3 engine control unit - engine sensors wiring harness ............................... Fig. 27
X89/1 Plug connection, EEM3 engine control unit - engine wiring harness EEM3 ................................... Fig. 28
Y20 Solenoid valve, high-pressure pump ............................................................................................. Fig. 10
Y21 Screw connection, injector, 1st cylinder.......................................................................................... Fig. 29
Y22 Screw connection, injector, 2nd cylinder......................................................................................... Fig. 30
Y23 Screw connection, injector, 3rd cylinder ......................................................................................... Fig. 31
Y24 Screw connection, injector, 4th cylinder.......................................................................................... Fig. 32
Y25 Screw connection, injector, 5th cylinder.......................................................................................... Fig. 33
Y26 Screw connection, injector, 6th cylinder.......................................................................................... Fig. 34
Fig. 1 Fig. 5
Fig. 2 Fig. 6
Fig. 3 Fig. 7
Fig. 4 Fig. 8
Fig. 9 Fig. 13
Fig. 10 Fig. 14
Fig. 11 Fig. 15
Fig. 12 Fig. 16
Fig. 17 Fig. 21
Fig. 18 Fig. 22
Fig. 19 Fig. 23
Fig. 20 Fig. 24
Fig. 25 Fig. 28
Fig. 26
Fig. 29
Fig. 27
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
BLANK PAGE
F20 5A
+15/1
ARMREST X89/1 40 9 8 3 2 11 10 5 6
17 18 X24/2 A3 EEM3
(11) CAN H (2)
A30 PRINT ARU 35
X30/1 X18/4 CAN L Supply F208 10A
34 +30
8 10 (11)
X30/3 7 13
B28 M13
1 9 9 X12/1
5V 12V
X30/7 Pre-glowing and K5/LP 9 3 M 1
0.4V to 4.7V fuel delivery pump 4
X 2 2 16 3 5
3
CAN H X89/1
17 1 2
CAN L 55 4 GND
GND 4 4 18 X12/1
(11)
X1/30/1 E10/1
+30
P8/1 4 3
P8 ICU + -
P8/2
3 K8/2
4 3 5
(12)
1 2
X36/1 X2/19 X2/19
4
A1 ADIC CN3 5
26
25
A1 ADIC X4/4 4-pin plug connection
A3 EEM3 X4/70 4-pin plug connection
A7 ID module X10/18 10-pin plug connection
A12 Central print X12/1 12-pin plug connection
Emergency signal A14 Engine print X18/4 18-pin plug connection
R8 X4/70 X24/3 X10/18 X89/1 A30 Print ARU X24/2 24-pin plug connection
4 16 10 79 0.8 to 4.4 V B28 Manual throttle X24/3 24-pin plug connection
CN3 26-pin plug connection X30/1 14-pin plug connection
E10/1 Heating flange X30/3 4-pin plug connection
K5/LP Relay, fuel delivery pump X30/7 4-pin plug connection
K8/2 Relay, heating flange X36/1 36-pin plug connection
M13 Fuel delivery pump X89/1 89-pin plug connection
P8 ICU (2) Ground point, EEM3 control unit
A7 ID module Engine identification P8/1 4-pin plug connection (11) Ground point, engine cable carrier,
X4/4 X89/1
12V P8/2 4-pin plug connection rear
4 21 R8 Potentiometer, accelerator pedal (12) Ground point, engine cable carrier,
GND front
120 Ω 1 29 120 Ω
X1/30/1 Screw connection
CAN L X1/30/EEM Screw connection
2 52
CAN H X2/19 2-pin plug connection
3 53
BLANK PAGE
A3 EEM3
B23 X3/12 X89/1 X16/1 X2/21
12V HP1
R A 50 9 1
Fuel OK = 12 V Y20
B 47 Water in fuel = 0 V
U GND HP2
C 65 10 2
C SH1
X4/29 X36/1 4
GND Y21
1 25
p,t 2.5 kOhm with 20° C C SL1
2 29 13
B29 5V
3 33
U,R 4 34 1.07 V with 1 bar 11
C SH2
atmospheric pressure Y22
C SL2
X2/22 X36/1 6
t 1 15
B22 GND 2.5 kOhm with 20° C C SH3
R 2 26 5
Y23
C SL3
X2/36 X36/1 12
t 1 35
B36 GND 2.5 kOhm with 20° C C SH4
R 2 8 3
Y24
C SL4
X3/37 X36/1 14
GND
p 1 24
C SH5
B37 2 27 0.5 to 4.5 V 1
U,R 3 5V
32 Y25
C SL5
16
X3/38 X36/1
GND C SH6
p 1 12 2
B38 2 14 0.5 to 4.5 V Y26
U,R 3 5V
13 15
C SL6
X3/39 X36/1
GND
p 1 17
A3 EEM3 X3/37 3-pin plug connection
B39 2 21 0.5 to 4.5 V
B20 Engine speed sensor X3/38 3-pin plug connection
U,R 3 5V
31 B22 Coolant temperature sensor X3/39 3-pin plug connection
B23 'Water in fuel' sensor X3/40 3-pin plug connection
B29 Sensor for charger pressure, X4/29 4-pin plug connection
X2/28 X36/1 charge-air temperature X16/1 16-pin plug connection
n GND B36 Fuel temperature sensor X36/1 36-pin plug connection
1 19
B20 approx. 855 Hz at 900 rpm B37 Oil pressure sensor X89/1 89-pin plug connection
f 2 23 B38 Rail pressure sensor Y20 Solenoid valve, high-pressure pump
B39 Fuel delivery pressure sensor Y21 Injector 1
B40 Camshaft position sensor Y22 Injector 2
X3/40 X36/1 X2/21 2-pin plug connection Y23 Injector 3
n 1 9 X2/22 2-pin plug connection Y24 Injector 4
GND approx. 52 Hz at 900 rpm
B40 2 10 X2/28 2-pin plug connection Y25 Injector 5
f X2/36 2-pin plug connection Y26 Injector 6
3 X3/12 3-pin plug connection
BLANK PAGE
FAULTCODES FMGR
FMGR - 1 Controller fault (Arithmetic, Push, Pop, Stack) ................................................................................. 473
FMGR - 2 Controller fault (Register) ................................................................................................................. 473
FMGR - 3 Controller fault (internal Watchdog) .................................................................................................. 474
FMGR - 5 Controller fault (external Watchdog) ................................................................................................. 474
FMGR - 7 FMGR in shipment condition, without valid parameters ................................................................... 475
FMGR - 8 Controller memory fault (Flash Checksum) at init ............................................................................ 475
FMGR - 9 Controller memory fault (Flash Checksum) at run ............................................................................ 476
FMGR - 12 Controller memory fault (RAM addressing) internal at init .............................................................. 476
FMGR - 13 Controller memory fault (RAM addressing) internal at run ............................................................. 477
FMGR - 14 Controller memory fault (RAM addressing) external at init ............................................................. 477
FMGR - 15 Controller memory fault (RAM addressing) external at runtime ..................................................... 478
FMGR - 16 Controller memory fault (EEPROM checksum 0 manufacture- and ISO-data incorrect) ............... 478
FMGR - 17 Controller memory fault (EEPROM checksum 1 vehicle data incorrect) ........................................ 479
FMGR - 18 Controller memory fault (EEPROM checksum 2 history track incorrect) ........................................ 479
FMGR - 24 Controller fault (ILLBUS illegal external bus access) ..................................................................... 480
FMGR - 25 Controller fault (ILLINA illegal instruction access) .......................................................................... 480
FMGR - 26 Controller fault (ILLOPA illegal word operand access) ................................................................... 481
FMGR - 27 Controller fault (PRTFLT Protection fault flag) ............................................................................... 481
FMGR - 28 Program fault (UNDOPC no valid C167 instruction) ...................................................................... 482
FMGR - 29 Controller fault (STKUF Stack underflow) ...................................................................................... 482
FMGR - 30 Controller fault (STKOF Stack overflow) ........................................................................................ 483
FMGR - 31 Non maskable interrupt (NMI) incorrect ......................................................................................... 483
FMGR - 32 Receive of local CAN Bussignal TR2 is failed (register 0) ............................................................. 484
FMGR - 33 Receive of local CAN Bussignal TR3 is failed (register 1) ............................................................. 485
FMGR - 34 Receive of local CAN Bussignal TR4 is failed (register 2) ............................................................. 486
FMGR - 37 Receive of local CAN Bussignal TR4 is failed (register 5) ............................................................. 487
FMGR - 47 CAN Bus OFF (transmission Bus) .................................................................................................. 488
FMGR - 48 Supply voltage (potential 30) too low ............................................................................................. 489
FMGR - 49 Supply voltage (potential 30) too high ............................................................................................ 489
FMGR - 50 Internal main switch not switchable ................................................................................................ 490
FMGR - 51 Internal main switch permanent on ................................................................................................ 490
FMGR - 63 Communication between FMGR/SGR is incorrect ......................................................................... 491
FMGR - 64 Engine false power classification up to DBD100000 ...................................................................... 491
FMGR - 64 Engine false power classification from DBD100001 ....................................................................... 492
FMGR - 69 Engine variation impossible ............................................................................................................ 492
FMGR - 84 Accelerator pedal potentiometer R8 - signal voltage (Analogue 1) above permissible range ........ 493
FMGR - 85 Accelerator pedal potentiometer R8 - signal faulty ......................................................................... 494
FMGR - 87 Accelerator pedal potentiometer R8 - signal voltage (Analogue 1) below permissible range ........ 495
FMGR - 93 Hand throttle sensor - signal incorrect ............................................................................................ 496
FMGR - 100 Clutch pedal angle of rotation sensor B17 - signal voltage above permissible range .................. 497
FMGR - 103 Clutch pedal angle of rotation sensor B17 - signal voltage below permissible range .................. 498
FMGR - 104 Signal of plus key (+) present for too long .................................................................................... 499
FMGR - 105 Signal of minus key (-) present for too long .................................................................................. 499
FMGR - 106 Signal of cruise control OFF/resume key present for too long ..................................................... 500
FMGR - 109 Signal of forwards/reverse key present for too long ..................................................................... 500
FMGR - 112 Signal of seat switch S8 is interrupted ......................................................................................... 501
FMGR - 114 Seat switch S8 - signal permanently at + ..................................................................................... 501
FMGR - 115 Seat switch S8 - incorrect phase angle of input signal ................................................................. 502
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error, switch ignition OFF and ON again. All old service information is possibly lost, but this doesn't influence
the controller function.
4. Correct checksums with configuration screen "TRANSMISSION - CLEAR NON-CRITICAL CHECKSUM
FAULTS" of the servicetool.
5. If error occurs again and is not due to mishandling of the vehicle, then replace FMGR.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.
a) If the signal voltage (Analogue 1) exceeds 4.6 V when the pedal is fully depressed, but drops again when the
pedal is released, the accelerator pedal potentiometer must be adjusted.
Sva 6-52632 EN Edition 06-2006
4011-494
b) If the signal voltage (Analogue 1) permanently stays above 4.6 V, check the signal line from R8 X4/70 PIN4 to
A4/4 PIN3 for a short circuit. If you cannot detect a short-circuit, replace potentiometer R8.
If you cannot detect a fault in step 1, replace the FMGR.
Measure the signal voltages over the entire range and note down the totals. The totals of the two signal voltages
may deviate by max. ±10%.
a) If the signal voltage (Analogue 1) is less than 0.6 V when the pedal is released, but rises again when the pedal
is operated, the accelerator pedal potentiometer must be adjusted.
FMGR - 104 Signal of plus key (+) present for too long
Cause:
The signal issued by the plus key on the multi-controller is present permanently or the key was pressed for too long
(> 5 minutes). The fault is stored.
Possible causes:
1. The key has an internal defect (does not open).
2. Incorrect operation.
Remedy:
Use the Service Tool monitor function "MULTI-CONTROLLER +KEY"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the key is not
operated. Turn the ignition switch to the ON position.
Read off the data value of the "MULTI-CONTROLLER +KEY" monitor function. If the data value is "ON" even if
the key is not pressed, replace the keyboard.
FMGR - 105 Signal of minus key (-) present for too long
Cause:
The signal issued by the minus key on the multi-controller is present permanently or the key was pressed for too long
(> 5 minutes). The fault is stored.
Possible causes:
1. The key has an internal defect. (does not open)
2. Incorrect operation.
Remedy:
Use the Service Tool monitor function "MULTI-CONTROLLER -KEY"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the key is not
operated. Turn the ignition switch to the ON position.
Read off the data value of the "MULTI-CONTROLLER -KEY" monitor function. If the data value permanently stays
at "ON", there is a fault in the key or in the wiring.
Take out the keyboard and disconnect the 14-pin plug (X21) (see "Replacing the keyboard). If the data value is
still "ON", there is a short-circuit in the wiring. If the data value changes to "OFF" when the plug is disconnected,
replace the keyboard.
NOTE: When plug X21 is disconnected, faults ARU 38 and ARU 40 are activated.
Replacing the keyboard:
• Remove the securing screw on the rear of the multi-controller
• Take out the keyboard and detach the plugs
• Connect the plugs to the new keyboard
• Place the keyboard in the multi-controller and secure it with a securing screw.
NOTE: Pay attention to the cable harness when inserting the keyboard. Do not shut in the cable harness!
a) If the data value is ON, start the tractor and preselect a driving direction at least 6 times. If the fault is activated
again, the FMGR must be replaced.
b) If the data value is OFF, there is a fault in the switch or in the wiring.
2. Disconnect plug X4/61 and check the clocked supply voltage (GSV3) at PIN2. The voltage should be approx.
3.1 V. If no voltage is present, check the supply line up to FMGR A4/2 PIN1.
3. Check the continuity through switch S8 using an ohmmeter.
a) If there is continuity (< 1 Ohm) when the seat is loaded and an interruption when it is not, check the signal line
from X4/61 to FMGR A4/2 PIN17.
b) If there is no continuity when the seat is loaded, check the X4/61 up to switch S8. If the wiring is ok, replace
switch S8.
b) If a voltage is present, try pinpointing the fault in the signal line of the seat switch. (short-circuit to plus)
Check the signal line from A4/2 PIN17 via X4/61 to seat switch S8.
b) If continuity is present, try pinpointing the fault in the cable route to the seat switch. There is a short circuit in
signal line S8 to clocked supply 1 or 2.
Check the signal line from A4/2 PIN17 via X4/61 to seat switch S8.
If Errors FMGR122, 158, 170, 174, 178 or FMGR 182 are recorded, the reason can be found also in that circuits,
because these components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the steeringbrake, the clutchpedal and the shuttle lever
S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR122, 158,
170, 174, 178, 182 or 218 are not activ, the defect can be found in the way to the steeringbrake switch.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control!
If error FMGR122, 158, 170, 174, 178 or 182 is activ, look for these error codes.
2. Disconnect connector A4/2 on the FMGR, check with voltage meter on PIN14 of the connector voltage to ground
(Ignition ON). Use service tool monitor function: - "STEERING BRAKE SWITCH".
Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the steeringbrake switch.
4. Please check wiring between A4/2 PIN14 over X24/3 PIN4 to S25
X4/14 PIN3.
5. Check wiring GSV 2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.
If errors FMGR119, 159, 171, 175, 179 or 183 are recorded, the reason can be found also in that circuit, because this
components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle lever
S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 159,
171, 175, 179, 183 or 217 are not active, the defect can be found in the way to the stoplight switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated! If errors FMGR119, 159,
171, 175, 179, 183 oder 217 are active, look for these error codes.
Use service tool monitor function:
• "STOP LAMP SWITCH".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN13 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the stoplightswitch.
4. For this check wire from A4/2 PIN13 over X24/3 PIN5 to S5
X4/14 PIN2.
5. Check wiring GSV 2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.
a) If the fault is activated again, then check switch S21, the signal line or the FMGR. (see step 2)
b) If the fault does not reoccur, then it was caused by incorrect operation.
2. Disconnect plug A4/2 on the FMGR and measure the resistance between PIN16 and PIN1 on the plug; apply and
release the parking brake.
a) If there is continuity with the parking brake applied and an interruption when released, then the FMGR must
be replaced.
b) If there is permanent continuity, then the fault is in the signal line or in switch S21.
3. Check the cabling between A4/2 PIN16 via X4/25 PIN1 to switch S21 and repair, if necessary. If the cabling is ok,
then switch S21 must be replaced.
b) If a voltage is present, try pinpointing the fault in the signal line of S21. (short-circuit to plus)
Check the signal line from A4/2 PIN16 via X4/25 to switch S21.
b) If continuity is present, try pinpointing the fault in the cable route to switch S21. There is a short circuit in signal
line S21 to the GSV 1 or 2.
Check the signal line from A4/2 PIN16 via X4/25 to switch S21.
b) If a voltage is present, try pinpointing the fault in the signal line from switch S2/58/2. (Short-circuit to plus)
Check the signal line from A4/1 PIN5 via X24/5 PIN8 to S2/58/2 PIN1.
b) If there is continuity, then check for a fault in the cable to switch S2/58/2. There is a short circuit in the signal
line to GSV 3 or 2.
Check the signal line from A4/1 PIN5 via X24/5 PIN8 to S2/58/2 PIN1.
If errors FMGR131, 135, 143, 187 or 191 are recorded, the reason can be found also in that circuit, because this com-
ponents are supplied by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR131, 135, 143, 187, 191 or 213 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated! If errors FMGR131, 135,
143, 187, 191 or 213 are activ, look for these errors code.
Use service tool monitor function:
• "MFD SWITCH MANAGEMENT"
• "MFD SWITCH ON"
• "FMGR-SGR AWD OFF"
• "FMGR AWD ENGAGED"
• "FMGR AWD MODE".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN1 of the connector the re-
sistance to and A4/2 PIN1 and PIN6 (Ignition OFF). Can no connection be read out, then there is a defect of the
FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the MFD switch (range Management).
• Check wiring from A4/1 PIN1 over X24/5 PIN3 to S2/59 PIN5.
• Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.
If Errors FMGR130, 134, 138, 186 or FMGR190 are recorded, the reason can be found also in that circuits, because
these components are supplied by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR130, 134, 138, 186, 190 or 214 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control! If error FMGR130, 134, 138, 186 or 190 is activ, look for these error codes.
Use service tool monitor function:
- "MFD SWITCH MANAGEMENT"
- "MFD SWITCH ON"
- "FMGR-SGR AWD OFF"
- "FMGR AWD ENGAGED"
- "FMGR AWD MODE".
2. Disconnect connector A4/1 on the FMGR, check with voltmeter on PIN2 of the connector voltage to ground (Igni-
tion ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the MFD switch (Connection ON).
- Check wiring from A4/1 PIN2 over X24/5 PIN4 to S2/59 PIN1.
- Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.
If errors FMGR131, 135, 139, 187 or 191 are recorded, the reason can be found also in that circuit, because this com-
ponents are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR131, 135, 139, 187, 191 or 213 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated! If errors FMGR131, 135,
139, 187, 191 or 213 are activ, look for these errors code.
Use service tool monitor function:
• "MFD SWITCH MANAGEMENT"
• "MFD SWITCH ON"
• "FMGR-SGR AWD OFF"
• "FMGR AWD ENGAGED"
• "FMGR AWD MODE".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN2 of the connector the re-
sistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the MFD switch (range ON).
• Check wiring from A4/1 PIN2 over X24/5 PIN4 to S2/59 PIN1.
• Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.
b) If a voltage is present, try pinpointing the fault in the seat switch signal line. (Short-circuit to plus)
Check the signal line from A4/1 PIN4 via X6/58 and X6/27 to seat switch S8/2.
b) If continuity is present, try pinpointing the fault in the cable route to switch S8/2. There is a short-circuit in signal
line S8/2 to GSV 1 or 2.
Check the signal line from A4/1 PIN4 via X6/58 and X6/27 to seat switch S8/2.
FMGR - 157 Clutch switch 80% plausibility with clutch sensor not
provided
Cause:
The input switchover signal is not in the tolerant range (compared with the clutch sensor) or does not happen.
Possible causes:
1. The switch cable has a short-circuit to the correctly clocked supply or is interrupted.
2. The plug is loose, touches the clocked supply or is free.
3. The switch (S46) is defective or never closes / opens.
4. The switch is not operated mechanically.
5. Incorrectly adjusted during conversion or not / incorrectly calibrated.
6. Clutch sensor or FMGR defective.
Remedy:
The most frequent occurrence of this fault will be a faulty switch or an interrupted line. In some cases, the switch or
clutch sensor B17 may also be incorrectly adjusted or the clutch sensor may be defective. When a fault occurs, the
cruise control is deactivated and the fault is stored and indicated by a warning triangle on the display.
1. Cancel the fault and turn the ignition switch to the OFF position for at least 10 secs. Turn the ignition switch to the
ON position again and press the clutch pedal right down. (at least at least 10 secs.)
Then turn the ignition switch to the OFF position and wait 2 secs.
2. If the fault does not reoccur, then it may be a vibration problem that only occurs when driving. If the clutch pedal
functions perfectly when driving, keep an eye on it until it is certain that the malfunction was a one-off occurrence.
Use the Service Tool monitor function:
• "CLUTCH PEDAL SWITCH"
• "CLUTCH PEDAL POSITION"
3. Repeat calibration. Refer to calibration instructions in the Configuration menu item.
4. If the fault continues to occur, disconnect plugs A4/1 and A4/2 on the FMGR and measure the resistance between
A4/1 PIN15 and A4/2 PIN6; fully engage and then release the clutch. There must be continuity when the clutch
is operated and an interruption when it is not. The changeover must be effected at approx. 80% of the pedal travel.
If this functions properly, the clutch sensor must be checked. See sensor setting - fault FMGR100. If there is no
fault here either, then the FMGR must be replaced, otherwise the fault lies in the cable to the clutch switch (80%).
5. Check the cabling:
• Check the signal cabling between A4/1 PIN15 via X24/3 PIN24 to S46 PIN2.
• Check the GSV 2 cabling from S46 PIN1 to X24/3 PIN12 to A4/2 PIN6.
FMGR - 159 Clutch switch 75% input signal with wrong circuit
Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supply line.
2. Connector on the switch is loose and touches another pulsed supply line.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Failure occured by repair or rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active.
If errors FMGR119, 123, 163, 171, 175, 179 or 183 are recorded, the reason can be found also in that circuit, because
this components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the the brake, the clutchpedal, the exhaust brake and
the shuttle lever S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors
FMGR119, 123, 163, 171, 175, 179, 183 or 217 are not activ, the defect can be found in the way to the clutch
switch 75%.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR119, 123, 163, 171, 175, 179, 183 oder 217 are activ, look for these error codes.
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN15 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1. (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced. Use service tool monitor function:
• "CLUTCH PEDAL SWITCH (75% TRAVEL)"
• "CLUTCH PEDAL POSITION".
3. Check wiring:
• Check the signal cabling between A4/1 PIN15 via X24/3 PIN24 to S46 PIN2.
• Check wiring GSV 2 from S46 PIN1 to X24/3 PIN12 and A4/2 PIN6.
b) If the fault does not reoccur, then it was caused by incorrect operation.
2. Disconnect plugs A4/1 and A4/2 on the FMGR and measure the resistance between A4/1 PIN3 and A4/2 PIN1
on the plug; fully apply and release the engine back pressure brake.
a) If there is continuity when the engine back pressure brake is applied and an interruption when released, then
the FMGR must be replaced.
b) If there is permanent continuity, then the fault is in the signal line or in switch S20.
3. Check the cabling from A4/1 PIN3 to S20 and repair it, if necessary.
b) If a voltage is present, try pinpointing the fault in the signal line of the engine back pressure brake switch. (short-
circuit to plus)
Check the signal line from A4/1 PIN3 to the engine back pressure switch S20.
b) If continuity is present, try pinpointing the fault in the cable route to the engine back pressure brake switch.
There is a short circuit in the signal line S20 to the GSV 1 or 2.
Check the signal line from A4/1 PIN3 to the engine back pressure switch S20.
a) If the shuttle lever is not operated, the data value must be "OFF" and must be "ON" when the lever is shifted
to forwards. If this is the case, the fault was probably caused by incorrect operation. (The shuttle lever was ope-
rated > 1 minute)
b) If the data value is permanently "ON", the signal line is shorted to the power supply (GSV2), or the switch has
an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the steering column switch and read off the data value of the "SHUTTLE LEVER
FORWARDS" monitor function.
a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2).
Check whether the signal line is shorted to GSV2.
From X6/3, PIN5 via the Limp Home plug connection X4/59/a, PIN1 to X24/3, PIN7 to A4/2, PIN11
b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.
a) If the shuttle lever is not operated, the data value must be "OFF" and must be "ON" when the lever is shifted
to reverse. If this is the case, the fault was probably caused by incorrect operation. (The shuttle lever was opera-
ted > 1 minute)
b) If the data value is permanently "ON", the signal line is shorted to the power supply (GSV2), or the switch has
an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the steering column switch and read off the data value of the "SHUTTLE LEVER RE-
VERSE" monitor function.
a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2).
Check whether the signal line is shorted to GSV2.
From X6/3, PIN6 via the Limp Home plug connection X4/59/a, PIN3 to X24/3, PIN8 to A4/2, PIN10
b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.
a) If the button is not operated, the data value must be "OFF" and must be "ON" when the lever is shifted to re-
verse. If this is the case, the fault was probably caused by incorrect operation. (The button lever was operated >
1 minute)
b) If the data value is permanently "ON", there is a short-circuit between the signal line and the power supply
(GSV2), or the button has an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the shuttle lever and read off the data value of the "NEUTRAL BUTTON ON THE SHUTT-
LE LEVER" monitor function.
a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2). Check whether the signal
line is shorted to GSV2:
From X6/3, PIN3 via X24/3 PIN10 to A4/2, PIN8
b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.
FMGR - 180 Signal of "Shuttle lever raised" present for too long
Cause:
The signal issued by the shuttle lever S4/4 in the raised position (dead man function) is present permanently or the
lever was operated for too long (> 1 minute). The fault is stored.
Possible causes:
1. The signal line is shorted to the clocked supply 2 (GSV2).
2. The switch has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "SHUTTLE LEVER RAISED"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the shuttle lever
is not operated. Turn the ignition switch to the ON position and read off the data value of the " SHUTTLE LEVER
RAISED" monitor function.
a) If the shuttle lever is not operated, the data value must be "OFF" and must be "ON" when the lever is raised.
If this is the case, the fault was probably caused by incorrect operation. (The shuttle lever was raised > 1 minute)
b) If the data value is permanently "ON", the signal line is shorted to the power supply (GSV2), or the switch has
an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the shuttle lever and read off the data value of the "SHUTTLE LEVER RAISED" monitor
function.
a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2). Check whether the signal
line is shorted to GSV2:
From X6/3 PIN2 via X24/3 PIN11 to A4/2, PIN7
b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.
b) If a voltage is present, try pinpointing the fault in the signal line from switch S2/58/1.
Check signal from A4/1 PIN17 via X24/5 PIN5 to S2/58/1 PIN1.
b) If there is continuity, try pinpointing the fault in the cable to switch S2/58/1.
Check signal line via A4/1 PIN17 via X24/5 PIN5 to S2/58/1 PIN1.
b) If a voltage is present, try pinpointing the fault in the signal line from switch S2/58/1.
Check signal from A4/1 PIN16 via X24/5 PIN23 to S2/58/1 PIN7.
b) If there is continuity, try pinpointing the fault in the cable to switch S2/58/1.
Check signal line via A4/1 PIN16 via X24/5 PIN23 to S2/58/1 PIN7.
a) If the resistance obtained is lower, the fault is caused by a short-circuit in the wiring or a defective potentiome-
ter. (see step 2)
b) If the value you have measured is ok, cancel the fault. Should the fault occur again when you turn the ignition
switch to "ON", the FMGR is defective and must be replaced.
2. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.
b) If a voltage is present, the line is shorted to a plus line. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.
b) If a voltage is present, the line is shorted to a plus line. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.
b) If the value you obtain is lower, there is a short between the supply and the ground line or the full-load poten-
tiometer is defective. (see step 3)
3. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.
Check A4/4 PIN5 (ground) via plug X24/5 PIN13 to plug X3/23 PIN2.
If the wiring is ok, check the resistance between full-load potentiometer PINA and PINC (4,7 kOhm +/- 10%).
If the resistance is ok, replace the FMGR.
b) If a voltage is present, try pinpointing the fault in the supply lines to the parking brake switch S21, seat switch
S8, reversible seat switch S8/2 (if the vehicle is equipped with a reversing facility) or engine back pressure brake
switch S20.
Check the wiring using the diagrams listed below and repair if required.
a) If the fault is active again, try pinpointing the fault in the supply lines to the parking brake switch S21, seat switch
S8, reversible seat switch S8/2 or engine back pressure brake switch S20. (go to step 2)
b) If the fault is not active, operate (close) all of the switches listed under "a" one after the other and check whether
the fault is activated. If the fault is activated, it can be attributed to the relevant function. (see 2b)
2. Disconnect plug A4/2 from the FMGR and use an ohmmeter to measure the resistance between PIN1 and GND
(ground connection) (turn the ignition switch to OFF).
b) If continuity is present, check the supply lines to the parking brake switch S21, seat switch S8, reversible seat
switch S8/2 or engine back pressure brake switch S20 using the diagrams listed below and repair them if requi-
red.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 ohms +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm 10%) by
measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2 bet-
ween PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%). s
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
FMGR - 246 Reception of vehicle side CAN bus signal AUX2 in regi-
ster 6 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 2 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX2.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX2.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX2 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX2:
I. Ground at X4/91 PIN4 via weld point X0/9/21 to weld point X0/9/11 via X4/83 PIN2 to plug connection X5/1
on central print A12.
II. 12V (Potential 15/1) at X4/91 PIN1 via weld point X0/9/20 to weld point X0/9/10 via X4/83 PIN1 to plug
X24/2 PIN24 on fuse F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm 10%) by
measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2 bet-
ween PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).
5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.
COMPONENTS SUMMARY
(8) Ground point roof, front right............................................................................................................. Fig. 1
(11) Ground point engine device carrier, rear up to DBD100000 ............................................................. Fig. 2
(11) Ground point engine cable carrier, rear from DBD100001 ............................................................... Fig. 3
(16) Ground point starter .......................................................................................................................... Fig. 4
AUX1 1st remote control valve.................................................................................................................... Fig. 5
AUX2 2nd remote control valve .................................................................................................................. Fig. 5
AUX3 3th remote control valve ................................................................................................................... Fig. 5
AUX4 4th remote control valve ................................................................................................................... Fig. 5
AUX5 5th remote control valve ................................................................................................................... Fig. 5
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 6
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 7
A4 FMGR ............................................................................................................................................... Fig. 8
A4/1 FMGR plug connection - white [1] .................................................................................................... Fig. 9
A4/2 FMGR plug connection - dark grey [2] .............................................................................................. Fig. 9
A4/3 FMGR plug connection - blue [3] ...................................................................................................... Fig. 9
A4/4 FMGR plug connection - grey [4] ...................................................................................................... Fig. 9
A21 SGR transmission controller .......................................................................................................... Fig. 10
A60 ECCU2.............................................................................................................................................Fig. 11
B17 Angle of rotation sensor, clutch ...................................................................................................... Fig. 12
B17/1 Angle of rotation sensor, clutch, reversing facility ........................................................................... Fig. 13
CN1a ECCU2 plug connection ................................................................................................................. Fig. 14
CN2/E ECCU2 plug connection ................................................................................................................. Fig. 14
P8 ICU.................................................................................................................................................... Fig. 5
P8 ICU plug connection ....................................................................................................................... Fig. 15
R8 Potentiometer, accelerator pedal ................................................................................................... Fig. 16
R8/1 Potentiometer, accelerator pedal, reversing facility ........................................................................ Fig. 25
R23 Limit load potentiometer ................................................................................................................ Fig. 17
S2/58/1 Switch for speed ranges[RANGE] .................................................................................................. Fig. 18
S2/58/2 Switch for manual mode [MAN.MOD] ............................................................................................. Fig. 18
S2/59 Switch for 4-wheel drive management [4 WD]................................................................................ Fig. 19
S2/61 Parking interlock switch ................................................................................................................. Fig. 20
S2/61/1 Parking interlock switch, reversing facility ...................................................................................... Fig. 21
S4/4 Shuttle lever ................................................................................................................................... Fig. 17
S4/4/1 Forwards - reverse switch [V/R]...................................................................................................... Fig. 21
S5 Brake light switch ............................................................................................................................ Fig. 22
S5/1 Brake light switch, reversing facility ................................................................................................ Fig. 23
S20 Switch, engine back pressure brake .............................................................................................. Fig. 24
S21 Switch, handbrake .......................................................................................................................... Fig. 22
S25 Switch, steering brake ................................................................................................................... Fig. 22
Fig. 1 Fig. 5
Fig. 4 Fig. 8
Fig. 10
Fig. 12 up to DBD100000
Fig. 13
Fig. 15 Fig. 18
Fig. 16
Fig. 19
Fig. 17
Fig. 20 up to DBD100000
Fig. 22
Fig. 25
Fig. 33 up to DBD100000
Fig. 38
Fig. 43 up to DBD100000
Fig. 41
Fig. 46 up to DBD100000
Fig. 48 up to DBD100000
Fig. 50 up to DBD100000
Fig. 59 up to DBD100000
Fig. 61 up to DBD100000
GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4
0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6
X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1
CAN H
CAN +
CAN L
12 4
CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H
A2 EEM2
CAN L
B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U
BLANK PAGE
A4 FMGR
A4/2 A21/2 A21 SGR
GSV3 5V
1 p 1 4
B47 GND
S8 2 7 A21/3 Y41
U 4V
X4/61 X4/61 A4/2 3 6 0.2 to 3.1 V 6 1
GND
2 1 17 Seat contact A21/2 7
5V
S21 p 1 11 2
GND
X4/25 X4/25 A4/2 B51 2 8
2 1 16 Parking brake (open) U 3 5 0.2 to 1.2 V A21/3 Y42
4V
5 1
S20 A21/2 GND
t 8
A4/1 Engine back pressure 1 3
B32 PTC 1 kΩ to 4.4 kΩ 2
2 1 3 brake R 2 10
X5 A21/4 A21/3 Y43
GND 4V
1 2 9 4 1
A16 X14/4 A4/1 GND
GSV1 S49/1 2 1 3 GND 9
8 18 p Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 S2/58/1
Speed ranges 12 V
1 A21/3 Y44
0
X24/5 A4/1 3 4V
1
1 23 16 increase "+" Y11 GND
2 10
7 5 17 decrease "-" 2
3 Sensors and 2
1 A4/3 solenoid valves
12 V
S2/58/2 5 1 A21/3 Y45
Brake oil cooling Y12 4V
8 2 1
GND
OFF
ON
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 Manual mode
(16) n 1 A21/3 Y46
S2/59 B24 10 to 6000 Hz 4V
f 2 1 1
GND
0 12
1
X24/5 A4/1 A21/8
2
Management 2
5 3 1 n 1
3 and B25 10 to 6000 Hz
1 4 2 all-wheel f 2
A21/9
X3/23 X24/5 A4/4 1
5.8 V n
a 1 11 14 Potentiometer B26 10 to 6000 Hz
f 2 Y57
R23 b 3 12 15 0 to 5.8 V for limit load
S2/61 GND A21/5 1
c 2 13 5 A21/10 10 V
4
n 1 GND
OFF
A4/1 B27 10 to 6000 Hz 8 2
ON
f 2
X24/3 13 3.0 V X17
Switch for parking Y58
1 3 18 A4/2 A21/6
GSV2 interlock 2
12 6 n 1
B35 10 to 6000 Hz A21/5
f 2 10 V
A4 FMGR A21/9 2-pin plug connection S2/58/2 Switch, manual mode 5 1
A4/1 18-pin plug connection A21/10 2-pin plug connection S2/59 Switch, all-wheel X24/5 24-pin plug connection
A4/2 18-pin plug connection B24 Speed sensor, cartridge input S2/61 Switch for parking interlock X17 Y - distributor
A4/3 15-pin plug connection B25 Speed sensor, planetary carrier 3/4 S8 Seat switch Y11 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B26 Speed sensor, cartridge output S20 Switch, engine back pressure brake Y12 Solenoid valve for brake oil cooling
A16 EDC print B27 Speed sensor, cartridge output S21 Switch, parking brake Y41 Solenoid valve, clutch 1
A21 SGR transmission controller B32 Temperature sensor, transmission oil S49/1 Switch, pressure filter Y42 Solenoid valve, clutch 2
A21/2 12-pin plug connection B35 Speed sensor, planetary carrier 1/2 X3/23 3-pin plug connection Y43 Solenoid valve, clutch 3 Y59
A21/3 12-pin plug connection B47 Pressure sensor for transmission X4/25 4-pin plug connection Y44 Solenoid valve, clutch 4 1
system pressure Y45 Solenoid valve, clutch, forward A21/5
A21/4 12-pin plug connection X4/61 4-pin plug connection 4V
A21/5 12-pin plug connection B51 Pressure sensor for transmission X5 2-pin plug connection Y46 Solenoid valve, clutch, reverse 6
lubrication pressure Y57 Solenoid valve, parking interlock ON GND
A21/6 2-pin plug connection X10/4 10-pin plug connection Y58 Solenoid valve, parking interlock OFF 7 2
A21/7 2-pin plug connection R23 Potentiometer for limit load X14/4 14-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection (16) Ground point, starter
BLANK PAGE
X30/11
F19 5A F51 10A F18 5A
+15/1 +15/1
A30 PRINT ARU 3R7
(11) F20 5A F14 7.5A F9 10A
X21 X30/1 X18/4 +15/1 +30 +30
M
A31 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 3R7
S60/1 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
S60/2 2 16 A4 FMGR 17 1 A21 SGR
GND
CAN H CAN L
11 V
11 11 3 17 3 18 2 Supply
CAN L Supply
4 18 2
S60/3
A23 1 12 2 11 9 10 3
10 12 S4/4
0 V or 5 V
X6/3 X24/3 A4/2 LIMP HOME circuit
S60/4 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE A23 ELECTRONICS
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)
X4/59/b
X4/59/a
plug connection is linked.
A21/4 X6/1
11 4
CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 3 20 9 2
F45 5A
+15/1 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 Brake A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
S25 3.9 Ω
3 4 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
A14 X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
F212 5A S5 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
+30 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 Clutch A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
3.9 Ω A21 SGR transmission controller X6/9 7-pin plug connection
S46 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
CAN H
CAN L
BLANK PAGE
BLANK PAGE
4 12 6 1
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL A12
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2 15/2
1 6 (16)
X4/59/b
X4/59/a
Shuttle lever
11 FORWARDS A21 SGR
A12 X24/3 10 REVERSE X16/21 LIMP HOME circuit
X2/4/1 X6/15 2 GND
10
19
15/2 6 12 V
1 21 14 Select 0 V** for FORWARDS
12 V
3 20 8 Select 0 V** for REVERSE
A70 X4/59/c A4/2
GSV3
1 **) Only if the
S8/1 S21 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 Parking brake (open) plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
S8/2 2 2 1 1 16
6 6 5 5 A4/2
S20 S8 Seat switch
4 4 3 3 1
S8 A4/1 A4/1 Engine back pressure S8/1 Reversible seat switch
S8/2 Reversible seat switch
2 1 3 3 brake S20 Switch for engine back
4 Signal pressure brake
reversing facility S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 Seat contact S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 Clutch X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
B17
X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
U 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
K5/60 GSV2 X4/70 4-pin plug connection
1 12 6 6
4 3.9 Ω X4/70/1 4-pin plug connection
1 3 S46 24 X6/3 6-pin plug connection
B17/1
5 X6/15 6-pin plug connection
2 2
2 1 X6/27 6-pin plug connection
U 3 A4/1 A4/1
X6/58 6-pin plug connection
1 15 15 3 V
3.9 Ω X16/21 16-pin plug connection
S46/1 X23/2 23-pin plug connection
A2 EEM2 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(16) 5.8V Accelerator pedal X70 70-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (16) Ground point, starter
A4/2 18-pin plug connection GND
1 1 1
A4/4 18-pin plug connection
A12 Central print R8 3 6 K5/61 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 K5/62
K5/62 Relay, accelerator pedal, reversing facility 3
P6 Display, reversing facility R8/1 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility A2 EEM2 X70 X23/2
36 U
(16)
A4 FMGR
X4/14 X24/3 A4/2 A4/2
GSV2 Brake
1 12 6 6
S25 3.9 Ω
3 4 14 14 3 V
S5 2 5 13 13 3 V
4
S5/1
3
S2/61
OFF
ON
A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 Switch for parking
GSV2
12 6 6 interlock
S2/61/1
OFF
ON
3 1
4 12 6 1
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL A12
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2 15/2
1 6 (11)
X4/59/b
X4/59/a
Shuttle lever
11 FORWARDS A21 SGR
A12 X24/3 10 REVERSE X16/21 LIMP HOME circuit
X2/4/1 X6/15 2 GND
10
19
15/2 6 12 V
1 21 14 Select 0 V** with FORWARDS
12 V
3 20 8 Select 0 V** with REVERSE
A70 X4/59/c A4/2
GSV3
1 **) Only if the
S8/1 S21 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 Parking brake (open) plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
S8/2 2 2 1 1 16
6 6 5 5 A4/2
S20 S8 Seat switch
4 4 3 3 1
S8 A4/1 A4/1 Engine back pressure S8/1 Reversible seat switch
S8/2 Reversible seat switch
2 1 3 3 brake S20 Switch, engine back
4 Signal pressure brake
reversing facility S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 Seat contact S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 Clutch X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
B17
X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
U 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
K5/60 GSV2 X4/70 4-pin plug connection
1 12 6 6
4 3.9 Ω X4/70/1 4-pin plug connection
1 3 S46 24 X6/3 6-pin plug connection
B17/1
5 X6/15 6-pin plug connection
2 2
2 1 X6/27 6-pin plug connection
U 3 A4/1 A4/1
X6/58 6-pin plug connection
1 15 15 3 V
3.9 Ω X10/18 10-pin plug connection
S46/1 X16/21 16-pin plug connection
A3 EEM3 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(11) 5.8V Accelerator pedal X89/1 89-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (11) Ground point, engine
A4/2 18-pin plug connection GND cable carrier, rear
1 1 1
A4/4 18-pin plug connection
A12 Central print R8 3 6 K5/61 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 K5/62
K5/62 Relay, accelerator pedal , reversing facility 3
P6 Display, reversing facility R8/1 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility A3 EEM3 X89/1 X10/18 X24/3
79 10 16
(11)
A4 FMGR
X4/14 X24/3 A4/2 A4/2
GSV2 Brake
1 12 6 6
S25 3.9 Ω
3 4 14 14 3 V
S5 2 5 13 13 3 V
4
S5/1
3
S2/61
OFF
ON
A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 Switch for parking
GSV2
12 6 6 interlock
S2/61/1
OFF
ON
3 1
FAULTCODES SGR
SGR - 1 Controller fault (Arithmetic, Push, Pop, Stack) .................................................................................... 633
SGR - 2 Controller fault (Register) .................................................................................................................... 633
SGR - 3 Controller fault (internal Watchdog) .................................................................................................... 634
SGR - 5 Controller fault (external Watchdog) ................................................................................................... 634
SGR - 7 In shipment conditions, without valid parameters ............................................................................... 634
SGR - 8 Controller memory fault (Flash checksum) at init ................................................................................ 635
SGR - 9 Controller memory fault (Flash checksum) at run ............................................................................... 635
SGR - 12 Controller memory fault (RAM addressing) internal at init ................................................................ 636
SGR - 13 Controller memory fault (RAM addressing) internal at run ................................................................ 636
SGR - 14 Controller memory fault (RAM addressing) external at init ............................................................... 637
SGR - 15 Controller memory fault (RAM addressing) external at run ............................................................... 637
SGR - 16 Controller memory fault (EEPROM checksum 0 incorrect) ............................................................... 638
SGR - 17 Controller memory fault (EEPROM checksum 1 incorrect) ............................................................... 638
SGR - 18 Controller memory fault (EEPROM checksum 2 incorrect) ............................................................... 639
SGR - 24 Controller fault (illegal external bus access) ..................................................................................... 639
SGR - 25 Controller fault (illegal instruction access) ......................................................................................... 640
SGR - 26 Controller fault (illegal word operand access, compiler fault) ............................................................ 640
SGR - 27 Controller fault (memory protection fault flag) ................................................................................... 641
SGR - 28 Program fault (no valid C167 instruction) .......................................................................................... 641
SGR - 29 Controller memory fault (stack underflow) ........................................................................................ 642
SGR - 30 Controller memory fault (stack overflow) ........................................................................................... 642
SGR - 31 Non maskable Interrupt is active (incorrect) ...................................................................................... 643
SGR - 32 Receive of local CAN Bus signal TR1 is failed (register 0) ............................................................... 643
SGR - 33 Receive of local CAN Bus signal TR5 is failed (register 1) ............................................................... 644
SGR - 35 Receive of local CAN Bus signal engine (EHS) is failed (register 3) ................................................ 645
SGR - 47 CAN Bus OFF (transmission Bus) .................................................................................................... 646
SGR - 48 Supply voltage (potential 30) too low ................................................................................................ 646
SGR - 49 Supply voltage (potential 30) too high ............................................................................................... 647
SGR - 50 Internal main switch for valves is not switchable ............................................................................... 647
SGR - 51 Internal main switch for valves is permanent on ............................................................................... 648
SGR - 52 Hydrostat, calibration data not in tolerance range ............................................................................. 648
SGR - 53 Hydrostat, transmission ratio is not reached ..................................................................................... 649
SGR - 54 Maximum hydrostat high pressure reached ...................................................................................... 649
SGR - 56 Impermissible activation of the gear clutches ................................................................................... 650
SGR - 60 Internal fault in the hydrostat ............................................................................................................. 650
SGR - 61 Hydrostat calibration data in EEPROM not plausible ........................................................................ 651
SGR - 63 FMGR-SGR check: failed .................................................................................................................. 652
SGR - 64 Cartridge input speed sensor B24 - interruption or short-circuit to ground ....................................... 652
SGR - 65 Cartridge input speed sensor B24 - sensor short-circuit ................................................................... 653
SGR - 66 Cartridge input speed too high .......................................................................................................... 653
SGR - 67 Cartridge input speed sensor B24 - signal dropout ........................................................................... 654
SGR - 68 Planet carrier 1/2 speed sensor B35 - interruption or short-circuit to ground .................................... 654
SGR - 69 Planet carrier 1/2 speed sensor B35 - sensor short-circuit ............................................................... 655
SGR - 70 Planet carrier 1/2 speed too high ...................................................................................................... 655
SGR - 71 Planet carrier 1/2 speed sensor B35 - signal dropout ....................................................................... 656
SGR - 72 Output speed 1 speed sensor B27 - interruption or short-circuit to ground ...................................... 656
SGR - 73 Output speed 1 speed sensor B27 - sensor short-circuit .................................................................. 657
SGR - 74 Output speed 1 too high .................................................................................................................... 657
SGR - 75 Output speed 1 speed sensor B27 - signal dropout .......................................................................... 657
Fault is stored, warnlamp signals. Check for additional stored errors of the FMGR and the SGR to limit the possible
reasons. If the failure occured only one time, and the error was not recorded after deleting and a testdrive again de-
tected, there is no additional check required. The operation of the vehicle is not limited.
1. If error code SGR - 63 is permanent active, refer to description of SGR - 63.
2. If several error codes SGR - 33 and 35 are recorded and error code SGR - 47 is not active, FMGR check is nes-
sesary (check if the FMGR is at least in one position of the servicetoolbutton ONLINE). If error code SGR - 47 is
active refer to description of SGR - 47.
3. If the FMGR works correctly, check the CAN Bus connection between SGR and FMGR.
• Check CANH wire from connector X16/21 PIN1 to A4/4 PIN17.
• Check CANL wire from connector X16/21 PIN2 to A4/4 PIN18.
4. If not working check the connector of SGR for bent, broken or corroded terminals, and repair if required.
5. Do the same on the FMGR.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version. Repeat the reprogramming or replace the FMGR or SGR if required.
Fault is stored, warnlamp signals and stopp tractor slowly. Check for additional stored errors of the FMGR and the
SGR to limit the possible reasons. If the failure occured only one time, and the error was not recorded after deleting
and a testdrive again detected, there is no additional check required. The operation of the vehicle is not limited.
1. If error code SGR - 63 is permanent active refer to description of SGR - 63.
2. If several error codes SGR - 32 and 35 are recorded and error code SGR - 47 is not active, FMGR check is nes-
sesary (check if the FMGR is at least in one position of the servicetoolbutton ONLINE). If error code SGR - 47 is
active refer to description of SGR - 47.
3. If the FMGR works correctly, check the CAN Bus connection between SGR and FMGR.
• Check CANH wire from connector X16/21 PIN1 to A4/4 PIN17.
• Check CANL wire from connector X16/21 PIN2 to A4/4 PIN18.
4. If not working check the connector of SGR for bended, broken or corroded terminals, and repair if required.
5. Do the same on the FMGR.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version. Repeat the reprogramming or replace the FMGR or SGR if required.
The calibration is already done automatically, clear error code, switch ignition OFF (at min 10 sec.) and ON again.
The new calibration values are stored automatically in the EEPROM.
The pressure sensor is defective. The oil pressure cannot be reached because of a leakage in the lubrication circuit.
Because of a broken spring the pressure limiting valve can open too early. The oil level in the engine is too low or the
lubrication oil pump is defective.
1. Install a pressure gauge on the desired connection and start the engine (see chapter 6002).
2. In case of sufficient pressure indicated on the gauge, while the servicetool indicates poor pressure, replace the
lubrication pressure sensor.
3. If the measured pressure is too low, check the lubrication pressure limiting valve. (see chapter 6002)
4. If the lubrication pressure limiting valve is OK, check the transmission, wether there is a leakage in the lubrication
circuit or a defect lubrication pump. (see chapter 6002)
Because of a broken spring the pressure limiting valve can open too early. If the lubrication pressure is too low the
reason could be a leakage in the whole lubrication circuit. The pressure sensor is sending an incorrect value. The oil
pump could be defective or the oil level is too low.
1. Install a pressure gauge on the provided connection and start the engine (see chapter 6002).
2. If the pressure is correct and the pressure which is displayed at service tool is low, the lubrication oil pressure
sensor has to be changed.
3. Check all lubrication pipes out of the transmission, wether they are OK or not.
4. Check if the fault occurres in special uses (PTO switch => leakage at PTO clutch).
5. Check the lubrication pressure - pressure limiting valve.
6. If the measured pressure is too low, check the lubrication pressure limiting valve.
7. If the lubrication pressure limiting valve is OK, check the transmission wether there is a leakage in the lubrication
or a defective lubrication pump.
8. Insufficient oil level causes sizzling suction noise.
If it is a problem with the sensor supply voltage, also error SGR115 will be active.
1. Unplug connector B51 of the lubrication pressure sensor and install an measure adapter in between. Check the
voltage between PIN1 and PIN2 (Ignition ON). Is the voltage exceeds 5V, continue with pt.2. Else disconnect sen-
sor connector B51. If the voltage remains below 5V, disconnect also system pressure sensor B47. If the voltage
exceeds now 5V, the system pressure sensor is defective and has to be replaced. If the voltage still remains below
5V, check the supply voltage.
2. Measure voltage between PIN3 and PIN1. The voltage must be app. 0.5V (Ignition ON and engine NOT running).
Is the voltage ok,
continue with pt.3. Else take a new pressure sensor and connect that one. If the voltage is OK now, the first lub-
rication sensor is defective and has to be replaced by the new one.
3. Remove the SGR and unplug connector A21/2. Switch ignition off, and check with ohmmeter the following con-
nections:
• A21/2 PIN11 and B51 PIN1,
• A21/2 PIN5 and B51 PIN3,
• A21/2 PIN8 and B51 PIN2.
If any of these has no conductance, the harness has to be replaced, or repaired. In case of no interruption, check
the conductance on the connector A21/2 PIN5 and the remaining pins of this connector (Ignition OFF and B51
disconnected). If there is a conductance to one of the other pins, the harness has to be replaced, or repaired.
4. If tests 1 to 3 do not discover any malfunctions, the SGR has to be replaced.
If there is a problem with the sensor supply voltage, also error SGR107 will be active.
1. Unplug connector B47 of the system pressure sensor and install a measuring adapter in between. Check voltage
between PIN1 and PIN2 with voltmeter (Ignition ON). If the voltage is more than 5V, continue with pt.2. Else dis-
connect sensor connector B47. If the voltage is still below 5V, disconnect also lubrication pressure sensor con-
nector B51. If the voltage is now more than 5V, the lubrication pressure sensor is defective and has to be
replaced. In case of a voltage now below 5V, the supply voltage has to be checked.
2. Measure voltage between PIN3 and PIN1. The voltage must be app.0.5V (Ignition ON and engine not running).
If the voltage is OK, continue with pt.3. Else, connect a new pressure sensor. If now the voltage is correct, the
first system pressure is defective and has to be replaced by the new one.
3. Remove SGR and unplug connector A21/2. Switch ignition off, and check the following connections with an ohm-
meter.
• A21/2 PIN4 and B47 PIN1,
• A21/2 PIN6 and B47 PIN3,
• A21/2 PIN7 and B47 PIN2.
If any of these has no conductance, the harness has to be replaced or repaired. If there is no interruption, check
the conductance on the connector A21/2 PIN6 and the remaining pins of the connector (Ignition OFF and B51
disconnected). If there is a conductance to one of the other pins, the harness has to be replaced, or repaired.
4. If tests 1 to 3 are not successful, the SGR has to be replaced.
SGR - 116 System pressure sensor - oil pressure out of range high
Cause:
The measured system pressure sensor is above 45 bar.
Possible causes are:
1. System pressure adjustment too high.
2. System pump is defective.
3. The pressure sensor is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. If the system pressure
is above 45 bar, the engine speed is limited to max.1700 rpm. The pressure can become too high because of a defect
in the pump regulation. Also the pressure sensor can be defective.
1. Install a pressure gauge on the desired connection and start the engine (see chapter 6002).
2. If there is normal pressure, but the servicetool reading is too high, replace the lubrication pressure sensor.
3. If there is a pump problem you have to change the transmission pump (see chapter 6002).
In case of an error appearance while the vehicle has already been operating properly at normal temperatures, the
temperature sensor is probably defective.
1. If this error occurs under vehicle cold conditions (below - 5°C), the appearance is normal, and the driving instruc-
tions for cold conditions has to be followed.
2. If this error occurs under normal driving temperatures, check the temperature sensor B32 as described in error
manual SGR120 and 123. It is possible, that the error is intermittent and occurs only under certain circumstances.
In case of an error apperance while the vehicle has already been operating properly at normal temperatures, the tem-
perature sensor is probably defective.
1. If this error occurs under vehicle extreme cold conditions (below -30°C) the appearance is normal, and the driving
instructions for cold conditions has to be followed.
2. If this error occurs under normal driving temperatures, check the temperature sensor B32 as described in error
SGR120 and 123. It is possible, that the error is intermittent and occurs only under certain circumstances.
This errorcode is only an additional information for development purposes for error SGR236.
During the second hydrostatic movement, the max. value of travel was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
During the first hydrostatic movement, the max. value of the calculated high pressure was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
During the second hydrostatic movement, the max. value of the calculated high pressure was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
During the first hydrostatic verification movement, the max. value of travel was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
During the second hydrostatic verification movement, the max. value of travel was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
During the first hydrostatic verification movement, the max. value of the calculated high pressure was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
During the second hydrostatic verification movement, the max. value of the calculated high pressure was exceeded.
This errorcode is only an additional information for development purposes for error SGR236.
Before shifting neutral, there was still too much hydrostatic high pressure calculated, or the travel was again too high.
This errorcode is only an additional information for development purposes for error SGR236.
BLANK PAGE
COMPONENTS SUMMARY
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 1
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 2
A4 FMGR ............................................................................................................................................... Fig. 3
A4/4 FMGR plug connection - grey [4] ...................................................................................................... Fig. 4
A21 SGR transmission controller ............................................................................................................ Fig. 5
A21/2 Plug connection, SGR grey .............................................................................................................. Fig. 6
A21/3 Plug connection, SGR black ............................................................................................................ Fig. 6
A21/4 Plug connection, SGR green ............................................................................................................ Fig. 6
A21/5 Plug connection, SGR brown............................................................................................................ Fig. 6
A21/6 Plug connection, speed sensor, black planetary carrier 1/2, B35 ..................................................... Fig. 7
A21/7 Plug connection, speed sensor, grey cartridge input B24................................................................. Fig. 7
A21/8 Plug connection, speed sensor, brown planetary carrier 3/4, B25.................................................... Fig. 7
A21/9 Plug connection, speed sensor, green cartridge output B26 ........................................................... Fig. 7
A21/10 Plug connection, speed sensor, orange cartridge output B27 .......................................................... Fig. 7
A23 Plug connection, Linde electronics ................................................................................................... Fig. 8
B24 Speed sensor, cartridge input .......................................................................................................... Fig. 9
B25 Speed sensor, planetary carrier 3/4 ................................................................................................. Fig. 9
B26 Speed sensor, cartridge output ......................................................................................................... Fig. 9
B27 Speed sensor, cartridge output ......................................................................................................... Fig. 9
B32 Speed sensor, temperature sensor, transmission oil ..................................................................... Fig. 10
B35 Speed sensor, planetary carrier 1/2 .................................................................................................. Fig. 9
B47 Pressure sensor for transmission system pressure .........................................................................Fig. 11
B51 Pressure sensor for transmission lubricating pressure ....................................................................Fig. 11
S49/1 Switch, pressure filter, 5bar ............................................................................................................ Fig. 12
X6/1 Plug connection, Linde electronics ................................................................................................ Fig. 13
X16/21 SGR plug connection ...................................................................................................................... Fig. 14
Y41 Solenoid valve, coupling 1 ..............................................................................................................Fig. 11
Y42 Solenoid valve, coupling 2 ..............................................................................................................Fig. 11
Y43 Solenoid valve, coupling 3 ..............................................................................................................Fig. 11
Y44 Solenoid valve, coupling 4 ..............................................................................................................Fig. 11
Y45 Solenoid valve, coupling, forward ....................................................................................................Fig. 11
Y46 Solenoid valve, coupling, reverse ................................................................................................... Fig. 15
Y57 Solenoid valve, parking interlock On............................................................................................... Fig. 15
Y58 Solenoid valve, parking interlock Off .............................................................................................. Fig. 15
Y59 All-wheel solenoid valve ................................................................................................................. Fig. 15
Fig. 1 up to DBD100000
Fig. 4 up to DBD100000
Fig. 3
Fig. 5 Fig. 7
Fig. 6
Fig. 8
Fig. 9 Fig. 11
Fig. 10
Fig. 13 Fig. 15
Fig. 14 up to DBD100000
GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4
0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6
X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1
CAN H
CAN +
CAN L
12 4
CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H
A2 EEM2
CAN L
B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U
BLANK PAGE
A4 FMGR
A4/2 A21/2 A21 SGR
GSV3 5V
1 p 1 4
B47 GND
S8 2 7 A21/3 Y41
U 4V
X4/61 X4/61 A4/2 3 6 0.2 to 3.1 V 6 1
GND
2 1 17 Seat contact A21/2 7
5V
S21 p 1 11 2
GND
X4/25 X4/25 A4/2 B51 2 8
2 1 16 Parking brake (open) U 3 5 0.2 to 1.2 V A21/3 Y42
4V
5 1
S20 A21/2 GND
t 8
A4/1 Engine back pressure 1 3
B32 PTC 1 kΩ to 4.4 kΩ 2
2 1 3 brake R 2 10
X5 A21/4 A21/3 Y43
GND 4V
1 2 9 4 1
A16 X14/4 A4/1 GND
GSV1 S49/1 2 1 3 GND 9
8 18 p Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 S2/58/1
Speed ranges 12 V
1 A21/3 Y44
0
X24/5 A4/1 3 4V
1
1 23 16 increase "+" Y11 GND
2 10
7 5 17 decrease "-" 2
3 Sensors and 2
1 A4/3 solenoid valves
12 V
S2/58/2 5 1 A21/3 Y45
Brake oil cooling Y12 4V
8 2 1
GND
OFF
ON
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 Manual mode
(16) n 1 A21/3 Y46
S2/59 B24 10 to 6000 Hz 4V
f 2 1 1
GND
0 12
1
X24/5 A4/1 A21/8
2
Management 2
5 3 1 n 1
3 and B25 10 to 6000 Hz
1 4 2 all-wheel f 2
A21/9
X3/23 X24/5 A4/4 1
5.8 V n
a 1 11 14 Potentiometer B26 10 to 6000 Hz
f 2 Y57
R23 b 3 12 15 0 to 5.8 V for limit load
S2/61 GND A21/5 1
c 2 13 5 A21/10 10 V
4
n 1 GND
OFF
A4/1 B27 10 to 6000 Hz 8 2
ON
f 2
X24/3 13 3.0 V X17
Switch for parking Y58
1 3 18 A4/2 A21/6
GSV2 interlock 2
12 6 n 1
B35 10 to 6000 Hz A21/5
f 2 10 V
A4 FMGR A21/9 2-pin plug connection S2/58/2 Switch, manual mode 5 1
A4/1 18-pin plug connection A21/10 2-pin plug connection S2/59 Switch, all-wheel X24/5 24-pin plug connection
A4/2 18-pin plug connection B24 Speed sensor, cartridge input S2/61 Switch for parking interlock X17 Y - distributor
A4/3 15-pin plug connection B25 Speed sensor, planetary carrier 3/4 S8 Seat switch Y11 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B26 Speed sensor, cartridge output S20 Switch, engine back pressure brake Y12 Solenoid valve for brake oil cooling
A16 EDC print B27 Speed sensor, cartridge output S21 Switch, parking brake Y41 Solenoid valve, clutch 1
A21 SGR transmission controller B32 Temperature sensor, transmission oil S49/1 Switch, pressure filter Y42 Solenoid valve, clutch 2
A21/2 12-pin plug connection B35 Speed sensor, planetary carrier 1/2 X3/23 3-pin plug connection Y43 Solenoid valve, clutch 3 Y59
A21/3 12-pin plug connection B47 Pressure sensor for transmission X4/25 4-pin plug connection Y44 Solenoid valve, clutch 4 1
system pressure Y45 Solenoid valve, clutch, forward A21/5
A21/4 12-pin plug connection X4/61 4-pin plug connection 4V
A21/5 12-pin plug connection B51 Pressure sensor for transmission X5 2-pin plug connection Y46 Solenoid valve, clutch, reverse 6
lubrication pressure Y57 Solenoid valve, parking interlock ON GND
A21/6 2-pin plug connection X10/4 10-pin plug connection Y58 Solenoid valve, parking interlock OFF 7 2
A21/7 2-pin plug connection R23 Potentiometer for limit load X14/4 14-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection (16) Ground point, starter
BLANK PAGE
X30/11
F19 5A F51 10A F18 5A
+15/1 +15/1
A30 PRINT ARU 3R7
(11) F20 5A F14 7.5A F9 10A
X21 X30/1 X18/4 +15/1 +30 +30
M
A31 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 3R7
S60/1 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
S60/2 2 16 A4 FMGR 17 1 A21 SGR
GND
CAN H CAN L
11 V
11 11 3 17 3 18 2 Supply
CAN L Supply
4 18 2
S60/3
A23 1 12 2 11 9 10 3
10 12 S4/4
0 V or 5 V
X6/3 X24/3 A4/2 LIMP HOME circuit
S60/4 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE A23 ELECTRONICS
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)
X4/59/b
X4/59/a
plug connection is linked.
A21/4 X6/1
11 4
CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 3 20 9 2
F45 5A
+15/1 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 Brake A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
S25 3.9 Ω
3 4 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
A14 X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
F212 5A S5 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
+30 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 Clutch A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
3.9 Ω A21 SGR transmission controller X6/9 7-pin plug connection
S46 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
CAN H
CAN L
BLANK PAGE
TABLE OF CONTENTS
SPECIAL TOOLS ....................................................................................................................................................... 3
GENERAL DESCRIPTION ......................................................................................................................................... 4
COMPONENTS .......................................................................................................................................................... 5
OPERATION .............................................................................................................................................................. 6
Main Switch, Suspension ON / OFF ................................................................................................................ 6
Auxiliary switch ................................................................................................................................................. 6
Indicator lamp on the instrument panel ............................................................................................................ 6
FUNCTION OF THE SUSPENSION .......................................................................................................................... 7
Calibration procedure ....................................................................................................................................... 7
Control Function ............................................................................................................................................... 8
AXLE SENSORS ........................................................................................................................................................ 9
General Remarks ............................................................................................................................................. 9
Testing the "Sensor Settings" ........................................................................................................................ 10
Adjusting the Sensors .................................................................................................................................... 12
LOWERING THE FRONT AXLE MANUALLY .......................................................................................................... 13
ERROR CODES ....................................................................................................................................................... 14
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ................................................................................. 15
Measurement table ........................................................................................................................................ 16
Test – solenoid valve control .......................................................................................................................... 18
Circuit Diagram, Sprung Front Axle ............................................................................................................... 19
63(&,$/722/6
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4-wheel drive planetary steering axle with independent suspension, cast main housing with front cover, centrally
located swing bearing and drive, bevel drive pinion borne in the main housing, differential fitted from the front end,
differential drive gear secured in the main housing by bridge type bracket.
Mechanical differential lock 100%, shift mechanism integrated into the front cover, electro-hydraulically operated.
Independent suspension at both sides through: two trapezoidal links, one hydraulic cylinder, one hydro-reservoir
and one torsion bar acting in opposition to the hydro-reservoir.
One control block, fitted with three solenoid valves and the two hydro-reservoirs, each of 1,4 litres capacity, is lo-
cated on the right-hand side of the vehicle chassis and forms the link between the two hydraulic system cylinders.
Connected in parallel to the hydraulic system (load sensing).
Each side and thus the movement of each wheel, within the total spring travel range of 90 mm, is actively monitored
by an angle of rotation sensor.
The sensor signal is decisive for the reaction of the hydraulics to increase or decrease the charge in the reservoir
This firstly forms the basis for the weight independent height control and secondly, actively assists the function of
the hydro-reservoir when necessary.
Conversion of the sensor signals, to control the hydraulics or solenoid valves respectively, is carried out in the elec-
tronic circuitry, designed as an independent element on the hydraulic control block.
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This switch has the following positions:
Switch pressed to the left
Suspension 2)) (suspension inhibited)
The suspension lowers the axle to the limit of the suspension cylinder.
Recommended mode for driving in hilly terrain and contour lines.
Stipulated mode prior to opening the system. (reservoir pressure-free)
Switch in the mid position
Suspension 21 (100% spring travel), indicator lamp lights. The suspension goes to or remains in the middle of
the total range of travel, independent of weight.
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$X[LOLDU\VZLWFK(pushbutton function only, pressed to the left – lower, to the right – raise)
Holding the button pressed
Active at 100% suspension travel – alteration of ground clearance in the respective direction.
During the calibration procedure – stipulating the upper and lower limits of suspension travel.
Push-button pressed briefly
Height control OFF
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Lamp does not light: Suspension OFF or suspension without height control.
Lamp lights: 100% suspension travel and height control active.
Lamp blinks regularly – confirms calibration procedure.
Lamp blinks irregularly: an error code will be presented (see error code list Page 14)
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The suspension can be operated in several operating modes. The relevant operating mode is indicated by the indi-
cator lamp on the instrument panel as follows:
Indicator lamp OFF
System switched OFF, reservoir or system free of pressure.
Axle at its limit, no suspension or suspension inhibited.
Manual height adjustment (ground clearance adjustment) has been made. Suspension from the newly selected
position only through the reservoir. Suspension travel is hereby restricted, in one direction, to the remaining travel
up to the limit. Changes in weight and leakage are not compensated for.
Indicator lamp lit
Height control from the middle of the total suspension travel, 100% suspension travel up and down, independent
of load and leakage, is or remains available through active reservoir pressure adaptation.
Indicator lamp blinks regularly (1 Hz)
Calibration process active.
Indicator lamp blinks irregularly (3 Hz)
An error code will be displayed
The blink pattern is interrupted by a long and a short pause.
Example: Error code 21 – long pause, blinks twice, short pause, blinks once.
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This serves to stipulate the upper and lower end limits of the suspension on both sides. If the control system does not
receive any recognisable data, the calibration procedure will be automatically activated when the supply voltage is
switched ON.
The calibration procedure can also be selected by the driver at any time (as described in the Operating Manual). Ca-
libration itself is always carried out in the following way:
Hold the main switch, pressed to the right, for at least 10 sec's. (indicator lamp must blink regularly).
Select and hold the auxiliary switch to the "raise" position until the upper limit is reached.
Select and hold the auxiliary switch to the "lower" position until the lower limit is reached.
To complete the procedure, press the main switch briefly to the right.
The indicator lamp must now be lit.
The suspension moves to the centre of its travel – the procedure is complete.
When the indicator lamp once again starts to blink, repeat the procedure.
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For active control, the position of the suspension is acquired every 100 ms.
The electronics recognise whether the suspension is within the fixed tolerance range, programmed in the E-Box, by
the sensor signals received or whether it makes significant changes for brief periods of time. The basis for this is the
mean value (S Nom) calculated from the relevant sensor signal from the total spring travel.
If this range is exceeded, in either direction, for longer than 2.5 sec’s. the valves will be regulated and the correspon-
ding change in reservoir pressure will be initiated. The valves will only then stop being regulated, when the position
signals acquired are once again within the tolerance range.
How often and for how long the valves will be regulated is always dependent upon the sensor signals received and
can not be influenced by the driver.
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Adjustment must always be carried out, when one or both of the sensors have been replaced or if the sensor fa-
stening was loosened.
Prior to adjusting the sensors, ensure that the drive wheel (rubber wheel) is correctly fitted and the guide wheel has
freedom of movement, not only externally in the bolt but also internally on the sensor. The tightening torque of the
securing bolts must also be strictly adhered to.
If either of the above mentioned items is not adhered to, or carried out incorrectly, the function will be impaired due to
deformation of the sensor housing.
The following limits are valid for the basic adjustment of both sensors:
Suspension (axle) at its lower limit .................................................................................................. >5 mA <6.5 mA
Suspension ( axle) at its upper limit ................................................................................................ <18.68 mA
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67(3
3 In order to test the left-hand sensor, connect the
measuring cables to the sockets in the blue field and re-
peat STEP 4.
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Remove the protective cover from the control block.
Separate the plug-in connector and connect the mea-
surement adapter into the sensor line.
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The following values should be indicated:
Lower limit .............................................. min. 5.00 mA
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Start the tractor and allow it to run at idling speed. Press The difference between the values indicated must not
the main suspension switch briefly to the right and wait be less than P$.
until the axle is in the mid position.
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Press the auxiliary switch to the left until the axle has
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reached the lower mechanical limit. Read the value in-
dicated off the multimeter and make a note of it.
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PDQXDOO\VHH3DJH re-connect the sensor cable connectors. Re-fit the pro-
tective cover to the control block.
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67(3 5
Put the tractor on solid, level ground and apply the par-
king brake. Lower the axle to its lower mechanical limit
and switch the engine OFF. Place chocks in front of and
behind the rear wheels.
1
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2
1
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6'& Check the reading on the multimeter and repeat STEP
Remove the protective cover from the control block. 4 if necessary.
Separate the plug-in connector and connect the mea-
surement adapter into the sensor line. 67(3
Turn the ignition switch to OFF. To adjust the left-hand
67(3 sensor, plug the measuring cables into the sockets in
the blue field and insert the plug-in jumper into the sok-
kets in the red field.
4 67(3
Repeat STEP 4 and STEP 5 to adjust the left-hand sen-
sor.
67(3
Re-fit the sensor covers to both sides and tighten the
securing screws to a torque of 13 Nm.
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To adjust the right-hand sensor, remove the plug-in
jumper from the measurement adapter’s red field and 67(3
replace it by the measuring cables. Disconnect the measurement adapter and
Plug the measuring cables into the multimeter sockets re-connect the sensor cable connectors. Re-fit the pro-
"40 mA" and "COM". Insert the plug-in jumper (4) into tective cover to the control block.
the sockets in the blue field.
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Put the tractor on firm, level ground, apply the parking
brake and switch the motor OFF. Place chocks in front
of and behind the rear wheels.
67(3
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Loosen the locking nut and turn the valve screw (2) out
by approx. one turn. The axle will sink to the lower me-
1 chanical limit and the pressure reservoirs will be relie-
ved of pressure.
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Remove the protective cover from the control block.
Remove the plastic cover (1) from the discharge valve. When the reservoirs are pressure-free, close the valve
screw and tighten the locking nut. Re-fit the plastic cap
to the discharge valve.
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Indication of an error code by the indicator lamp in the instrument panel blinking at 3 Hz.
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The following error codes can be displayed:
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Engine running
0HDVXUHPHQWV
V Voltage
∆V Voltage drop
R Resistance
∞ Resistance infinity = open circuit (multimeter indication OL)
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Measurement
Cable colour
Measure
X12/20
Pin
Designation Requirements from pin Value
to pin
12 - 14
Permanent plus F27 10 A 6 V 45W 6 9
VDC
12 - 14
Permanent plus F28 5 A 8 V 45W 8 10
VDC
Suspension inhibited
C307
12 - 14
Main switch (S2/15/2) 4 V Switch pressed to the 4 9
VDC
in position 2 left
Suspension active
C307
Suspension active
C308
Calibration
C308
12 - 14
Main switch (S2/15/2) 5 V Main switch pressed to 5 9
VDC
in position 1 the right
2 V 2 9 0 VDC
Auxiliary switch (S2/15/1)
in position 0 Auxiliary switch not
3 V 3 9 0 VDC
pressed
12 - 14
Auxiliary switch (S2/15/1) 2 V Auxiliary switch 2 9
VDC
in position 2 pressed to the left
12 - 14
Auxiliary switch (S2/15/1) 3 V Auxiliary switch 3 9
VDC
in position 1 pressed to the right
Measurement
Cable colour
Measure
X12/20
Pin
Designation Requirements from pin Value
to pin
C281
Switching voltage from A60 approx.
12 V 12 9
ECCU electronic - box at v = > 14 km/h: 13,8 VDC
approx. 0
B143
Indicator lamp
11 V Main switch pressed 11 9 VDC
lights
briefly to the right (ground)
B143
Indicator lamp
11 V Main switch pressed to 11 9 7 - 11 VDC
does not light
the left
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To carry out these tests, the multimeter must be connected to the individual solenoid valves using the "Y" adapter
380000066 and the measuring cables.
Test the solenoid valves in accordance with the table below.
Solenoid valve energised 9'&
Solenoid valve not energised 9'&
Function SV SV SV
blue plug green plug black plug
Raise front axle (auxiliary switch pressed to the right)
Lower front axle (auxiliary switch pressed to the left)
Control – increase pressure right and left
Control – raise right only
Control – raise left only
Control – decrease pressure right and left
Control – decrease pressure right only
Control – decrease pressure left only
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Measurement
Measure
Designation Requirements from pin Value
to pin
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Electrical equipment
A1 ADIC
A12 Print, central electrics
A60 ECCU
A61 Sprung front axle electronics
F27 Sprung front axle fuse
potential 30
F28 Sprung front axle fuse
potential 15/2
S2/15/1 Auxiliary switch RAISE/LOWER
S2/15/2 Main switch
X2/45 Plug-in connection - rump, sprung front axle
X4/45 Plug-in connection, sprung front axle
X9/4 Plug-in connection, combination instrument
X12/20 Plug-in connection, sprung front axle
X24/1 Plug-in connection line, ADIC
5002
TROUBLESHOOTING
AND SETTINGS
Front Axle with
Independent Suspension 20.29S
Table of Contents
SPECIAL TOOLS ....................................................................................................................................................... 3
GENERAL DESCRIPTION ......................................................................................................................................... 4
COMPONENTS .......................................................................................................................................................... 5
OPERATION .............................................................................................................................................................. 6
Main Switch, Suspension ON / OFF ................................................................................................................ 6
Auxiliary switch (pushbutton function only, pressed to the left – lower, to the right – raise) ............................ 6
Indicator lamp on the instrument panel ............................................................................................................ 6
FUNCTION OF THE SUSPENSION .......................................................................................................................... 7
Calibration procedure ....................................................................................................................................... 7
Control Function ............................................................................................................................................... 8
AXLE SENSORS ........................................................................................................................................................ 9
General Remarks ............................................................................................................................................. 9
Testing the "Sensor Settings" ........................................................................................................................ 10
Adjusting the Sensors .................................................................................................................................... 12
LOWERING THE FRONT AXLE MANUALLY .......................................................................................................... 14
ERROR CODES ....................................................................................................................................................... 15
FAULTS WITHOUT ERROR CODES ...................................................................................................................... 15
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ................................................................................. 16
Measurement table ........................................................................................................................................ 17
Test – solenoid valve control .......................................................................................................................... 19
Circuit Diagram, Sprung Front Axle ............................................................................................................... 20
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4-wheel drive planetary steering axle with independent suspension, cast main housing with swing bearing, diffe-
rential carrier screwed in from the rear. Bevel pinion mounted directly in the differential carrier, differential drive gear
mounted in the differential carrier by means of bridge-type brackets.
Adjustment of the position of the bevel pinion by means of a packing ring. Adjustment of the bevel pinion bearings
by means of a shrunk-on sleeve and bevel pinion nut (slotted nut). Adjustment of the differential bearings and tooth
flank play by means of 2 slotted nuts.
Differential lock 100%, multi-disk version running in oil bath, integrated in the differential housing. Electro-hydrau-
lically controlled. The system pressure is used as the control pressure P2 (20 bar). The pressure oil is fed from the
differential carrier (stationary) to the differential housing (rotating) without any leakage via special sealing elements.
Independent suspension on both sides through: two trapezoidal links, one hydraulic cylinder, one hydro-reservoir
and one torsion bar acting in opposition to the hydro-reservoir. The steering-knuckle is mounted in two ball joints.
The universal drive shafts from the differential to the wheel drive are made in two parts. A sliding piece provides
axial compensation. The section of the universal drive shaft on the differential side is guided by the bearing in the
centering bush, which is fixed in the main housing of the front axle. The section of the universal drive shaft on the
wheel side is guided axially in the axle stub / radially in the protective sleeve.
A control block, fitted with three solenoid valves and two hydro-reservoirs, each of 1.4 litres capacity, is located on
the right-hand side of the vehicle chassis. Nitrogen is used as a cushioning element in the hydro-reservoir. The pre-
load pressure is 35 bar. The control block forms the link between the two cylinders and the hydraulic system. Con-
nected in parallel to the working hydraulic system (load sensing).
Each side, and thus the movement of each wheel, within the total spring travel range of 87 mm, is actively monito-
red by an angle of rotation sensor. The electronics box detects the momentary wheel position via the size of the
signal current (mA).
The sensor signal is decisive for the reaction of the hydraulic control to increase or decrease the charge in the re-
servoir. This firstly forms the basis for the weight independent height control and secondly, actively assists the
function of the hydro-reservoir when necessary.
The right and left-hand sides of the front axle have separate and independent sensors and control elements for the
independent suspension.
Conversion of the sensor signals, to control the hydraulics or solenoid valves respectively, is carried out in the elec-
tronic circuitry, designed as an independent element on the hydraulic control block.
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This switch has the following positions:
Switch pressed to the left
Suspension 2)) (suspension inhibited)
The suspension lowers the axle to the limit of the suspension cylinder.
Recommended mode for driving in hilly terrain and contour lines.
Stipulated mode prior to opening the system. (reservoir pressure-free)
Switch in the mid position
Suspension 21 (100% spring travel), indicator lamp lights. The suspension goes to or remains in the middle of
the total range of travel, independent of weight.
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$X[LOLDU\VZLWFK(pushbutton function only, pressed to the left – lower, to the right – raise)
Holding the button pressed
Active at 100% suspension travel – alteration of ground clearance in the respective direction.
During the calibration procedure – stipulating the upper and lower limits of suspension travel.
Push-button pressed briefly
Height control OFF
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Lamp does not light: Suspension OFF or suspension without height control.
Lamp lights: 100% suspension travel and height control active.
Lamp blinks regularly – confirms calibration procedure.
Lamp blinks irregularly: an error code will be presented (see error code list Page 15).
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The suspension can be operated in several operating modes. The relevant operating mode is indicated by the in in-
dicator lamp on the instrument panel as follows:
Indicator lamp OFF
System switched OFF, reservoir or system free of pressure.
Axle at its limit, no suspension or suspension inhibited.
Manual height adjustment (ground clearance adjustment) has been made. Suspension from the newly selected
position only through the reservoir. Suspension travel is hereby restricted, in one direction, to the remaining travel
up to the limit. Changes in weight and leakage are not compensated for.
Indicator lamp lit
Height control from the middle of the total suspension travel, 100% suspension travel up and down, independent
of load and leakage, is or remains available through active reservoir pressure adaptation.
Indicator lamp blinks regularly (1 Hz)
Calibration process active.
Indicator lamp blinks irregularly (3 Hz)
An error code is displayed.
The blink pattern is interrupted by a long and a short pause.
Example: Error code 21 – long pause, EOLQNVWZLFH, short pause, EOLQNVRQFH
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This serves to stipulate the upper and lower end limits of the suspension on both sides. If the control system does not
receive any recognisable data, the calibration procedure will be automatically activated when the supply voltage is
switched ON.
The calibration procedure can also be selected by the driver at any time (as described in the Operating Manual). Ca-
libration itself is always carried out in the following way:
Hold the main switch, pressed to the left, for at least 10 sec's. (indicator lamp must flash regularly).
Select and hold the auxiliary switch to the "raise" position until the upper limit is reached.
Select and hold the auxiliary switch to the "lower" position until the lower limit is reached.
To complete the procedure, press the main switch briefly to the right.
The indicator lamp must now be lit.
The suspension moves to the centre of its travel – the procedure is complete.
When the indicator lamp once again starts to flash, repeat the procedure.
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For active control, the position of the suspension is acquired every 100 ms.
The electronics recognise whether the suspension is within the fixed tolerance range, programmed in the E-box, by
the sensor signals received or whether it makes significant changes for brief periods of time. The basis for this is the
mean value (S nom) calculated from the relevant sensor signal from the total spring travel.
If this range is exceeded, in either direction, for longer than 2.5 secs., control valves are regulated and the correspon-
ding change in reservoir pressure is initiated. The valves will only then stop being regulated, when the position signals
acquired are once again within the tolerance range.
How often and for how long the valves are regulated is always dependent upon the sensor signals received and can
not be influenced by the driver.
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Adjustment must always be carried out, when one or both of the sensors have been replaced or if the sensor fa-
stening was loosened.
Prior to adjusting the sensors, ensure that the drive wheel (rubber wheel) is correctly fitted and the guide wheel has
freedom of movement, not only externally in the bolt but also internally on the sensor. The tightening torque of the
securing bolts (3 Nm) must also be strictly adhered to.
If either of the above mentioned items is not adhered to, or carried out incorrectly, the function will be impaired due to
deformation of the sensor housing.
The following values are valid for both sensor settings:
Suspension (axle) at its lower limit ................................................................................................. .. 7.8 mA ± 0.5
Suspension (axle) at its upper limit ................................................................................................ 16.0 mA ± 0.5
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67(3
3 In order to test the left-hand sensor, connect the
measuring cables to the sockets in the blue field and re-
peat STEP 4.
6'-
67(3
Remove the protective cover from the control block.
Separate the plug-in connector and connect the mea-
surement adapter into the sensor line.
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The following values must be reached:
Lower limit ............................................... 7.8 mA ± 0.5
$X[LOLDU\VZLWFK 66( Upper limit ............................................. 16.0 mA ± 0.5
Start the tractor and allow it to run at idling speed. Press 127( ,I WKH YDOXHV LQGLFDWHG DUH RXWVLGH WKH JLYHQ
the main suspension switch briefly to the right and wait YDOXHVWKHVHQVRUVPXVWEHQHZO\DGMXVWHGVHH3DJH
until the axle is in the mid position.
Press the auxiliary switch to the left until the axle has
reached the lower mechanical limit. Read the value in- 67(3
dicated off the multimeter and make a note of it.
Disconnect the measurement adapter and
,03257$17 ,I DQ HUURU FRGH LV GLVSOD\HG DQG WKH re-connect the sensor cable connectors. Re-fit the pro-
IURQWD[OHFDQQRWEHORZHUHGXVLQJHLWKHUWKHPDLQRU tective cover to the control block.
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67(3
Put the tractor on solid, level ground and apply the par- 5
king brake. Lower the axle to its lower mechanical limit
and switch the engine OFF. Place chocks in front of and
behind the rear wheels.
67(3
1
6'-
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Put the tractor on firm, level ground, apply the parking When the reservoirs are pressure-free, close the valve
brake and switch the motor OFF. Place chocks in front screw and tighten the locking nut. Re-fit the plastic cap
of and behind the rear wheels. to the discharge valve.
67(3
6'-
67(3
2
6'-
Loosen the locking nut and turn the valve screw (2) out
by approx. one turn. The axle will sink to the lower me-
chanical limit and the pressure reservoirs will be relie-
ved of pressure.
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Indication of an error code by the indicator lamp in the instrument panel blinking at 3 Hz.
127( ,QWKHFDOLEUDWLRQPRGHWKHLQGLFDWRUODPSEOLQNVUHJXODUO\DWDIUHTXHQF\RI+]7KLVLVQRWDQHUURUFRGH
The following error codes can be displayed:
)DXOW/RFDWLRQ 6\VWHP5HDFWLRQ 3RVVLEOH)DXOW
(UURU&RGH
&DXVH
Left-hand sensor signal Axle remains in the cur- • Cable defective or sensor disconnected
not ok rent position • Short circuit or short to earth
• Sensor incorrectly adjusted
• Signal < 4 mA or >19.68 mA
• Sensor defective
Right-hand sensor Axle remains in the cur- • Cable defective or sensor disconnected
signal not ok rent position • Short circuit or short to earth
• Sensor incorrectly adjusted
Signal < 4 mA or >19.68 mA
• Sensor defective
No power supply to the Axle remains in the cur- • Cable or plug defective
E-box. rent position • Potential 30, fuse defective (F27)
(potential 30 is missing)
Left-hand control valve Axle remains in the cur- • Cable defective or solenoid disconnected
does not function rent position • Short circuit in the solenoid or cable
• E-box output stage defective
Right-hand control Axle remains in the cur- • Cable defective or solenoid disconnected
valve does not function rent position • Short circuit in the solenoid or cable
• E-box output stage defective
)$8/76:,7+287(5525&2'(6
)DXOW/RFDWLRQ 6\VWHP5HDFWLRQ 3RVVLEOH)DXOW
&DXVH
Signal variation at one Calibration is not possible, • Sensor shaft stiff
or both sensors too there is no middle position (Sensor fitted under tension, rust on the
small (uneven spring travel) sensor shaft, centering disk missing)
• Rubber disk (sensor shaft drive)
worn out
• Contact fault in the signal line (oxidation)
• Sensor defective
Signal variation at one Calibration is not possible, • Bearing of one or several
or both sensors too there is no middle position trapezoidal links stiff
small (uneven spring travel) • Hydraulic pressure too low
• Front axle load too high
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Engine running
0HDVXUHPHQWV
V Voltage
∆V Voltage drop
R Resistance
∞ Resistance infinity = open circuit (multimeter indication OL)
0HDVXUHPHQWWDEOH
Measurement
Cable colour
Measure
X12/20
Pin
Designation Requirements from pin Value
to pin
12 - 14
Permanent plus F27 10 A 6 U 45W 6 9
VDC
G315
12 - 14
Permanent plus F28 5 A 8 U 45W 8 10
VDC
Suspension inhibited
C307
12 - 14
Main switch (S2/15/2) 4 U Switch pressed to the 4 9
VDC
in position 2 left
Suspension active
C307
Suspension active
C308
Calibration
C308
12 - 14
Main switch (S2/15/2) 5 U Main switch pressed 5 9
VDC
in position 1 to the right
2 U 2 9 0 VDC
Auxiliary switch (S2/15/1)
in position 0
C302
12 - 14
Auxiliary switch (S2/15/1) 2 U Auxiliary switch 2 9
VDC
in position 2 pressed to the left
12 - 14
Auxiliary switch (S2/15/1) 3 U Auxiliary switch 3 9
VDC
in position 1 pressed to the right
Measurement
Cable colour
Measure
X12/20
Pin
Designation Requirements from pin Value
to pin
approx.
B143
Indicator lamp
11 U Main switch pressed 11 9 0 VDC
briefly to the right (ground)
B143
Indicator lamp
11 U Main switch pressed 11 9 7 - 11 VDC
does not light
to the left
7HVW±VROHQRLGYDOYHFRQWURO
To carry out these tests, the multimeter must be connected to the individual solenoid valves using the "Y" adapter
380000066 and the measuring cables.
Test the solenoid valves in accordance with the table below.
Solenoid valve energised 9'&
Solenoid valve not energised 9'&
Function SV SV SV
blue plug green plug black plug
Raise front axle (auxiliary switch pressed to the right)
Lower front axle (auxiliary switch pressed to the left)
Control – increase pressure right and left
Control – raise right only
Control – raise left only
Control – decrease pressure right and left
Control – decrease pressure right only
Control – decrease pressure left only
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Measurement
Measure
Designation Requirements from pin Value
to pin
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Electrical equipment
A1 ADIC
A12 Print, central electrics
A60 ECCU
A61 Sprung front axle electronics
F27 Sprung front axle fuse
potential 30
F28 Sprung front axle fuse
potential 15/2
S2/15/1 Auxiliary switch RAISE/LOWER
S2/15/2 Main switch
X2/45 Plug-in connection - rump, sprung front axle
X4/45 Plug-in connection, sprung front axle
X9/4 Plug-in connection, combination instrument
X12/20 Plug-in connection, sprung front axle
X24/1 Plug-in connection line, ADIC
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SPECIAL TOOLS
Wrench for differential nut Wrench for bevel pinion nut
SS02A055 SS02A056
SS02A062
SS02A060
380000439
SS02A076
380000018
Driver for bushing - swivel housing and Driver for shaft seal - swivel housing
axle housing
SS02A063
SS02A061
380000032 (1TSW 551)
380000024 (1TSW 552)
SS04G033
GENERAL INFORMATION
Using the Manual
Maintenance
• Trouble-free operation of the mechanical components is influenced by regular and correct maintenance.
• The use of qualified personnel during maintenance and repairs guarantees a longer lifetime of the components
and trouble-free operation.
• READ THE MANUAL. Non-observance of recommended worksteps can reduce the lifetime and the durability of
the unit and can result in damage or accidents.
Repairs
The instructions for removal and fitting were drawn up for an overall repair of the axle and constitute the correct order
of the tasks to be performed. Drawings and photos provide personnel with a complete and safe guide through all work
steps.
A good knowledge of the axle makes it possible to assess the repair, and as a result, it is often the case that only
certain parts have to be removed.
Diagrams
Photos and drawings are NOT to exact scale.
Photos are only intended to clarify the sequence of worksteps.
General Remarks
• The axle should only be repaired by qualified personnel, who are acquainted with all of its technical
characteristics, and under strict compliance with the corresponding safety standards.
• The axle must be carefully cleaned before carrying out a repair. Dirt and/or grease must be removed.
• All disassembled parts must be cleaned using a suitable cleaning agent to avoid possible damage.
• Damaged or worn parts must be replaced to avoid possible subsequent damage. In particular, motion and
sealing elements must be checked if they are subject to larger amounts of stress, wear and ageing.
• The renewal of the bevel pinion or differential master gear necessitates the renewal of the entire set.
• Only use original spare parts
‘O’ rings
Grease before installing.
Shims
Always individually measure the shims used.
Bearings
We advise that you warm up the bearing inner rings to 80 °C - 90 °C before assembly. Bearing outer rings should be
cooled down before assembly.
Always use suitable extractors when removing bearings. Always use suitable insertion tools when inserting bearings.
Draining oil
The oil must be drained before removing the planetary train and/or the axle housing.
WARNING: Dispose of old oil according to statutory regulations.
Cleaning
• All moving parts (bearing, gear wheels, shafts) must be cleaned carefully.
• Petrol, water or alkaline solutions should not be used. Do not use steam or hot water as it is difficult to remove
surface dampness.
• Clean all components using an air jet or a cloth to free the surfaces from any remains.
• All surfaces should be covered by a thin layer of oil to protect them from oxidation.
Using lubricants
Only use lubricants which meet the stipulated specifications (see Technical Data, page 10).
Type plate
TOTAL RATIO
CARRARO NUMBER
TYPE OF
DIFFERENTIAL LOCK
DIFFERENTIAL
OIL QUANTITY
DIRECTION OF
ROTATION OF
DRIVE SHAFT
RECOMMENDED
DIFFERENTIAL OIL
TECHNICAL DATA
DIFFERENTIAL
Number of teeth – pinion shaft / diff. master gear ...................................................................................... 14 / 32
Differential transmission ratio ................................................................................................................... 2.286 /1
Pinion shaft initial bearing tension (P)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) ..................................................... P = 92 to 137 N
Total initial bearing tension – pinion bearing and differential (T)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) .................................. T = 92 (+40) to 137 (+60) N
Bevel pinion / differential master gear tooth flank play ................................................................ 0.17 to 0.24 mm
Compensating washer thickness for pinion height .............................. at least 2.5 mm to a maximum of 3.4 mm
PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) .......................................................................... 15.824 / 1
BRAKE (optional)
Type .................................................................................................................................................wet disk brake
Nominal brake disc thickness................................................................................................................. 10±0.1 mm
Maximum brake disc wear (per side) ........................................................................................................1-0.2 mm
SS04G032
STEERING
Steering angle .................................................................................................................... adjustable up to 50° -2
DIFFERENTIAL LOCK
Type ............................................................................ Radial pin lock, running in oil bath – 100 % locking value
Activation .................................................................................................................................... electro-hydraulic
Control pressure ...................................................................................................................................... 18+2 bar
TRACK ALIGNMENT
toe-in ...................................................................................................................................................... 0 to 2 mm
FILLING QUANTITIES
Planetary drive without brake (each side) ............................................................................................... 1.5 litres
Planetary drive with brake (each side) ........................................................................................................ 2 litres
Differential ............................................................................................................................................... 8.0 litres
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7HFQROXEH32/<0(5(
/RFWLWH SS04F082
Tightening Torques
1P
1P 1P
1P
1P
1P
1P
1P
1P 1P
1P
1P
1P
1P 1P
1P
1P
1P
1P
1P
1P
1P
1P 1P 1P
SS04F088
Dimensions 20.25
0[
∅
∅
∅
∅
SS04F91
Dimensions 20.25 FR
0[
∅
∅
∅
∅
SS04F089
20
15
18
16
19
17
13
11
10
6 8
14
3 4 12
9
7
5
1
2
SS04F061
Disassembly
STEP 1 STEP 2
4
2
2 5
1
SS04F062 SS04F063
Remove the nut (3) and bolt (2). Remove the bolt (4).
Remove the flange (1). Remove the rear support (5) from the differential
support.
Remove the bushes (6) from rear support (5).
STEP 3 STEP 6
7
20
18
8 19
15
6
SS04F063 SS04F067
Remove the O-Ring (8) from the bush (7). Remove the bolt (19).
Remove the bush (7) from the rear support (5). Remove the front support (20) from the axle housing
(15).
STEP 4
Remove the bush (18) from the front support (20).
STEP 7
15 16
13
11
17
12
SS04F065
10
SS04F066
Assembly STEP 3
STEP 1
6
7
10
9
8
5
4
SS04F069
SS04F066
Apply Loctite 542 on bushes (6) contact surface.
Assemble the bushes (6) to the rear support (5).
Insert the washer (10) onto the differential support.
Assemble the bush (7) in the rear support (5).
Heat the bush (9) to 110-120 °C than assemble it to
the differential support. 127( Align the bush hole with the fastening bolt (4)
hole.
127( If necessary assemble the bush (9) with a
driver and a hammer. Assemble and tighten the fastening bolt (4) to the
requested torque.
STEP 2
Tightening torque......................................... 70 Nm
Lubricate a new O-Ring (8) with grease and assemble
it in the bush (7).
127( Insert the O-ring on the shown support side.
13
STEP 4
11
12
SS04F065
Assemble the seal ring (13) to the cover (11) with the
special tool 380000702.
4
Assemble the new O-Ring (12) to the cover (11).
Lubricate the O-Ring (12) and the seal ring (13). 5
Assemble the cover (11) to differential support. SS04F070
STEP 5 STEP 7
20
3 18
19
2
15
1 2
SS04F062 SS04F067
Assemble the flange (2) to the pinion shaft end (14). Assemble the bush (18) into the front support (20) with
Lock the flange (1) with the bolt (2) and nut (3). a suitable driver and a hammer.
Tighten the nut (3) to the requested torque. :$51,1* Align the bush hole with the fastening
Tightening torque ..........................................57 Nm screw (19) hole.
Mount the fastening screw (19).
STEP 6
Tighten the fastening screw (19) to the requested
torque
15 16
Tightening torque .......................................... 70 Nm
Assemble the front support (20) to the axle housing.
17
SS04F068
19
21 12
11
20 10
17
18
15
7
16
14 6
8 9
5
13 4
3
2
1
SS03M070
Disassembly
STEP 1 STEP 2
3 12
2
11
6
10
1 4
7
5
3
SS03M083
SD03M004
Remove the tie rods (3) and (12) by loosing the nuts
Loosen the nut (1) with enough turns till it is protruding (4) and (11) with a suitable wrench. Unscrew also the
over the threaded pin end of the tie rod (3). ball joints (5 and 10). Check the condition of the parts
Beat on the nut (1) with an appropriate hammer in removed.
order to disjoin the tie rod (3) from the swivel housing Unscrew the fastening screws (6) and take the
(2). steering cylinder (7) out of its housing, if necessary
:$51,1* Do not strike on the threaded pin end of use a rubber hammer.
the tie rod (3). Remove only parts that need to be overhauled and/or
Repeat the whole sequence at the other side. replaced.
STEP 3 Assembly
19 20 STEP 1
19 20
14 17 21
15
14 17 21
13
18 15
13
18
16
SS03M084
17
19
15
SD03M005
11
6
10
4
7
17
5
3
SS03M083
Fit the tie rods (3) and (12), the ball joints (5) and (10),
the nuts (4) and (11) to the ends of the rod (17), then
tighten with a torque wrench.
Tightening torque .................... (pos. 5, 10) 300 Nm
Tightening torque .................... (pos. 4, 11) 250 Nm
STEP 4 STEP 6
6 3
7 1
SD03M006
2 SS01M015
Install the steering cylinder (7) already assembled on Insert the ball joint of the tie rod (3) into the swivel
the central body. housing (2).
Assemble and tighten the screws (6) with a torque Assemble and tighten the lock nut (1) with a torque
wrench. wrench.
Tightening torque ........................................ 120 Nm Tightening torque........................................ 220 Nm
STEP 5 Repeat the whole sequence of the mentioned
operations to the other side.
12
11 STEP 7
11 12
8
SD03M007
inserted into the swivel housing (8) arm. Screw the lock nuts (4) and (11) of the tie rods (3) and
127( It is important to unscrew the lock nut (11) to (12) only when the toe-in adjustment has been carried
carry out this operation. out (see Page 58).
11
1 10
9
6
5
4
12
2
SS04F071
Disassembly
STEP 1 STEP 2
SD04F037
SS04F038
Drain the oil completely from the epicyclic reduction Unscrew the fastening screws (2) of the planetary
gear. carrier (1).
STEP 3 Assembly
1 3 STEP 1
7
1 4
10
9
6
5
11 SD04F039
Remove the planetary carrier (1) from the wheel hub SS04F072
(11) and collect the relative O-Ring (3).
Collect all epicyclic reduction gear parts:
Position the planetary carrier (1) on a workbench and
check its wear conditions. - the planetary carrier (1),
- the thrust washer (4),
STEP 4 - the planetary gear (6) with the roller bearings (5),
- the washers (7) and (9),
7 - the fixing screw (10) of every planetary carrier
4 pin.
1
10 127( With new planetary gears (6) it is advisable to
assembly new needle bearings (5).
9
6 STEP 2
5
SS04F072
STEP 3 STEP 5
9
12
SD04F041 SD03M014
Fit the thrust washers (7) and (9) to the planetary Top up the oil on the wheel hub.
carrier (1) pins. Fit the filling/drain and level oil plug (12) on the
127( The intermediate thrust washers (7) has a planetary carrier (1) and tighten to the requested
hole for centering with the dowel pin (8) fitted on the torque.
planetary carrier (1) pins. Tightening torque .......................................... 80 Nm
11
SS04F042
BRAKE GROUP
13
12
9
8 11
14
4 33
8 34
10 31 32
2 30
7 24
23 29
5
27 28
21
25 26
3 19
1 22
20
SS04F073
Disassembly
127( Before disassembling the brake group (if equipped with it) remove epicyclic reduction gear group. (see page
22)
STEP 1 STEP 2
SS04F074 SD03M015
Remove the lock ring (1). Using a lever to push the double U-Joint in the
Remove the brake counter disk (2) and disk (3). direction of the wheel hub to allow the lock ring (5)
removal.
,03257$17 Do not damage the double U-Joint.
STEP 3 STEP 6
6 7
5
SD04F043 SD03M019
Remove the lock ring (5) from the double U-Joint shaft. Extract and remove the wheel carrier (10) together
Collect the washers (6) and (7). with the epicyclic ring gear (4).
STEP 4 STEP 7
SD03M017 SD03M020
Unscrew the fastening screws (8) from the wheel Remove the O-rings (11).
carrier (10). Remove the lock ring (12) and disjoin the wheel carrier
group (10) from the epicyclic ring gear (4).
STEP 5
STEP 8
9 26
22
19
25
24
21
23
SD03M018 20
SS04F075
For disassembing the wheel hub group use three
screws (M10). Unscrew the kit self-adjust fastening screws to
disassembly the separator disk (19) from the wheel
carrier (26).
127( Remove all of the self-adjusting parts.
Remove the steel lock ring (20) from the epicyclic ring
gear (4) only if necessary.
STEP 9 STEP 11
26
SD02A016 SS04F077
In order to remove the brake piston (23) from the Remove the centering bushes (9) from the wheel
wheel carrier (26) screw in 2 screws (M4) into the carrier (26) with a hammer and a suitable ejector drift
existing threaded holes. Extract symmetrically the if necessary.
piston with a lever and an appropriate support as
shown in the above figure.
STEP 10
22
21
23
SS03M093
Assembly STEP 4
STEP 1 26
27
SS03M091
SS03M095 Push the bushes (27) into the shown seats in the
wheel carrier (26) with an appropriate driver till they
Position the wheel carrier (26) on a workbench and
are leveled with the counter disk (19) supporting inner
force the bushes (9) to the carrier surface level with an
surface.
appropriate driver.
Assemble the others self-adjusting parts as shown in
STEP 2 the diagram.
127( See next step.
STEP 5
26
19
SD03M021
20
127( At least two bushes (diametrically-opposed)
should be set slightly higher than the carrier surface SS04F079
level to be used as dowel pins.
Assemble the steel lock ring (20) to the intermediate
STEP 3 seat of the epicyclic ring gear (4).
Assemble the separator disk (19) and the epicyclic
22
25
ring gear (4) to the wheel carrier (26) with the self-
adjust kit (27-34).
Tighten the self-adjust screws to the requested torque
23
Tightening torque .......................................... 10 Nm
26
21
24
SS04F078
SD03M022
Assemble the lock ring (12) into its seat of the epicyclic
ring gear (4).
Insert two new greased O-Rings (11) in the wheel
carrier (26). SD03M015
6 7
SD03M023
Screw in the screws (8) in order to put in contact the Slide the washers (6) and (7) onto the double U-Joint
group with the wheel hub. shaft end.
Insert the lock ring (5) and push it into its seat.
STEP 8
127( Check that the lock ring (5) is correctly fitted
in its seat.
SD03M024
STEP 11
3
2
SS04F080
Insert the brake disk (3) and the brake counterdisk (2),
as in figure.
127( See next step.
Lock the disks with the lock ring (1).
STEP 12.
19
p1
SS04F081
25
17
16
20
24
12
23
11
21
9 10
5
4 13
19
18
14
3
1
7 15
6
2 SS01M098
Disassembly
127( Before disassembling the wheel hub group/swivel housing remove the epicyclic reduction gear group. (see
page 22)
STEP 1 STEP 2
SS04F074 SD03M015
Remove the lock ring and remove the brake disks. Using a lever to push the double U-Joint in the
(see page 25) direction of the wheel hub to allow the lock ring (1)
removal.
:$51,1*Do not damage the double U-Joint.
STEP 3 STEP 6
6 7
5
SD04F043 SD03M019
Remove the lock ring (1) from the double U-Joint shaft. Extract and remove the wheel carrier (6) together with
Remove the washers (2) and (3). the epicyclic ring gear as mentioned in the previous
section.
STEP 4
STEP 7
SD03M017
SD03M025
Unscrew and remove the fastening screws (4) from
the wheel carrier group (6). Remove the wheel hub (9) using levers and a hammer
to facilitate the operation.
STEP 5
127( Remove the bearing cone (7).
SD03M018
STEP 8 STEP 10
7
7
SS03M099 SD03M027
Position the wheel hub (9) on a flat surface and Remove the swivel housing (12) from the axle beam.
remove the seal ring (11) with a lever. Remove the belleville washers (23) and (25).
Remove the bearing cups (7) and (10) using a
hammer and a suitable driver. STEP 11
Remove the bearing cone (10) from the swivel housing
end (12).
STEP 9
SD03M028
Assembly STEP 3
STEP 1
12
13
26
19 14
18
SD03M030
SD03M027
SD03M029
:$51,1* Secure the swivel housing (12) with a
belt or a rope to a hoist or any other supporting
device.
Protect the splined end of the axle shaft by winding it
with an adhesive tape to avoid damage to the seal ring
(21).
Assemble the swivel housing (12) on the axle beam.
127( Completely remove the adhesive tape.
SS04G056
Force the bush (20) into the swivel housing (12) with
the special tool 380000024 and a hammer or a press.
Assemble the seal ring (21) on the swivel housing (12)
with the special tool 380000032 and a hammer.
Carefully grease the seal ring (21).
STEP 5 STEP 7
SD03M031 SD03M033
Assemble the king pins, the lower (14) and the upper Assemble the bearing cone (10) on the swivel housing
(16), and tighten the retaining screws (15) and (17) to (12) end.
the requested torque. Assemble the wheel hub (9) on the swivel housing (12)
Tightening torque ........................................ 190 Nm and fit the bearing cone (7).
127( Ensure that the belleville washers (23) and 127( When fitting the wheel hub, moisten the inner
(25) remain in their position. surface of the cartridge sealing ring with a mixture of
white spirits and water.
STEP 6
STEP 8
SD03M032
SD03M023
Force both bearing cups (7) and (10) to their wheel
hub (9) housings using an appropriate driver under a Assemble the wheel carrier group (6) according to the
press or with a hammer. previous section.
Insert the seal ring (11) into the wheel hub (9) with the Assemble the wheel carrier group on the wheel hub
special tool 380000042 and a hammer. using the two projecting bushes (5) as dowel pins and
screw the relative screws (4) in order to put in contact
127( Do not lubricate the seal ring (11).
the ring bevel gear with the wheel hub.
STEP 9 STEP 11
SD03M024 SD03M015
Force all the hub dowel bushes (5) completely with an Using a lever to push the double U-Joint in the
appropriate driver and a hammer. direction of the wheel hub to facilitate the insertion of
Apply locking fluid Loctite 270 on fastening screws (4) the lock ring (1).
thread.
STEP 12
Assemble the fastening screws (4) and tighten to the
requested torque.
Tightening torque ........................................230 Nm
STEP 10
C A C
SD03M016
B Slide the thrust washers (3) and (2) onto the double U-
Joint shaft end (22).
Insert the lock ring (1) at the end of the splined hub and
SD03M014 push it into its housing.
The special operation “Set Right” of the bearings (10) 127( Check that the lock ring (1) is correctly fitted
and (12) does not require preload or backlash in its seat.
adjustment. Anyway, before assembling new
components check the indicated dimensions.
A= 17.950 - 18.000 mm
B= 64.275 - 64.325 mm
C= 23.070 - 23.172 mm
1
2
4
5
6
3
SS03M102
Disassembly
127( Before disassembling the double U-joints remove the wheel hub group. (see page 31)
STEP 1 STEP 2
1
4
6
5
5
SD03M034 SS03M103
Remove the two double U-Joints (6) from the axle Remove the seal rings (5) from the axle beam (1).
beam (1). Remove the bush (4) from the axle beam (1) only if the
wear conditions require this.
,03257$17 Be careful not to damage the bush
housing.
STEP 3 Assembly
STEP 1
2
3
SS03M104
3
Remove the upper king pin bush (2) and the ball SS03M105
bearing cup (3) from the king pin housings using a
Cool the upper king pin bush (2) and the ball bearing
suitable extractor only if the wear conditions require
cup (3) at a temperature lower than -100 °C with liquid
this.
nitrogen.
:$51,1*Wear safety gloves.
Assemble the upper king pin bush (2) on the axle
beam housing with an appropriate driver and a
hammer.
Assemble the ball bearing cup (3) on the axle beam
housing with an appropriate driver and a hammer.
STEP 2
1
4
5
SS03M106
Assemble the bush (4) on the axle beam (1) with the
driver 380000024 and a hammer.
Assemble the seal ring (5) on the axle beam with the
driver 380000702 and a hammer.
127( Carefully grease the seal rings with
Tecnolube POLYMERE 400.
STEP 3
4 5
SS03M107
SD03M035
Insert the double U-Joint (6) inside the axle beam (1).
:$51,1* Be careful not to damage the seal ring
(5).
14
8 9 12
7 11
6
10
2 4 13
3
SS04F083
Disassembly
127( Before dissasembling the differential support group remove the axle beam group. (see page 37)
STEP 1 STEP 2
9
14
8
2 1
SS04F084 SS04F093
Drain the oil completely from the differential. Loosen and remove the screws (9) to take out the two
Loosen and remove the screws (2) on the differential ring nut retainers (8).
support (1).
Remove the differential support (1) from the axle
housing (14).
:$51,1* Support the differential support with a
rope or other appropriate means.
STEP 3 STEP 6
11 4
6
1
SS04F094 SS04F097
Before removing the bolts, mark both half-collars (11) Remove the differential housing (5).
and the differential support with permanent reference The bearing cups (4) and (6) are removed together
marks to avoid inverting them during re-assembly. with the differential housing.
Mark the area between the ring nuts (3) and (7) and
the differential support (1) as well. :$51,1* Do not invert the bearing cups if the
bearings are not replaced.
STEP 4
a1
SS04F095
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 (a1).
STEP 5
12
11
10
SS04F096
Assembly STEP 3
STEP 1 12
11
5
4
10
SS04F100
a1
SS04F095
SS04F099
Assemble the adjuster ring nuts (3) and (7) to the
Position the complete differential group with bearings differential support.
on the differential carrier (1). At the same time insert Tighten both ring nuts (3) and (7) with special tools
the differential locking fork in the sleeve. 380000406 (a1), till the backlash is eliminated and the
:$51,1* Check the right side of the bevel crown differential bearings are slightly preloaded.
assembly. Check that the differential bearings are well settled. If
necessary, knock slightly with a soft hammer, in order
to properly set the bearings in position.
STEP 5 STEP 7
A A
B B
SS04F128 SS04F130
Position a magnetic-base dial gauge on the differential Adjust the ring nuts (3) and (7), remembering that:
support, so that the feeler stylus touches the surface (A)- if the measured backlash is greater than the
of one tooth of the crown gear with a 90° angle. given tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the same
STEP 6
measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut (3) and
screw in the adjuster ring nut (7) by the same
measure.
STEP 8
SS03M119
STEP 9 STEP 11
SS04F131 SS04F032
Once the pinion-ring gear backlash has been Once all the adjustment operations have been
established, measure the total preloading (T) of the completed, fit the ring nut locks (8) and their screws
bearings (pinion-crown bevel gear system), using a (9), tightening them to the requested torque.
dynamometer whose cord is wound on the pinion Tightening torque ......................................... 13 Nm.
splined end. The measured value should be within the
following range: STEP 12
T= 92(+40) ÷ 137(+60) N
(T=preloading pinion + bevel gear)
:$51,1* All preloadings must be measured
without seal ring (pinion).
STEP 10
A A
SS04F133
SS04F130
14
13
13
SS04F134
127( Check the correct seat of the two dowel pins STEP 2
(13) in their housing.
STEP 14
14
SS03M126
STEP 3
SS03M127
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
14
16 12
10
8
15
13
11 6
9
4
2
1
SS03M128
Disassembly
127( Before disassembling the differetial locking group remove the differential housing. (see page 40)
STEP 1 STEP 2
15
9
16
10
11
12
13
14
SS03M129 SS03M130
Unscrew the bolt (16) and remove the cylinder support Remove the lock ring (11) keeping the bush (10) that
(15). is pushed out by the spring (9).
Collect the piston (13) and the O-rings (14) and (12).
:$51,1* Possible ejection of the bush (10) and
spring (9).
Remove the bush and the spring from the control shaft
(3).
STEP 3 Assembly
STEP 1
2 1
4
5 8
6
SS03M131
Remove the bolt (1) and the cover (2) keeping the SS03M133
bush (4) that is pushed out by the spring (5).
Place the differential support on a workbench.
:$51,1* Possible ejection of the bush (4) and Assemble the lock ring (11) in the housing at the end
spring (5). of the control shaft (3).
Remove the bush, the spring and spacer (6) from the Insert the spacer (10) and the spring (9) on the control
control shaft (3). shaft (3).
STEP 4 Insert the shaft in the differential support and in the
fork (8), paying attention to the illustrated position for
each element.
STEP 2
15
16
12
SS03M132
13
Remove off the control shaft (3), collecting the lock 14
ring (7) that is still in the housing on the shaft and
remove the fork (8). SS03M134
Insert the piston (13) with new O-rings (14) and (12) at
the ends of the shaft and assembly the support (15),
screwing the relative fastening screws to the
requested torque.
Tightening torque ....................................... 27.6 Nm
STEP 3
SS03M135
Insert the lock ring (7) on the control shaft (3) from the
fork side by pushing it in the housing with a pipe of
suited dimension.
Insert the spacer (6), the spring (5) and the bush (4) on
the control shaft.
Apply sealant (Loctite 518) on the cover (2).
Assembly the cover (2), pushing the spring (5), with
the fastening screws (1).
:$51,1* Possible ejection of the bush and the
spring.
DIFFERENTIAL GROUP
11
13
9
12
1
10 5
2 7
5
6
4
SS04F085
Disassembly
127( Before disassembling the differential group remove the differential housing. (see page 40)
STEP 1 STEP 2
1
13
12
11
SD03M036 SD03M037
Remove the differential group from differential Unscrew the fastening screws (1) and remove the
support. bevel gear crown (3).
Remove the sleeve (13) and the pins (11) from the
127( This will make both differential half boxes (4)
differential housing (12).
and (12) free, so take care not to drop the internal
components.
STEP 3 Assembly
STEP 1
4
12
SS04F086
SS04F086
STEP 3 STEP 5
SD03M039 SD03M014
Before matching surfaces, make sure that they are $VVHPEOHWKHVOHHYHRQWKHGLIIHUHQWLDOKRXVLQJ
perfectly clean, degrease and clean them with
appropriate detergents.
,03257$17 Take care to assemble it in the correct
Place the bevel gear (3) on the differential housing. position.
Apply locking fluid (Loctite 270) on the threads and
tighten the bolts (1) to the requested torque.
Tightening torque ..........................................95 Nm
STEP 4
SD03M040
PINION GROUP
2
3
7
4
5
6
9
10
SS03M139
Disassembly
127( Before disassembling the pinion group remove the differential housing. (see page 40)
STEP 1 STEP 2
9
10
SS03M140 SS03M141
Fit the differential carrier in a vise. Remove the lock nut (10) and collect its retaining
Unscrew the lock nut (10) using special tools washer (9).
380000021 and 380000020.
127( This operation will irretrievably damage the
lock nut (10).
STEP 3 STEP 5
8
5 2
1
6
4
SS03M142 SS03M144
Tap the shaft with a soft hammer to remove the bevel To remove the bearing cone (3) of the bevel pinion (1),
pinion (1). use a standard extractor.
127( Take care not to drop the bevel pinion (1). Remove the the leveling shim (2).
Collect the washers (4) and (6), the collapsible spacer STEP 6
(5) and the bearing cone (8).
STEP 4
5
10
SS03M181
8
Check all pinion components for wear.
SS03M143 ,03257$17 The lock nut (10) and the collapsible
Place the differential carrier (7) on a flat surface and spacer (5) must be replaced when reassembling the
remove the bearing cups (3) and (8) using an unit.
appropriate driver and a hammer.
STEP 1 , 0 3 2 5 7$ 1 7 T i g h t e n u n t i l t h e b a c k l a s h i s
eliminated.
The bearings must be rotatable by hand.
3 STEP 4
7
7
SS03M143
X
SS04G058
SS04G057
STEP 6 STEP 9
3 6
5
4
1 1
SS03M186 SS03M188
In order to determine the necessary thickness value Insert the chosen shim (2) with the chamfer against
(S) between the pinion and the bearing, subtract the the gear onto the pinion shaft (1).
value (V), stamped on the pinion head (V=requested Heat the inner bearing ring to 90 °C and attache it on
conical distance), from the measured value (X). the pinion.
S = X - V mm Insert the shims (4) and (6) and a new collapsible
spacer (5).
STEP 7
,03257$17 Always use a new collapsible spacer
(5).
STEP 10
SS03M187
SHIMS RANGE Assemble the bevel pinion (1) unit into the differential
support housing (7) and the bearing cone (8).
Thickness 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm Use an appropriate driver to drive the bearing (8).
Quantity -- -- -- -- -- -- -- -- -- --
STEP 8
Remove the measuring tool from the differential
housing (7).
STEP 11 STEP 13
7
9
10
SS03M141 SS03M121
Insert the ring nut washer (9) and screw a new lock Carry out the preloading measurement P of the pinion
ring nut (10) on the pinion end. taper roller bearings (3) and (8) by using a
dynamometer.
STEP 12
The adjustment is carried out by increasing the lock
nut (10) torque gradually, being careful not to exceed.
,03257$17 All preloadings must be measured
without the seal ring.
P=92 ÷ 137 N
STEP 14
SD03M014
TRACK ALIGNMENT
Ä$³
'ULYLQJGLUHFWLRQ
Ä%³
SS03M274
127( Before aligning the track, check the tyre air pressure (see Operating Manual).
STEP 1 STEP 5
Make marks on the rear inside of the wheel rim (rim
flange), at the same height as the centre of the wheel Z
hub.
127( The front wheels must face straight ahead. Z
STEP 2
Measure the distance B between these marks and X
make a note of it.
STEP 3
Drive the tractor forwards until the marks at the front
are level with the centre of the wheel hub. X
STEP 4 SS03M275
Measure the distance (A) between these marks and
make a note of it. The track must be adjusted so that Loosen the locking nuts (X). Extend or shorten the
value A is 0 to 2 mm smaller than value B. track rods by turning the knuckle joints (Z). Repeat
toe-in ........................................................0 to +2 mm STEP 1 to STEP 4.
When the track has been aligned correctly, tighten the
127( If the value determined is outside the
locking nuts (X).
prescribed setting, the track alignment must be
corrected in accordance with 67(3 Tightening torque ........................................ 250 Nm
TABLE OF CONTENTS
BRAKE ......................................................................................................................................................................17
Disassembly ...................................................................................................................................................17
Assembly ........................................................................................................................................................20
Bleeding the brakes ........................................................................................................................................22
SECTIONAL DRAWING THROUGH THE PLANETARY GEAR AND WHEEL HUB ...............................................25
SECTIONAL DRAWING, THROUGH THE PIVOT BEARING HOUSING AND THE KING PIN HOUSING .............36
SPECIAL TOOLS
DIFFERENTIAL ADJUSTMENT TOOLS AXLE SUSPENSION TOOLS
11 12 13
3 1
5
14
2
DD99K234 DD99K237
1. GAUGING TUBE 380001925 (CAS1839/1) 11. SLEEVE FITTING TOOL 380000027 (CAS2717)
2. ALIGNMENT ADAPTER 380001919 (CAS2489-4) 12. SLEEVE FITTING TOOL 380001922 (CAS2718)
3. GRIP 380002420 (CAS1596A-4) 13. SLEEVE FITTING TOOL 380000029 (CAS2719)
4. BOLT 380002421 (CAS1596A-7) 14. GRIP 380001920 (CAS2555)
5. MEASUREMENT CYLINDER 380001918 (CAS2489-2)
TOOLS FOR PIVOT BEARING HOUSING AND AXLE PIVOT BOLT
DIFFERENTIAL HOUSING TOOLS
18 16
6
17
15
7 8 SS00B036
SD00B035 15. GRIP 380000506 (CAS1924)
6. PINION NUT WRENCH 380000021 (CAS1885A) 16. FITTING TOOL, CARTRIDGE SEALING RING
7. DOLLY 380000020 (CAS2483) 380000042 (1TSW549)
8. WRENCH AND FITTING TOOL 380000037 (CAS2714) 17. SLEEVE FITTING TOOL 380001921 (CAS2716)
18. FITTING TOOL, SLEEVE 380000024 (CAS2723)
FITTING TOOL, SEALING RING 380000032 (CAS2723)
KINGPIN HOUSING TOOLS
10
DD99K236
9. WRENCH 380000038 (CAS2713)
10. FITTING TOOL, CARTRIDGE SEALING RING
380000025 (CAS2720)
EMTY PAGE
GENERAL INFORMATION
Using the Manual
Maintenance
• Trouble-free operation of the mechanical components is influenced by regular and correct maintenance.
• The use of qualified personnel during maintenance and repairs guarantees a longer lifetime of the components
and trouble-free operation.
• READ THE MANUAL. Non-observance of recommended worksteps can reduce the lifetime and the durability of
the unit and can result in damage or accidents.
Repairs
The instructions for removal and fitting were drawn up for an overall repair of the axle and constitute the correct order
of the tasks to be performed. Drawings and photos provide personnel with a complete and safe guide through all
worksteps.
A good knowledge of the axle makes it possible to assess the repair, and as a result, it is often the case that only
certain parts have to be removed.
Diagrams
Photos and drawings are NOT to exact scale.
Photos are only intended to clarify the sequence of worksteps.
General Remarks
• The axle should only be repaired by qualified personnel, who are aquainted with all of its technical
characteristics, and under exact observance of the corresponding safety standards.
• The axle must be carefully cleaned before carrying out a repair. Dirt and/or grease must be removed.
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5001).
Switch the engine OFF and remove the ignition key.
• All disassembled parts must be cleaned using a suitable cleaning agent to avoid possible damage.
• Damaged or worn parts must be replaced to avoid possible subsequent damage. In particular, motion and
sealing elements must be checked if they are subject to larger amounts of stress, wear and ageing.
• The renewal of the bevel pinion or differential master gear necessitates the renewal of the entire set.
• Only use original spare parts
‘O’ rings
Grease before installing.
Shims
Always individually measure the shims used.
Bearings
We advise that you warm up the bearing inner rings to 80 °C - 90 °C before assembly. Bearing outer rings should be
cooled down before assembly.
Always use suitable extractors when removing bearings. Always use suitable insertion tools when inserting bearings.
Draining oil
The oil must be drained before removing the planetary train and/or the axle housing.
WARNING: Dispose of old oil according to statutory regulations.
Cleaning
• All moving parts (bearing, gear wheels, shafts) must be cleaned carefully.
• Petrol, water or alkaline solutions should not be used. Do not use steam or hot water as it is difficult to remove
surface dampness.
• Clean all components using an air jet or a cloth to free the surfaces from any remains.
• All surfaces should be covered by a thin layer of oil to protect them from oxidation.
Using lubricants
Only use lubricants which meet the stipulated specifications (see Technical Data, page 10).
Type plate
AXLE TYPE CUSTOMER NUMBER CARRARO SERIAL NUMBER
OVERALL RATIO
CARRARO NUMBER
TYPE OF
DIFFERENTIAL LOCK
DIFFERENTIAL
DIRECTION OF OIL QUANTITY
ROTATION OF
DRIVE SHAFT
RECOMMENDED
DIFFERENTIAL OIL
TECHNICAL DATA
DIFFERENTIAL
Number of teeth – pinion shaft / diff. Master gear ...................................................................................... 14 / 32
Differential transmission ratio .................................................................................................................. 2.286 / 1
Pinion shaft initial bearing tension (measured at the pinion shaft Ø = 34.8 mm) ............................... 92 to 137 N
Pinion Bearing and Differential
Total initial bearing tension (measured at the pinion shaft Ø = 34.8 mm) ......................................... 112 to 167 N
Differential master gear tooth flank play ..................................................................................... 0.18 to 0.23 mm
Compensating washer thickness for pinion height ............................... at least 2.5 mm to a maximum of 3.4 mm
PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) .......................................................................... 15.824 / 1
STEERING
Steering lock ................................................................................................................................................... 50°
DIFFERENTIAL LOCK
Type ....................................................................................................................................... 100% elliptical lock
Differential operating pressure .................................................................................................................... 20 bar
WHEEL ALIGNMENT
Axle in mid-position .................................................................................................................................... 0±3 mm
FILLING LEVELS
Differential..............................................................................................................................................2,2 litres
Planetary drive without brake (each side) ............................................................................................1,5 litres
Planetary drive with brake (each side) ..................................................................................................2,0 litres
270 542
542
510
542
542
510
270
= Loctite
SS04M021
Tightening Torques
SS04M022
Dimensions 20.25 S
SS04M025
Dimensions 20.25 SI FR
SS04M020
GENERAL NOTES
NOTE: The all-wheel drive axle must not be removed for work on the following components:
• Planetary drive, see page 15.
• Brake,see page 17
• Wheel hub, see page 23.
• Pivot bearing housing, see page 26.
• King pin housing, see page 28.
• Drive shafts, see page 37.
PLANETARY DRIVE
STEP 1 STEP 2
1
2
2
SD00B029 SD00B029
Turn the drain/level plug (1) to point downwards. Place Remove the two countersunk screws (2).
a container, with a minimum capacity of 2 litres, under
NOTE: When re-fitting the screws (2), tighten them to
the wheel hub.
a torque of 25 Nm.
Remove the drain/level plug (1) and remove the ‘O’
ring. Drain the oil.
STEP 3
NOTE: When re-assembling, turn the wheel hub so
that the drain/level plug (1) is positioned horizontally to Tap the planetary gear carrier surface (3) with a soft-
the centre of the axle. Fill the wheel hub with the cor- faced hammer and remove the planetary gear carrier.
rect type of oil, to the prescribed level, refer to the Remove the ‘O’ ring and dispose of it.
”Technical Data” on page 10. Replace the drain/level NOTE: Use a new ‘O’ ring when re-assembling.
plug (1) with ‘O’ ring and tighten it to a torque of
80 Nm. NOTE: Re-fit parts in the same manner but in the
reverse order.
Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly.
Tightening torque = 79 Nm
5 4
6
7
1
2
3
DS99D050
STEP 4 STEP 6
Make alignment markings on the planetary gears (5) Clean all component parts in a cleaning solvent and dry
and the shaft. with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
STEP 5 wear or damage and replace as necessary.
Remove the securing bolt (1), the washer (2), the thrust NOTE: Re-assemble parts in the same manner but in
washer (3) and the securing pin (4). Remove the the reverse order.
planetary gear (5), the needle bearing (6) and the thrust
washer (7). Repeat the procedure for the remainder of
the planetary gears.
NOTE: When re-assembling, ensure that there are 28
needle rollers per planetary gear (5). Hold the needle
rollers in place with grease (NL GI 2).
NOTE: When re-fitting the securing bolt (1), tighten it
to a torque of 79 Nm.
BRAKE
HINWEIS: Before disassembling the brake, the planetary gear unit must be removed (see page 15)
Disassembly
STEP 1 STEP 4
13
SD04M001
SD04M004
16
SD04M002 20
Remove the pressure plate (2) and the lining disk (3).
STEP 3
SD02A010
Remove the ’O’ rings (20). Remove the centre pins (16)
using a mandrel.
8
SD04M003
STEP 6 STEP 9
21 12
SD02A011 SD02A014
Remove the circlip (21). Remove the circlip (12) and the pressure plate (5).
STEP 7 STEP 10
18 22
SD02A016
SD02A012
13
SD02A013
STEP 11 STEP 12
7 24
9
10
11
SD02A017
SD02A015
Remove the clamping sleeve for automatic brake
Remove the sealing rings (9 and 11) and the support adjustment (24).
rings (7 and 10) from the inside and outside piston
seal. Check the piston for damage and replace as re- NOTE: Check the sealing surface of the ring-shaped
quired. Replace the sealing rings support rings. brake cylinder in the support frame carrier for scoring
and wear and replace the support frame carrier if
necessary.
5
4
3
18
19
17
2 15
20
14
1
13 21
12
22
11
10
9
7
6
23
24
25
16
SS04M023
Assembly
STEP 1 STEP 4
SD01M129 SD02A020
Prefit the centring bushes in the ring gear carrier. Lea- Oil the piston sealing ring (6). Press the piston manu-
ve two bushes on opposite sides protruding slightly for ally and parallel into the support frame carrier (cylin-
subsequent assembly. der) until the sealing rings are slipped on. Then press
the piston fully in using a suitable assembly tool.
STEP 2
STEP 5
24 24
5
24
SD02A019
10
11
SD02A015
STEP 6 STEP 8
13
21
20
SD02A022
SD02A010
Align the support frame carrier (13) to the pressure pla-
te and mount onto the internal geared wheel. Fit the Grease the new ’O’ rings (20) and insert into the
circlip (21). support frame carrier.
SD01M133
Fit the ring gear carrier on the knuckle housing and use
SD02A023
two screws to screw down onto the bushes protruding
Insert the springs (14) and sleeves (15) into the support inwards.
frame carrier. Mount the pressure plate (5) onto the STEP 10
support frame carrier using fixing screws (18) and
washers (17).
Tightening torque .......................................... 10 Nm
Insert the remaining three sleeves (25) into the holes
with the clamping sleeves (24). Insert the fixing screws
(22) with the washers (23) and tighten them.
Tightening torque .......................................... 10 Nm
SD01M134
SD04M002
Mount the lining disk (3) and the pressure plate (2).
IMPORTANT: Fit the pressure plate with the free
location pointing towards the planetary gear.
STEP 13
SD04M001
WHEEL HUB
Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly.
The following work must be carried out prior to disassembling the wheel hub:
• Remove the planetary gear unit, refer to page 15.
STEP 1
Remove the securing bolts (8). Fit two of the securing
bolts to the threaded holes (A) in the crown gear
carrier (9). Tighten the bolts evenly to loosen the crown
ring carrier.
NOTE: When re-fitting the securing bolts (8), tighten
them to a torque of 220 Nm.
13
11 12
15
10
A 14
STEP 2 STEP 4
Use a soft-faced hammer to loosen the wheel hub from 14
the bearings Remove the outer bearing (10), the wheel
hub (11) and the inner bearing (12).
STEP 3
15
13
DI99E120
Alignment
Wheel hub alignment is based on extremely small
tolerances and does not therefore require adjustment.
DI99D052 Before fitting, check that components dimensions are
within tolerance. Parts which are out of tolerance must
be replaced.
380000042
SD00C015
SS00B186
A = 17.950 - 18.000 mm
B = 64.275 - 64.325 mm
C = 23.070 - 23.172 mm
5
11
13
12
10
1
16
7 3
2
15
14
DI99E116
6
2
9
10
SEE NOTE 1
11 7
12
3
DS99D051
*1) NOTE: Check the sleeves in the king pin housing for wear or damage. To carry out work on the sleeves, refer to
STEP 15 on page 30.
STEP 1 STEP 6
Loosen the nut (1). Remove the ball head connection
(2) from the pivot bearing housing (7) using the appro- 11
priate tools.
NOTE: When reassembling, fit a new nut (1) and
tighten it to a torque of 220 Nm.
STEP 2
Remove the king pin securing bolt (3) and the king
pin (4).
STEP 3 12
SS05C421
If the planetary gear unit and wheel hub are still fitted,
support the pivot bearing housing (7) with suitable
lifting gear.
STEP 4
Remove the upper king pin securing bolt (5) and the
king pin (6).
NOTE: When reassembling, grease the king pins (4),
(6) with NL GI 2 grease. Tighten the king pin securing
bolts (3) and (5) to a torque of 190 Nm.
STEP 5
Remove the pivot bearing housing (7) from the king pin
housing. Remove the disk springs (8) and (9) and thrust DD99K189
washer (10). Mark the disk springs for reassembly. Remove the shaft sealing ring (11) from the pivot
bearing housing (7) and dispose of it. Check the sleeve
NOTE: When reassembling, fill the bearing bushes in
(12) for wear or damage and replace as necessary.
the king pin housing with grease (NL GI 2). Fit the
thrust washer (10) with the grooved side up. Fit the NOTE: When assembling, use a new bush (12) and a
disk springs (8) and (9) with the concave side towards new shaft seal (11). Insert bush (12) with tool
the king pin housing (7) (refer to page 36). 380000024. Then insert shaft seal (11) with tool
380000032. Ensure that the sealing lip faces the bush
NOTE: Re-fit parts in the same manner but in the
(12).
reverse order. If the planetary gear unit and the wheel
hub are still fitted, ensure that the teeth on the drive
shaft are seated correctly in the planetary gear unit.
IMPORTANT: If work is only to be carried out on the differential, carry out STEP 1 and STEP 2. Then carry out
STEP 7 to STEP 14 to remove the planetary gear housing, the wheel hub, the pivot bearing housing and the king pin
housing as one unit.
IMPORTANT: For reassembly, the king pin housing must be fully reassembled before the torsion bars are adjusted,
refer to page 48.
STEP 1 STEP 3
Remove the lower king pin securing bolt (3) and the
king pin (6).
STEP 4
If the planetary gear unit and wheel hub are still fitted,
support the pivot bearing housing (7) with suitable lifting
gear.
STEP 5
Remove the upper king pin securing bolt (5) and the
king pin (6).
SD00B030
NOTE: When reassembling, grease the king pins (4),
Jack the front end of the tractor up and lower the centre (6) with NL GI 2 grease. Tighten the king pin securing
of the axle onto suitable support trestles. Do NOT place bolts (3) and (5) to a torque of 190 Nm.
the trestles under the swinging arms. Loosen the front
wheel nuts and remove the front wheels
STEP 6
NOTE: When re-fitting the front wheels, tighten the
Remove the pivot bearing housing (7) from the king pin
nuts to a torque of 570 Nm.
housing. Remove the disk springs (8) and (9) and thrust
washer (10). Mark the disk springs for reassembly.
STEP 2
NOTE: When reassembling, fill the bearing bushes in
Loosen the nut (1). Separate the ball head connection the king pin housing with grease (NL GI 2). Fit the
using the appropriate tools. Remove the nut and the thrust washer (10) with the grooved side up. Fit the
ball head from the pivot bearing housing (7). disk springs (8) and (9) with the concave side towards
NOTE: When reassembling, fit a new nut (1) and the king pin housing (7) (refer to page 36).
tighten it to a torque of 220 Nm. NOTE: If the planetary gear unit and the wheel hub
are still fitted, ensure that the teeth on the drive shaft
are seated correctly in the planetary gear unit.
2
6
9
10
8
Tightening torque = 190 Nm
4
3
DR99D058
STEP 7 STEP 14
Remove the securing bolts (11) and sleeves (12). Remove the shaft (35) and remove the swinging arm
Loosen the lock nut (14) and turn the adjusting screw (29) from the axle. Remove the ‘O’ rings (36) from the
(13) out as far as it will go. Remove the cover (15) and axle housing and dispose of them. Remove the sealing
the circlip (16). rings (37) and dispose of them (when reassembling, fit
the sealing rings (37) with to sealing lip facing towards
STEP 8 the swinging arm).
If the planetary gear unit and wheel hub and the pivot NOTE: When reassembling, observe the procedure
bearing housing are still fitted, support the pivot bearing for adjusting the torsion bar, refer to page 48.
housing and wheel hub with suitable lifting gear.
STEP 15
STEP 9 Check the sleeve (38) in the king pin housing for wear or
Remove the cover (17) and the circlip (18) from the damage. If it is necessary to remove the sleeve, use a
housing (25). Remove the torsion bar (19) with housing blind-hole puller.
(20) and seal (21). Check the pin (22) for wear or
damage and replace as necessary. IMPORTANT: To reassemble, place the sleeve (38) in
a container with dry ice and then insert it into the king
STEP 10 pin housing. Grease the sleeve (38) and fill the hole for
Remove the securing bolts (23) and sleeves (24). the king pin with grease (NL GI 2).
Screw the bolt (23) into the threaded hole in the
housing (25) and pull the housing off. WARNING: Always wear protective gloves,
! to prevent frost-burn, when handling parts
STEP 11 which have been deep frozen. SM118A
Make alignment markings on the bolt (28) and king pin
housing. Loosen the lock nut (26) and remove the
securing bolt (27). Remove the bolt (28) and pivot the
swinging arm (29) downwards. Remove the ’O’ ring 39
from the bolt (28) and dispose of it.
STEP 12
Make alignment markings on the bolt (33) and king pin
housing. Loosen the lock nut (31) and remove the
securing bolt (32). Remove the bolt (33) from the upper
swinging arm. Remove the ‘O’ ring (34) and dispose
of it.
NOTE: When re-assembling, fit new ‘O’ rings (30) and
(34) and apply grease (NL GI 2) to the bolts (28) and
(33). Ensure that the markings on the bolts are aligned DI96K287
to those on the housing. Tighten the securing bolts
(27) and (32) to a torque of 135 Nm. Tighten the lock Check the bearing (39) on the lower king pin for wear or
nuts (26) and (31) to a torque of 70 Nm. damage. A hydraulic press must be used, if it is
necessary to remove the bearing.
STEP 13 NOTE: To reassemble, place the bearing’s inner ring
Remove the king pin housing from the axle. When (38) in a container with dry ice and then insert it into
disassembling, the hydraulic cylinder piston will come the king pin housing. Grease the bearing (38) and fill
completely out of the cylinder. Catch the piston and
the hole for the king pin with grease (NL GI 2).
inner drive shaft when disassembling.
NOTE: When reassembling, ensure that the hydraulic WARNING: Always wear protective gloves,
piston is inserted into the cylinder correctly. Ensure ! to prevent frost-burn, when handling parts
that the teeth on the inner drive shaft mesh correctly which have been deep frozen. SM118A
with the differential.
STEP 16
Check the washers (40) and sleeves (41) at the bearings NOTE: Re-fit parts the king pin housing the same
for the upper and lower swinging arms for wear and manner but in the reverse order.
damage and replace as necessary.
NOTE: Use the special tool 380001921 to insert new
sleeves. Fit new washers (40) and fill the sleeves (41)
with grease (NL GI 2).
Tightening torque = 70 Nm
34
31 40
33
41
38
41 32
40 39
LOCTITE 518
LOCTITE 510 26
37 17 27
25 18
36
35 23
13 LOCTITE 542
14
19
12
24
30
29
22 28
21
11 20
16
LOCTITE 542 15
LOCTITE 510
SS00B185
11. SECURING BOLT 19. TORSION BAR 27. SECURING BOLT 35. SHAFT
12. SLEEVE 20. HOUSING 28. BOLT 36. ’O’ RING
13. ADJUSTING SCREW 21. SEALING RING 29. LOWER SWINGING ARM 37. SEALING RING
14. LOCK NUT 22. PIN 30. ’O’ RING 38. SLEEVE
15. COVER 23. SECURING BOLT 31. LOCK NUT 39. BEARING
16. CIRCLIP 24. SLEEVE 32. SECURING BOLT 40. WASHER
17. COVER 25. HOUSING 33. BOLT 41. SLEEVE
18. CIRCLIP 26. LOCK NUT 34. ’O’ RING
STEP 17 STEP 20
Remove the inner drive shaft from the king pin housing. Remove the ‘O’ ring (47) and dispose of it. Remove the
Remove the ‘O’ ring (42) and dispose of it. Ensure that outer needle bearing (49) and the cartridge sealing ring
the circlip (43) remains seated on the inner drive shaft. (50) from the drive shaft, using a standard puller.
STEP 18 STEP 21
Remove the inner bearing ring from the needle bearing
(53), the spacer ring (51) and the cartridge sealing ring
(52), using an inside puller. Remove the outer bearing
ring from the needle bearing (53) using an inside puller.
Remove the shim rings (54) and the circlip (55).
380000038 Remove the outer bearing ring from the needle bearing
(49).
STEP 22
Clean all component parts in a cleaning solvent and dry
with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
DP99K225
wear or damage and replace as necessary.
Bend the tab on the locking washer (45) back. Use the
socket wrench 380000038 to remove the union nut
(44). Remove the locking washer (45) and dispose of it.
STEP 19
DP99F157
42
44
45
52
51
53
54
49 43
50
46 47
48
55
DS99D053
42. ’O’ RING 47. ’O’ RING 52. CARTRIDGE SEALING RING
43. CIRCLIP 48. SPACER RING 53. INNER BEARING
44. SLOTTED ROUND NUT 49. OUTER BEARING 54. SHIM RINGS
45. LOCKING WASHER 50. CARTRIDGE SEALING RING 55. CIRCLIP
46. DRIVE SHAF’T 51. SPACER RING
Assembly
STEP 23 STEP 25
380000038
46
DD99K191 SD00B034
Select the number of shim rings, so that the total Fill the king pin housing with 32 g of grease (NL GI 2).
thickness of the shim ring package (54) is 0.5 mm. Fit Insert the spacer ring and the needle bearing (53) into
the circlip (55) and push the 0.5 mm shim ring package the king pin housing. Position the king pin housing onto
(54) against the inside of the circlip. To re-insert the a hydraulic press and support the needle bearing (53)
outer bearing rings of needle bearings (49) (53) into the with a pipe (A). Use the hydraulic press to press the
king pin housing, use a hydraulic press and the socket drive shaft carefully into the king pin housing, until it
wrench 380000038. Ensure that the bearing rings are bottoms.
pressed snugly against the circlip and the shim rings.
NOTE: Align the pipe (A) precisely to the bearing (53),
NOTE: Ensure that the correct number of shim rings so that the thread on the drive shaft (46) will not be
(54) are fitted. Shim rings are available in a sizes of damaged when it is being pressed in!
0.05 mm, 0.10 mm and 0.30 mm.
STEP 26
STEP 24
380000506
380000506
380000025
380000025
52
50
DP99K214
DD99K192
Fit a new ’O’ ring to the drive shaft (46). Push the spacer
Grease the needle bearing with NL GI 2 grease and sleeve (51) into the cartridge sealing ring (52). Fit the
insert it into the king pin housing. Insert the cartridge spacer sleeve (51) and the cartridge sealing ring (52)
sealing ring (50) with sleeve 380000025 into the king pin into the king pin housing, using the sleeve 380000025.
housing.
STEP 27 STEP 28
Fit a new ‘O’ ring (42) and ensure that the circlip (43) is
seated correctly in the groove in the inner drive shaft.
Fit the inner drive shaft into the king pin housing.
380000038
DP99K225
55 54 52
50 51
47
48
46
43 42
44
49 53 45
Tightening torque = 175 Nm
DI99F167
42. ’O’ RING 47. ’O’ RING 52. CARTRIDGE SEALING RING
43. CIRCLIP 48. SPACER RING 53. INNER BEARING
44. SLOTTED ROUND NUT 49. OUTER BEARING 54. SHIM RINGS
45. LOCKING WASHER 50. CARTRIDGE SEALING RING 55. CIRCLIP
46. DRIVE SHAF’T 51. SPACER RING
31 33
32
A 6
9
49 53
10
38
39
52
46
50
8
DI99E117
DRIVE SHAFTS
Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly.
The following work must be done before carrying out work on the drive shafts:
• Remove the pivot bearing housing, see page 26.
NOTE: In order to remove the drive shaft from the pivot bearing housing, the planetary gear unit and the wheel hub
need not be removed.
• Remove the king pin housing, see page 28.
• In order to remove the drive shaft, the king pin housing must be disassembled, see page 32.
6
2
1
5
3
DS99D054
STEP 1 STEP 2
2 2
3 X 3
1
SD00B017 SD00B018
Remove the brackets (2) for the hydraulic lines from the
support frame (1) (left and right).
4
4
SD00B019
STEP 3 STEP 6
8
5 5
SD00B020 SD00B021
Remove the securing bolts (5) and remove the support Loosen the securing bolts (8) and remove the front
frame. mudguard (if fitted).
NOTE: When assembling the screws (5), coat with
243 Loctite and tighten to 200 Nm. STEP 7
STEP 4
NOTE: For tractors fitted with front lifting gear, the
shaft protector for the 4-wheel drive shaft must first be
removed.
Place a hydraulic jack under the centre of the axle and
raise the tractor. Lower the front of the tractor onto
suitable support trestles and remove the front wheels.
NOTE: When re-fitting the front wheels, tighten the 10
nuts to a torque of 570 Nm. 9
STEP 5 SD00B022
SS00B171
STEP 8 STEP 11
12 15
11
SD00B023 SD00B026
STEP 9
13 16
SD00B027
Place a hydraulic jack under the centre of the front axle.
Loosen the front and rear bearing block securing
bolts (15 and 16).
NOTE: The rear bearing block is fitted with two
SD00B024 sleeves (see page 41).
Mark the connectors (13) (both sides) and disconnect NOTE: For reassembly, lightly coat the securing
them. bolts (15 and 16) with LOCTITE 243 and tighten them
to a torque of 540 Nm.
STEP 10
STEP 12
14
SD00B025
NOTE: When re-assembling, ensure that the NOTE: Lower the front axle by means of the hydraulic
intermediate ring (14) is positioned correctly. jack and remove the jack.
PIVOTED BEARING
Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly. Clean all component parts in a cleaning solvent and dry with compressed air (wear a FACE MASK).
Check all component parts for wear or damage and replace as necessary.
NOTE: If the sleeves (2 and 6) are replaced, ensure correct alignment of the grease access hole when
reassembling.
1
2
A 3
4
11
10
12
9
8
7
10 11 6
SS00B171
8. FRONT BEARING BLOCK 12. REAR BEARING BLOCK 16. THRUST WASHER
9. SLEEVE 13. SLEEVE 17. GREASE NIPPLE
10. SLEEVE 14. ’O’ RING 18. SCREW-IN SUPPORT
11. THRUST WASHER 15. SLEEVE 19. SLEEVE
SWINGING ARMS
Disassembly
NOTE: The parts are numbered in order of disassembly.
Before work can be carried out on the differential, the following preparatory work must be carried out:
• Remove the king pin housing as a complete unit together with the planetary gear unit, the wheel hub and pivot
bearing housing. Remove the king pin housing as a complete unit together. To do this, proceed in accordance with
STEP 7 to STEP 15 on page 30.
STEP 13 STEP 16
Make alignment markings on the potentiometer (2) and Remove the sealing ring (16), sleeves (16) and (17)
the upper swinging arm (9). Loosen the securing from the upper and lower swinging arms (9) and (20).
screws (1) and remove the potentiometer from the axle. Remove the sealing ring (18), sleeves (19) from the
Remove the washers (3) and the rubber disk (4). upper and lower swinging arms (9) and (20).
STEP 14 STEP 17
Make alignment markings on the bolt (8) and axle Inspect the washers (22) and sleeves (23) in the axle
housing. Loosen the lock nut (5) and remove the housing for wear or damage and replace as necessary.
securing bolt (6). Remove the bolt and the upper To replace sleeves and sealing rings, refer to the proce-
swinging arm (9) from the axle. Remove the 'O' ring dure for reassembly on page 44.
(10) from the bolt (8) and dispose of it.
STEP 15
Remove the circlip (11), the washer (12), the hydraulic
cylinder (13) and the thrust washer (14) from the bolt
(15).
12 11
14
15
13
6
2 1
22
4 3
23 17
16
18
19
10
17
23
22
8
21
10 9
16
17
18
19
20
16
17
SS00B057
Assembly
STEP 1 STEP 4
23
12
11
380000506 380001921
DP99K220 DP99F113
Fit new bearing sleeves (23) (both sides), using special Fit the washer (12) and the circlip (11).
tool 380001921.
STEP 5
STEP 2
22
380001920
380000027
17
DP99K217
DP99K221
Fit new sleeves (17) to the upper and lower swinging
Fit new washers (22). Grease the sleeves (22) and arms, using special tool 380000027 and the grip
washers (23) with NL GI 2 grease. 380001920. Fill the sleeves with grease (NL GI 2).
STEP 3 STEP 6
14
16
13
DP99F114 DK99D063
Fit the thrust washer (14), with the chamfered side to- Fit new sealing rings (16) and make sure that the
wards the housing and fit the hydraulic cylinder (13). sealing lips are facing towards the axle housing.
STEP 7 STEP 8
18
380000506
19
380001922
DP99K223 DK99D065
Fit the circlips (18) and make sure that they are seated
A correctly in the grooves.
STEP 9
6 5 9
19
17
DI99E118
8
Fit new sleeves (19) in the upper and lower swinging 10
arms, using special tool 380001922. Make sure that the
graduated surface of the sleeve faces the sleeve (17). DP99F147
NOTE: The sleeves must be fitted at a depth (A) of Fit new ’O’ rings at both ends of the bolt (8). Grease the
8.6 mm for the inner bolt and 3.6 mm for the outer bolt. bolt with grease (NL GI 2) and fit it into the upper swin-
Make sure that the correct side of the special tool ging arm. Make sure that the alignment markings on the
380001922 is used for reassembly. bolt (8) and the housing coincide. Fit the securing bolt
(6) with lock nut (5) and tighten to a torque of 135 Nm.
Tighten the locking nut (5) to a torque of 70 Nm.
STEP 10 STEP 13
B
36
37
DP99F109 DK99D067
Fit the rubber disk (4). Make sure that the tab (B) he Fit new ‘O’ rings (item 36, page 31) in the lower seat of
rubber disk meshes into the bolt and that the marking the swinging arm. Fit new sealing rings (item 37,
"OUTSIDE" is facing outwards. page 31) and make sure that the sealing lips are facing
towards the swinging arm.
STEP 11
STEP 14
380001920
3 380000029
21
DP99F111
Fit the washer (3) and the potentiometer (2). Make sure DR99K222
that the flat side of the potentiometer is seated correctly in Fit new sleeves (21) to the lower securing arm, using a
the rubber disk and that the alignemt marking is correctly
hydraulic press and special tool 380000029. Fill the
aligned to the swinging arm.
sleeves with grease (NL GI 2).
STEP 12
DP99F112
STEP 15
A
B
C
DP99K224
Grease the shaft (C) with grease (NL GI 2). Fit the
swinging arm and the shaft (C). Make sure that the
groves (A) in the shaft (C) are aligned vertically and are
on the same side as the pinion shaft (B).
NOTE: In order to fit the pivot bearing housing, the
wheel hub and the planetary gear unit, carry out
STEP 7 to STEP 14 (page 30) in the reverse order.
STEP 16
Fit the torsion bars and adjust them, refer to "Adjusting
the Torsion Bars" on page 48.
STEP 1 STEP 3
21
22 20
SD00B037 DK99D125
Clean the flange surfaces and place a continuous line Insert the pins (22) and sealing rings (21) into the
of LOCTITE 518 around the hole in the lower swinging housing (20) Ensure that the sealing lip is towards the
arm. swinging arm.
STEP 2 STEP 4
25
23
SX 19 19 DX
SD00B038 SD00B039
Fit the housing (25) with the centring sleeves. Lightly Connect a suitable lifting device to the pivot bearing
coat the securing screws (23) with LOCTITE 542 and housing and raise the suspension to the upper limit.
tighten the securing screws to a torque of 95 Nm. Support the suspension in the raised position, using
suitable support trestles.
Fit the torsion bar (19). Make sure, that the end of the
torsion bar with the punched marking is at the same
side as the pinion shaft. To differentiate between torsion
bars for the left and right-hand side of the axle, they are
punch marked as follows:
SX .............................................. Left-hand torsion bar
DX ........................................... Right-hand torsion bar
STEP 5 STEP 7
11
18
12
19
20
DP99K232 SD00B040
Fit the housing (20). Align the pins in the housing (20) Fit the circlip (18). Fit the torsion bar (19) completely.
to the grooves in the shaft of the lower securing arm Fit
NOTE: If necessary, lower the suspension in order to
the sleeves (12) and securing bolts (11) loosely, using
align the teeth on the torsion bar with the grooves in
LOCTITE 542.
the housing (20).
STEP 6 STEP 8
11
13
DP99K227
DP99K208
Turn the left-hand housing in an anti-clockwise
Turn the adjusting screw (13) in, till it seats on the axle
direction, so that the securing bolts (11) can be
housing. Turn the adjusting screw in 6 turns, in order to
aligned to the right-hand side of the slit.
achieve the correct pre-tension of the torsion bar.
Turn the left-hand housing in a clockwise direction, so
NOTE: During this procedure, the housing (20) turns
that the securing bolts (11) can be aligned to the right-
to pre-tension the torsion bar (19). If the adjusting
hand side of the slit.
screw (13) is difficult to turn, make sure that the
screws (11), which were fitted during STEP 5, are not
over-tightened.
STEP 9 STEP 11
Repeat STEP 1 to STEP 10 to fit the other torsion bar.
11
STEP 12
Fit the 4-wheel axle in the reverse sequence to that
used to remove it (see page 38).
14
STEP 13
Adjust the potentiometer and calibrate the axle. See
"Adjusting the Potentiometer" and "Axle Calibration" in
chapter 5001 – FUNCTIONAL DESCRIPTION; ADJU-
STMENTS AND TROUBLESHOOTING INDEPEN-
DP99K209 DENTLY SUSPENDED FRONT AXLE.
Tighten the locking nut (14) to a torque of 45 Nm.
Tighten the securing screws (11) to a torque of 169 Nm.
STEP 10
16
15
DP99K210
Fit the circlip (16) and the cover (15 and 17) (both
ends).
NOTE: Clean the sealing faces of the covers (15 and
17) and apply LOCTITE 510.
AXLE HOUSING
Disassembly STEP 3
NOTE: The parts are numbered in order of disassem-
bly. When re-assembling, the position of the pinion
shaft must be set precisely. See "Adjusting the Pinion
Shaft" on page 58.
STEP 1
2
SD00B004
7 5
SD00B002
6
Remove the securing screws (1) and remove the front
housing cover (2).
STEP 2
SD00B005
STEP 4
SD00B003
10
SD00B006
Remove the circlip (8), spacer ring (9) and the spring
(10).
STEP 5 STEP 7
380000037
11
SD00B007 DP99F152
13 15 STEP 8
12
Mark the position of the differential unit (24) with
14 respect to the axle housing (A) for later alignment.
Remove the screws (19) and bearing cover (16).
Remove the differential unit (24) from the differential
housing.
NOTE: Make marks on the differential unit and the
11 axle housing, for correct alignment during reassembly.
SD00B008
Remove the circlip (11). Remove the shaft (12), the shift STEP 9
fork (13), the spring (15), the washer (14) and the
circlip (11).
STEP 6
26
A
25
SD00B009
16 Remove the shift ring (25) and the four locking pins (26)
from the differential unit.
SD00B041 STEP 10
Make alignment markings on both the bearing cover Remove the securing screws (27) and remove the
(16) and the differential housing (A). Remove the flange (28) from the pinion shaft. Remove the sealing
locking screws (17). Loosen the screw (19). cover (29). Remove the shaft sealing ring (31) and
'O' ring (30) from the sealing cover (29) and dispose of
them.
1 19
2 4 3 17 21
7
6
5
8
9 16
10
20
12 22
11 23
26
13
19 17
14
15 16
25
21
24
20
34 23
22
39
38
36
37
36
35
33
32
31
30
29
28
A
27
SS00B063
1. SECURING BOLT 11. CIRCLIP 22. SEALING RING 32. SLOTTED ROUND NUT
2. HOUSING COVER 12. SHAFT 23. SLEEVE 33. WASHER
3. SECURING BOLT 13. SHIFT FORK 24. DIFFERENTIAL UNIT 34. PINION SHAFT
4. CYLINDER 14. WASHER 25. SHIFT RING 35. BEARING
5. PISTON 15. SPRING 26. LOCKING PINS 36. WASHER
6. ‘O’ RING 16. BEARING COVER 27. SECURING BOLT 37. SPRING COLLET
7. ‘O’ RING 17. LOCKING SCREW 28. FLANGE 38. BEARING
8. CIRCLIP 19. SECURING BOLT 29. SEALING COVER 39. PACKING RING
9. SPACER RING 20. CLAMPING RING 30. ‘O’ RING
10. SPRING 21. ‘O’ RING 31. SHAFT SEAL
STEP 11 STEP 13
Unlock the slotted round nut (32) and put the socket
wrench 380000021 on it. Fit the rod 380000020 to the
input flange (28), using 2 bolts, in order to block the
pinion shaft. Remove the union nut (32) and locking
washer (33) and dispose of them.
STEP 12 38
34
SD00B010
1 19
2 4 3 17 21
7
6
5
8
9 16
10
20
12 22
11 23
26
13
19 17
14
15 16
25
21
24
20
34 23
22
39
38
36
37
36
35
33
32
31
30
29
28
A
27
SS00B063
1. SECURING BOLT 11. CIRCLIP 22. SEALING RING 32. SLOTTED ROUND NUT
2. HOUSING COVER 12. SHAFT 23. SLEEVE 33. WASHER
3. SECURING BOLT 13. SHIFT FORK 24. DIFFERENTIAL UNIT 34. PINION SHAFT
4. CYLINDER 14. WASHER 25. SHIFT RING 35. BEARING
5. PISTON 15. SPRING 26. LOCKING PINS 36. WASHER
6. ‘O’ RING 16. BEARING COVER 27. SECURING BOLT 37. SPRING COLLET
7. ‘O’ RING 17. LOCKING SCREW 28. FLANGE 38. BEARING
8. CIRCLIP 19. SECURING BOLT 29. SEALING COVER 39. PACKING RING
9. SPACER RING 20. CLAMPING RING 30. 'O' RING
10. SPRING 21. ‘O’ RING 31. SHAFT SEAL
DIFFERENTIAL UNIT
Disassembly STEP 20
NOTE: Make alignment markings on the housing
sections for later re-assembly.
9
STEP 14
Remove the securing bolts (3) and differential master
gear (4). 7
STEP 15
Remove the bearing (5) from the differential housing.
STEP 16
SD00B013
STEP 18
Clean all component parts in a cleaning solvent and dry
with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
wear or damage and replace as necessary.
Assembly SD00B011
SD00B012
Fit the axle bevel gear (8) and the thrust washer (7).
1
2
10
11
5
6 12 R
Tightening torque = 95 Nm 2
4
3 7
9
11
10
LOCTITE 270 7 8
L
5
SS00B080
STEP 23 STEP 24
2
2
4
SD00B014 SD00B015
Position housing section (L) on housing section (R) and Fit the locking pin (2) into the differential housing and
align them to the markings. Fit the differential master push the shift ring (1) on.
gear (4). Fit the securing bolts (3) with LOCTITE 270
NOTE: To fit the differential unit, see page 62.
and tighten them to a torque of 95 Nm.
STEP 2
Assemble the alignment adapter 380001919 (4) and the
measurement cylinder 380001918 (5) with the screw 10
380002421 (6).
STEP 3
5
DP99F159
STEP 6
To determine the shim thickness for correct adjustment
of the pinion shaft, proceed as follows:
9 A +B=C
C – D = X (shim thickness required)
DP99F161
A = Measurement constant 110.04 mm – calculated
Fit the inner bearing ring (8), using the special tool from:
assembled in STEP 2. Fit the inner bearing ring (7) and fit “r” differential bearing (45,00 mm) + length of the
the grip (9) 380002420. Hand tighten the grip (9) until the measurement cylinder (5) (65.04 mm)
bearings (7) and (8) can only be turned with difficulty.
B = dimension measured in STEP 5
NOTE: Turn the grip, so that the bearings are aligned C = Housing dimension (measured with pinion shaft
to the bearing rings. bearing)
D = Pinion dimension (etched into the end of the pinion
STEP 4 shaft)
10 X = Shim
Example:
A = ............................................................ 110.04 mm
B = ............................................................ +0.25 mm
C = ............................................................ 110.29 mm
C = ............................................................ 110.29 mm
11 D = ........................................................... -107.25 mm
X = ............................................................ 3.04 mm
266 Nm
12
11
380001925
10 3
380001918
380002421
6
2
4
380001919
8
9
380002420
SS00B083
STEP 8
Fit the shim (1), the size which was calculated in
STEP 6 to the pinion shaft (6), making sure that the
chamfered side of the shim faces the pinion wheel.
STEP 9
Heat the bearing (2) to 90° C in a bearing heater and fit
it to the pinion shaft.
6
NOTE: Make sure that the bearing is in contact with
SD00B043
the shim (1).
Tie a piece of string to the pinion shaft (6) and wind the
string, without overlapping it, around the pinion shaft.
WARNING: Always wear protective gloves,
Tie a spring balance to the end of the string and mea-
! to prevent burns, when handling parts which
have been heated. SM121A
sure the rolling resistance.
Tighten the slotted round nut, until the rolling resistance
STEP 10 is between 92 and 137 N.
Fit a new washer (3), a new spring collet (4) and a new NOTE: If the slotted round nut is overtightened and
washer (5) to the pinion shaft (6). Fit the pinion shaft (6) the rolling resistance is still out of tolerance, the spring
into the axle housing. collet (4) must be replaced (refer to STEP 11 and
STEP 12 on page 54).
STEP 11
Heat the bearing (7) to 90° C in a bearing heater and fit STEP 14
it to the pinion shaft or into the axle housing repsective- Lock the slotted round nut (9) with a suitable pin in the
ly. Fir a new washer (8) and a new slotted round nut (9) groove in the pinion shaft (6).
to the pinion shaft (6).
STEP 12
B
A
SD00B044
3
4
6 5
1
2
7
8
9
SS00B086
1. SHIM 7. BEARING
2. BEARING 8. WASHER
3. WASHER 9. SLOTTED ROUND NUT
4. SPRING COLLET A. FLANGE
5. WASHER
6. PINION SHAFT
A 380000037
B
DP99K233 SD00C005
Fit the sleeve to the wrench 380000037. Press the new Fit the bearing cover (5) and make sure to align the
sleeves (1) into the clamping ring (7) using a hydraulic markings.
press.
STEP 19
NOTE: When pressing the sleeves in, make sure that
the pins (A) on the wrench 380000037 are aligned cor- Hand tighten the bolts (6) evenly.
rectly to the holes (B) in the clamping ring. IMPORTANT: Before finally tightening the bolts (6),
make sure that there is freedom of travel between the
STEP 16 differential master gear and the pinion.
STEP 20
A 380000037 380000037
B
DP99K228
STEP 17
Fit the differential unit (4) into the axle housing (A) and
make sure that the alignment markings coincide.
266 Nm 6 3
2
5 1
7
7
1
2
3
DI99G016
STEP 21 STEP 24
In order to reduce the tooth flank play, the clamping ring
on the crown wheel side of the differential must be
380000037 turned in a clockwise direction and the clamping ring on
the opposite side of the crown wheel is turned by the
same amount in an anti-clockwise direction.
In order to increase the tooth flank play, the clamping
ring on the crown wheel side of the differential must be
turned in an anti-clockwise direction and the clamping
ring on the opposite side of the crown wheel is turned
by the same amount in a clockwise direction.
Check the tooth flank play and repeat the procedure if
SD00C006
necessary, until the tooth flank play has been adjusted
to within tolerance.
Turn the clamping ring on the crown wheel side of the
differential, using the wrench 380000037, in a clockwi- STEP 25
se direction, until the crown wheel makes contact with
the pinion. Simultaneously tap the bearing covers with Tighten the bolts (6) to a torque of 266 Nm. Check that
a soft-faced hammer, to align the bearings. the tooth flank play is still within tolerance.
STEP 22
Turn the clamping ring at the opposite side of the crown
wheel in a clockwise direction, until there is no play in
the bearings. Simultaneously tap the bearing covers
with a soft-faced hammer, to align the bearings. Play
has been eliminated, when the clamping ring can only
be turned with difficulty.
STEP 23
SD00C007
SD00C008
STEP 29
SD00B043
Tie a piece of string to the pinion shaft and wind the
string, without overlapping it, around the pinion shaft.
Tie a spring balance to the end of the string and mea-
sure the rolling resistance of the pinion wheel.
The rolling resistance must be 20 N to 30 N above the 9
bearing pre-tension, which was measured during
10
STEP 13 on page 60.
If the rolling resistance exceeds the prescribed value,
both clamping rings must be turned, in an anti-
clockwise direction, by the same amount.
If the rolling resistance is below the prescribed value,
both clamping rings must be turned, in a clockwise SD00C009
direction, by the same amount. Clean the surfaces on the cover (9) and on the axle
NOTE: If the clamping rings require adjustment, housing. Apply a continuous line of LOCTITE 518 to the
STEP 23, to check the tooth flank play, must be subse- sealing surfaces. Fit the cover and make sure that the
quently repeated. If the tooth flank play is now out of shift fork (10) engages in the shift ring. Fit the securing
tolerance, loosen the bolts (6) and repeat STEP 24 to bolts with LOCTITE 542 and tighten them to a torque of
STEP 25. 169 Nm.
STEP 30
Press a new sealing ring (12) into the sealing cover
(14). Fit the sealing cover, with a new ’O’ ring (13) into
the axle housing. Fit the flange (15) to the pinion shaft,
using the bolts (16).
12
14
15
16 13
SS00B087
TRACK ALIGNMENT
"A"
Driving direction
"B"
SS02B101
NOTE: Before aligning the track, check that tyre pressures are correct (see Operating Manual).
STEP 1 STEP 7
The front axle must be recalibrated before starting the
track alignment.
(see Chapter 5001) 1
STEP 2
Lower the front axle to the lower limit and then activate
the suspension. Once the axle is in the middle position,
switch 2
off the engine and apply the parking brake.
NOTE: The front wheels must face straight ahead.
STEP 3
Make marks on the rear inside of the wheel rim (rim
flange), at the same height as the centre of the wheel SS00C121
hub.
Loosen the locking nuts (1). Extend or shorten the track
STEP 4 rods by turning the knuckle joints (2). Repeat STEP 2 to
Measure the distance B between these marks and make STEP 6.
a note of it. When the track has been aligned correctly, tighten the
locking nuts (1).
STEP 5
Drive the tractor forwards until the marks at the front are Tightening torque........................................ 250 Nm
level with the centre of the wheel hub.
STEP 6
Measure distance A between the marks and note down.
The track must be set so that value “A“ equals value “B“.
Setting:
Axle in “mid-position“ ...................................... 0±3 mm
NOTE: If the value determined is outside the prescribed
setting, the track alignment must be corrected in
accordance with STEP 7
5007
Front Axle 20.29SI / FR
7$%/(2)&217(176
BRAKE .......................................................................................................................................................... 23
Disassembly ........................................................................................................................................... 23
Assembly ................................................................................................................................................ 26
Bleeding the brakes ............................................................................................................................ 28
SENSORS .....................................................................................................................................................58
Removal ..................................................................................................................................................58
Fitting .......................................................................................................................................................59
Adjusting the Sensors .........................................................................................................................60
DIFFERENTIAL .............................................................................................................................................82
Removal ..................................................................................................................................................82
Removing the Pinion Shaft ......................................................................................................................83
SPECIAL TOOLS
Wrench for left differential nut Measuring disks (meshing adjustment)
SS02A055
SS02A077
380000439
Wrench for bevel pinion, slotted nut
Clamping device (meshing adjustment)
SS02A056
SS02A076
380000021 (CAS 1885A; 1TSW 504)
380000018
NOTE: Dolly 380000020 (CAS 2483) is additionally
required. Insertion tool for cartridge sealing ring,
hub
Insertion tool for cartridge sealing ring,
bevel pinion
SS02A062
SS02A058
380000022
Insertion tool for bush in axle stub Insertion tool for sealing ring in
protective sleeve
SS02A061
SS02A057
380000024
380000443
Insertion tool for sealing ring in axle stub
Insertion tool for needle bearing in
protective sleeve
SS02A063
380000032
SS02A072
SS02A075
380000034
SS02A074
Insertion tool for sealing ring in 380000398
protective sleeve
Wrench for slotted nut, lower
swinging arm
SS02A064
380000444
SS02A070
380000041
Insertion tool for bush in upper Insertion tool for bush in lower
swinging arm swinging arm
SS02A065
SS02A068
380000445
380000447
Insertion tool for sealing ring,
Driver for sealing ring in centering bush
upper swinging arm
SS02A069
380000031 (294216)
SS03D086
380001488
SS03D080
380001512
GENERAL INFORMATION
Using the Manual
Maintenance
• Trouble-free operation of the mechanical components is influenced by regular and correct maintenance.
• The use of qualified personnel during maintenance and repairs guarantees a longer lifetime of the components
and trouble-free operation.
• READ THE MANUAL. Non-observance of recommended worksteps can reduce the lifetime and the durability of
the unit and can result in damage or accidents.
Repairs
The instructions for removal and fitting were drawn up for an overall repair of the axle and constitute the correct order
of the tasks to be performed. Drawings and photos provide personnel with a complete and safe guide through all
worksteps.
A good knowledge of the axle makes it possible to assess the repair, and as a result, it is often the case that only
certain parts have to be removed.
Diagrams
Photos and drawings are NOT to exact scale.
Photos are only intended to clarify the sequence of worksteps.
General Remarks
• The axle should only be repaired by qualified personnel, who are aquainted with all of its technical
characteristics, and under exact observance of the corresponding safety standards.
• The axle must be carefully cleaned before carrying out a repair. Dirt and/or grease must be removed.
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5002).
Switch the engine OFF and remove the ignition key.
• All disassembled parts must be cleaned using a suitable cleaning agent to avoid possible damage.
• Damaged or worn parts must be replaced to avoid possible subsequent damage. In particular, motion and
sealing elements must be checked if they are subject to larger amounts of stress, wear and ageing.
• The renewal of the bevel pinion or differential master gear necessitates the renewal of the entire set.
• Only use original spare parts
‘O’ rings
Grease before installing.
Shims
Always individually measure the shims used.
Bearings
We advise that you warm up the bearing inner rings to 80 °C - 90 °C before assembly. Bearing outer rings should be
cooled down before assembly.
Always use suitable extractors when removing bearings. Always use suitable insertion tools when inserting bearings.
Draining oil
The oil must be drained before removing the planetary train and/or the axle housing.
WARNING: Dispose of old oil according to statutory regulations.
Cleaning
• All moving parts (bearing, gear wheels, shafts) must be cleaned carefully.
• Petrol, water or alkaline solutions should not be used. Do not use steam or hot water as it is difficult to remove
surface dampness.
• Clean all components using an air jet or a cloth to free the surfaces from any remains.
• All surfaces should be covered by a thin layer of oil to protect them from oxidation.
Using lubricants
Only use lubricants which meet the stipulated specifications (see Technical Data, page 12).
Type plate
OVERALL RATIO
CARRARO NUMBER
TYPE OF
DIFFERENTIAL LOCK
DIFFERENTIAL
OIL QUANTITY
DIRECTION OF
ROTATION OF
DRIVE SHAFT
RECOMMENDED
DIFFERENTIAL OIL
TECHNICAL DATA
DIFFERENTIAL
Number of teeth – pinion shaft / diff. master gear ...................................................................................... 13 / 30
Differential transmission ratio ................................................................................................................... 2.307 /1
Pinion shaft initial bearing tension (P)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) ..................................................... P = 92 to 138 N
Total initial bearing tension – pinion bearing and differential (T)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) ................................ T = 92 (+92) to 138 (+107) N
Bevel pinion / differential master gear tooth flank play ................................................................ 0.20 to 0.28 mm
Compensating washer thickness for pinion height .............................. at least 2.5 mm to a maximum of 3.4 mm
PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) .......................................................................... 15.976 / 1
STEERING
Steering angle ........................................................................................................................adjustable up to 50°
DIFFERENTIAL LOCK
Type .............................................................................. Multi-disk lock running in oil bath – 100 % locking value
Activation .................................................................................................................................... electro-hydraulic
Control pressure ......................................................................................................................................... 20 bar
TRACK ALIGNMENT
Axle in mid-position ..................................................................................................................... 0 to 4 mm toe-in
FILLING LEVELS
Planetary drive without brake (each side) .............................................................................................. 1.5 litres
Planetary drive with brake (each side) ................................................................................................... 2.0 litres
Differential ............................................................................................................................................... 5.5 litres
SS03D055
/RFWLWH
Tightening Torques
SS04C056
SS03D058
Dimensions 20.29 SI
SS01M136
Dimensions6,)5
SS03D056
GENERAL NOTES
127( The all-wheel drive axle must not be removed for work on the following components:
• Planetary drive
• Brakes, when equipped (see page 23)
• Wheel hub (see page 30)
• Torsion bar (see page 34)
• King pin housing (see page 41)
• Drive shaft (see page 51)
• Swinging arm (see page 61)
• Hydraulic cylinder (see page 49)
• Steering cylinder (see page 71)
PLANETARY DRIVE
127( The following points must be observed prior to removing the planetary gear unit:
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5002).
Switch the engine OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
• Loosen the front wheel nuts. Place a jack under the centre of the front axle, raise the tractor and lower it onto
suitable front axle support trestles. Remove the front wheels.
Disassembly
STEP 1 STEP 3
2 3
SD01M023
SD01M026
Before dismantling, discharge the oil through the Remove the planetary gear carrier (item 3).
drain/filler plugs (item 1) into a suitable container.
Remove the two countersunk screws (item 2). STEP 4
STEP 2
17
SD01M027
SD01M025 Remove the ‘O’ ring (item 17) from the wheel hub.
Tap the planetary gear carrier surface with a soft- 127( Before assembling, replace the ’O’ ring.
faced hammer.
STEP 5 STEP 8
10
SD01M031
SD01M029
SS01M015
Remove both discs (items 7 and 9).
STEP 7 If one or more bearing journal, or the thrust washer of
the drive shaft is damaged then the entire planetary
gear (item 3) must be replaced.
SD01M030
3A 10
9
7
5
4
3
1
2 SS01M138
Assembly
STEP 1 Attach both washers (items 7 and 9).
127( Align the hole X in the washer (item 7) onto
the pin.
4 STEP 5
SD01M135
SD01M136
SD01M140
Attach a new ‘O’ ring (item 17) onto the wheel hub.
Place the planet carrier onto the wheel hub and
tighten it using countersink screws (item 2).
Tightening torque ..........................................25 Nm
127( Secure the countersink screws (item 2) with
Loctite 542.
If new wheel bolts are mounted in the wheel hub then
SD01M137
these should be secured using Loctite 270.
Mount the planetary gears (item 6) onto the bearing Tightening torque ..........................................70 Nm
journal of the planetary carrier.
STEP 7
STEP 4
Turn the wheel hub so that the drain/level plug (item 1)
9 is positioned horizontally to the centre of the axle. Fill
up the wheel hub to its prescribed level using the
X correct oil (see the Technical Specifications on page
12). Screw in the plugs (item 1, step 60) together with
the 'O' ring and tighten to a torque of 60 Nm.
SD01M138
BRAKE
127( Before disassembling the brake, the planetary gear unit must be removed (see page 19).
Disassembly
STEP 1 STEP 4
260
12
SD02A005 SD02A008
Remove the circlip (item 260). Remove all securing bolts (item 12) from the support
STEP 2 frame carrier.
262 STEP 5
271
261
SD02A006
SD02A009
Remove the pressure plate (item 261) and the lining
disk (item 262). Disconnect the support frame carrier (item 271) using
the three screws (M10x60) and then remove it.
STEP 3
127( When removing using the screws, burrs may
occur at the kingpin housing. Remove the burrs using
filers.
6''
STEP 6 STEP 9
13
277
271
SD02A010 SD02A013
Remove the ’O’ rings (item 277). Remove the centre Remove the support frame carrier (item 271).
pins (item 13) using a mandrel.
STEP 10
STEP 7
270
278
264
SD02A014
SD02A011
Remove the circlip (item 270) and the pressure plate
Remove the circlip (item 278). (item 264).
STEP 8 STEP 11
275 279
265
SD02A016
SD02A012
Remove the piston (item 265) from the support frame
Loosen the securing screws (items 275 and 279).
carrier.
Remove the washers, springs and sleeves.
127( To dismount the piston, mount two screws
127( Mark the position of the support frame carrier
(M4) into the existing thread. Using a levering tool
to the pressure plate.
and a suitable surface, press out the piston evenly.
STEP 12 STEP 13
266 281
267
268
269
SD02A017
SD02A015
Remove the clamping sleeve for automatic brake
Remove the sealing rings (items 267 and 269) and the adjustment (item 281).
support rings (items 266 and 268) from the inside and
outside piston seal. Check the piston for damage and 127( Check the sealing surface of the ring-shaped
replace as required. Replace the sealing rings support brake cylinder in the support frame carrier for scoring
rings. and wear and replace the support frame carrier if
necessary.
264
263
262
275
276
274
261 273
277
272
260
271 278
270
279
269
268
267
266
265
280
282
281
SS02A033
Assembly
STEP 1 STEP 4
Premount the centre pins into the support frame
carrier. (see step 4, page 32)
STEP 2
281 281
265
281
SD02A020
Oil the piston sealing ring (item 265). Press the piston
manually and parallel into the support frame carrier
SD02A019
(cylinder) until the sealing rings are slipped on. Then
Mount the clamping sleeves (item 281) into the press the piston fully in using a suitable assembly tool.
support frame carrier with the bevel towards the brake
disc. STEP 5
127( The clamping sleeves must be mounted flush 264
to the support frame carrier.
STEP 3
266
267
268
SD02A021
269
Mount the pressure plate (item 264) onto the internal
geared wheel. Fit the circlip (item 270).
SD02A015 ,03257$17 Fit the pressure plate with the free
location pointing towards the support frame carrier.
Fit new support rings (items 266 and 268) and sealing
rings (items 267 and 269) for the inside and outside pi-
ston seals.
127( Observe the correct mounting position!
Mount the support rings facing towards the brake
disc.
STEP 6 STEP 8
271 271
278
277
SD02A022
SD02A010
Align the support frame carrier (item 271) to the
pressure plate and mount onto the internal geared Grease the new ’O’ rings (item 277) and insert into the
wheel. Fit the circlip (item 278). support frame carrier.
SD02A023
STEP 11 STEP 13
262 Mount the planetary gear unit. (see page 19)
260
SD02A005
WHEEL HUB
127( The following work must be carried out prior to disassembling the wheel hub:
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
Disassembly
STEP 1 STEP 4
14
6''
Move the drive shaft in the direction of the sun gear. SD01M035
Remove the circlip (item 90). Remove the thrust was- Remove the support frame carrier (item 14).
hers (items 91 and 92).
STEP 5
STEP 2
15
13
12
SD01M033 SD01M036
Loosen all the securing screws (item 12) of the Place the support frame carrier onto a workbench and
support frame carrier. drive out the centre pins (item 13) using a suitable
mandrel.
STEP 3
Remove the circlip (item 15) and the support frame
carrier.
STEP 6
14
SD01M034
STEP 7
21
SD01M038
$
SS03D059
Assembly
Adjusting the wheel bearing STEP 3
The components of the wheel hub alignment are
based on extremely small tolerances and therefore
require no adjustment. Before fitting, check that 20
components’ dimensions are within tolerance. Parts
which are out of tolerance must be replaced.
SD01M128
Slide the inner ring of the bearing onto the king pin
housing.
STEP 4
SS01M131
13
A = 17.950 - 18.000 mm
B = 64.275 - 64.325 mm
C = 23.070 - 23.172 mm
STEP 1
13
SD01M129
SD01M126 STEP 5
Drive the outer rings of the tapered roller bearings into
the wheel hub using a suitable insertion tool.
STEP 2
15
SS01M130
SD01M127
STEP 6 STEP 9
16
SD01M134
17
SD01M027
Attach a new ‘O’ ring (item 17) onto the wheel hub.
14
STEP 11
SD01M132
12
66'
TORSION BAR
NOTE: The following points must be observed prior to removing the torsion bar:
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5002).
Switch the engine OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
Removal
STEP 1 STEP 4
25
SD01M039 SD01M042
With the axle dismounted, secure the kingpin housing Screw out the adjusting screw (item 25) until the
to the uppermost position using a lifting device. torsion bar is no longer pre-tensioned.
STEP 2 STEP 5
22 23
SD01M040 SD01M043
Remove the cover (items 22 and 35) from the flanges. Remove the circlip (item 23).
STEP 3 STEP 6
Remove the three fixing screws (item 26) and the
26 three sleeves (item 27). Remove the rear flange.
WARNING: Before disassembling the rear flange, the
torsion bar must be loosened (see step 4).
24
SD01M041
STEP 7 STEP 10
30
29
SD01M046 SD01M049
Check the ’O’ ring (item 29) and replace if required. Pull out the front flange with the torsion bar (item 30)
from the axle housing.
STEP 8
STEP 11
37
SD01M047
SD01M050
Remove the three fixing screws (item 37) from the
front flange. Drive out the torsion bar through the front flange using
a soft hammer.
STEP 9
STEP 12
X
SD01M048
66'
Pull out the front flange by screwing a screw into the
threaded hole X. Remove the O-ring (item 31) from the front flange.
127( 5HSODFHWKH2ULQJ
STEP 13 STEP 14
36
34
SD01M051 SD01M052
If necessary, drive out the two centre pins (item 36) Remove the circlip (item 34).
from the front flange using a soft hammer and an
insertion tool.
SS03D062
Fitting
STEP 1 STEP 4
66' SD01M112
Use grease to fit the new O-Ring (item 31) on the front Screw in the screws (items 33 and 37) of the front
flange (item 32). flange and tighten them.
127( Insert the sealing ring with the spring pointing 127( Observe the correct screw lengths! Secure
towards the flange. the screws with Loctite 542.
STEP 2 Tightening torque...........................................95 Nm
STEP 5
SD01M110
Position the front flange at the lower swinging arm and SD01M039
insert using a soft hammer.
With the axle dismounted, lift up the kingpin housing
127( 'R QRW GDPDJH WKH 2ULQJV LWHPV DQG to the uppermost position using a lifting device.
6HLWH
127( The uppermost point of the spring travel has
STEP 3 been reached when the piston is moved in the
hydraulic cylinder up to the stop.
STEP 6
36
SD01M111
Drive the centre pins (item 36) into the front flange
using a suitable insertion tool. SD01M115
STEP 7 STEP 10
29
SD01M116 SD01M046
Before inserting the torsion bar, observe the labelling: Grease the new ’O’ ring (item 29) and insert into the
sx = left torsion bar, dx = right torsion bar. rear flange (item 28).
The arrow shows the direction of rotation in which the STEP 11
torsion bar is pre-tensioned.
,03257$17 The labelling "dx" or "sx" must be on
the side of the pinion shaft (drive flange).
STEP 8
25
24
SD01M118
28
34
SD01M045
Fit the rear flange (item 28). Screw in the fixing screws
SD01M114
(item 26) with their sleeves (item 27) but do not yet
tighten them.
Fit the circlip (item 34).
127( Only tighten the fixing screws of the rear
flange after the torsion bar has been set.
23
SS01M129 SD01M043
• With the axle dismounted, lift up both kingpin Insert the circlip (item 23) of the torsion bar at the rear
housings to the uppermost position. flange.
• With the axle inserted, lower this to the stop
position. STEP 5
STEP 2
25
SD01M042
SD01M045
Turn the adjusting screw (25) into the rear flange, until
it sits on the axle housing.
Turn the lower flange at the left (as shown in the Then turn the adjusting screw in another 7.5 turns, in
picture) anticlockwise until it reaches its final stop order to achieve the correct pre-tension of the torsion
position. bar.
Turn the lower flange at the right clockwise until it
reaches its final stop position. STEP 6
STEP 3
26
34
SD01M122
SD01M119
Tighten the securing screws (item 26) of the rear
flange.
Insert the torsion bar into the profile of the front and Tightening torque.........................................145 Nm
rear flange until the circlip (item 34) is in its stop
position.
STEP 7
SD01M123
Removal
STEP 1 STEP 4
SD01M054 66'
Screwan eye screw into the kingpin housing and Pull out the centre pin (item 42) using a standard
secure it with a lifting device. extractor (M8x1 thread) from the fork holder.
STEP 2 127( Check the ’O’ ring (item 45) and replace if
required.
STEP 5
46
SD01M055
STEP 3 Pull out the bearing bolt (item 46) using a standard
extractor (M8x1 thread) from the fork holder or from
the protective sleeve (item 106).
127( If necessary, lift up the protective sleeve
slightly by the drive shaft to ease removal of the
bearing bolt.
6''
Remove the circlip (item 41) from the fork holder. Un-
screw the lubrication nipple (item 40) from the cen-
tering bush.
STEP 6 STEP 9
SD01M057 SD01M060
Secure the lower swinging arm using a lifting device Remove the hexagonal nut (item 50) of the upper
until disassembly is completed. knuckle joint.
STEP 7 STEP 10
71
SD01M058 SD01M061
Unscrew both the securing screws (item 71) of the Remove the hexagonal nut (item 63) of the lower
lower bolt of the hydraulic cylinder. knuckle joint.
STEP 8 STEP 11
61
62
69
SD01M059 SS01M019
Pull out the bearing bolts (item 69). If necessary, lift up Unscrew the securing screws (item 62) of the lower
the protective sleeve slightly to ease removal of the flange. Pull out the lower flange (item 61).
bearing bolt. Remove he spacers and disk springs
127( If the knuckle joint sticks in the flange,
from the lower side of the hydraulic cylinder.
unscrew the nut and place it flush to the end of the
127( There are two threads for thrust screws in the spigot. Using a lever, press between the kingpin
bearing bolt. The threads are closed by plastic caps. housing and the swinging arm and simultaneously
remove the knuckle joint from the flange using a soft
hammer.
,03257$ 17 Always replace the nuts and the
knuckle joints.
STEP 12 STEP 15
52
53
55
56
SD01M062 SS01M020
Slowly lower the kingpin housing until the lower Screw off the hexagonal nut (item 56) of the upper
swinging arm is free. knuckle joint and remove the washer (item 55). Pullout
the upper knuckle joint (item 52) or, when necessary,
127( Do not damage the thread of the knuckle
drive it out using a suitable extraction tool.« To do this,
joint.
screw on the nut and place it flush to the end of the
STEP 13 spigot. If the sleeve has to be replaced (item 53) then
drive it out or press it out using a suitable extraction
tool.
127( Check the upper and the lower knuckle joint
for wear and check their sealings for tightness. If
necessary, replace the knuckle joint.
STEP 16
58
SD01M063
SD01M064
50
51
46
45
44
43
42
41 81
40 80
79
40 78
52 49 77
53 48 76
82 47 75
54 55
68
56
67
66
74
71 73
57 72
58
70
69
65
59
83
64
60
61
62 SS03D065
63
Fitting
67(3 STEP 3
53
66' SS01M125
Fit the stop screw (item 59) together with the nut (item Drive in or press in the sleeve (item 53) into the
60) and the washer (item 83). kingpin housing using a suitable insertion tool.
Tightening torque Nut ..................................450 Nm
127( To ease assembly, cool the sleeve using dry
127( $GMXVWWKHVWRSVFUHZVRWKDWWKHW\UHVPXG ice.
JXDUGVGRQRWFROOLGHZLWKWKHFKDVVLVRQUHDFKLQJWKH
PD[LPXPVWHHULQJDQJOHDQGUDQJHRIPRYHPHQW STEP 4
STEP 2 52
53
55
56
SS01M020
SD01M057
STEP 6 STEP 9
SD01M054 SD01M105
Screw in an eye screw into the holes in the kingpin Slowly lower the upper swinging arm, simultaneously
housing and hang the kingpin housing onto a lifting inserting the knuckle joint.
device. 127( Make sure that the thread of the knuckle joint
STEP 7 is not damaged.
STEP 10
61
62
SD01M103
shaft to protect the shaft sealing ring from damage Insert the flange (item 61) into the lower swinging arm.
(item 58). Lift up and position the kingpin housing. Fit Screw in and tighten the three screws (item 62).
the drive shaft into the kingpin housing.
Tightening torque ........................................ 169 Nm
127( Grease the sealing lip of the shaft sealing ring
before assembly.
STEP 11
STEP 8
SD01M061
STEP 12 STEP 15
46 147
SD01M060 106
SS01M126
Attach a new hexagonal nut to the upper knuckle joint
and tighten. Grease the sleeve in the fork holder (item 147) suf-
Tightening torque ........................................ 250 Nm ficiently and align it to the hole in the protective sleeve
(item 106). Grease the bolt (item 46) and push it in.
STEP 13
127( Align the nut in the bolt to the threaded hole
of the fixing screw (item 107).
STEP 16
Screw the fixing screw (item 107) into the protective
sleeve until the nut grips onto the bolt.
STEP 17
SD01M106
71
SD01M058
STEP 19
SD01M107
SD01M108
SD01M109
HYDRAULIC CYLINDER
127( The following points must be observed prior to removing the hydraulic cylinder:
• Remove the torsion bar (see page 34)
• Swing up the upper swinging arm (see page 41)
Removal
STEP 1 STEP 4
78
79
80
81
71
SD01M058 SD01M074
Unscrew both securing screws (item 71) of the lower Remove the circlip (item 81) from the upper bolts.
bearing bolt. Remove the washer (item 80), the spacers (item 79)
and the disk springs (item 78).
STEP 2
STEP 5
69
SD01M059
SD01M075
Lift the swinging arm to unload the bearing bolt. Pull
out the bearing bolts (item 69) or press out with two Pull out the hydraulic cylinder from the upper bolt and
screws. Remove the spacers (items 67 and 73) and the remove the spacer (item 75) behind it.
the disk springs (items 68 and 72) from under the Check all parts of the cylinder fixing including the
hydraulic cylinder. bearing bolts and replace as necessary. Check
STEP 3 tightness and easy accessibility of the cylinder. Check
the condition of the piston surface.
64 127( A sealing set is available for the hydraulic
cylinder.
SD01M067
Fitting
STEP 1 STEP 4
75
74
69
SD01M091 SD01M106
Attach the spacer ring (item 75) at the upper hole with Grease the holes of the swinging arm and the
the chamfer pointing towards the housing. Position hydraulic cylinder as well as the bearing bolts
the hydraulic cylinder at the upper bolt and mount it (item 69). Align the holes and push in the bearing
using a suitable insertion tool. bolts.
,03257$17 Before mounting the cylinder, check
STEP 5
the position of the screwed joint (item 74). The
threading must be tilted forwards by 8° (in driving
direction).
STEP 2
78
79
71
80
81 SD01M058
68
67 73
72
SS01M025
DRIVE SHAFT
127( The following points must be observed prior to removing the drive shaft:
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
• Remove the torsion bar (see page 34)
• Remove the kingpin housing together with the wheel hub (see page 41)
Removal
STEP 1 STEP 3
42 45
SD01M055 SS01M017
Loosen the locking nut (item 108) and the fixing screw Pull out the centre pin (item 42) from the fork holder
(item 107) of the baring bolt in the protective sleeve using a standard extractor (M8x1 thread).
(item 106).
127( Check the ’O’ ring (item 45) and replace if
STEP 2 required.
STEP 4
46
6'0
Unscrew the lubrication nipple (item 40) from the cen- SS01M018
tering bush. Remove the circlip (item 41) from the fork
holder. Pull out the bearing bolt (item 46) using a standard
extractor (M8 thread).
127( If necessary, lift up the protective sleeve by
the drive shaft to ease removal of the bearing bolt.
STEP 5 STEP 8
64
SD01M067 SD01M069
Swing the lower swinging arm (item 64) downwards. Turn the locking nut (item 190) and the fixing screw
Swing the hydraulic cylinder upwards. (item 191) of the centre pin (item 114) of the inner
drive shaft several times. Do exactly the same with
STEP 6 the fixing screw (item 179) on the opposite side of the
axle housing.
STEP 9
106
SD01M068
106
Remove the outer drive shaft from the protective
sleeve (item 106).
SD01M070
110
100
109 105
SS01M021
STEP 11 STEP 14
115
SD01M072 SS01M024
Pull out the inner drive shaft together with the bearing • Remove the circlip (item 104) from the drive shaft
and the sealing rings from the protective sleeve. (wheel side).
Remove the ’O’ rings (item 115). • Pull off the bearing (item 103).
• Pull off the sleeve (item 102) together with both
STEP 12 sealing rings (item 101).
• Remove both sealing rings (item 101) from the
sleeve (item 102).
127( Check all parts of the inner and outer drive
shaft (joints, drive profile, teeth of the sun gear,
bearing, running surfaces of sealing rings, surfaces
of bearings and sealing rings in the protective sleeve
and in the centre pin) for wear. Replace worn parts.
114 112 111
SS01M022
116
113
SS01M023
97
96
95
94
93
92 98
91
90
99
100
101
102
103
104
105
106
107
108
111
109 112
113
110
114
115
116
SS01M164
Fitting
127( The following units must already be mounted prior to inserting the drive shaft:
• The differential carrier in the axle housing (see page 92)
• The lower swinging arm (see page 61)
STEP 1 STEP 3
114
102
116
113
101
SS01M023
SS01M120
Fit the bearing (item 113) and the circlip (item 112).
Insert two new sealing rings (item 101) into the sleeve Insert a new cartridge sealing ring (item 116) into the
(item 102) up to the stop using insertion sleeve (item 114) up to the stop using a suitable
tool 380000444. The grease the sealing rings. insertion tool.
,03257$17 Insert both sealing rings with the lip STEP 4
seals pointing towards the universal joint shaft. When
later filling the protective sleeve with grease, the
grease must be able to exit via the sealing ring. 103
STEP 2
102 102
100 100
SS01M121
114
Place the circlip (item 100) (which will be required
SD01M122
later) onto the drive shaft. Push the sleeve (item 102)
onto the drive shaft together with the sealing rings. Fit the bearing (item 103) and the sleeve (item 114)
onto the drive shaft.
127( To ensure that the sealing rings are not
damaged when pushing them on, attach insulating
tape at the edge X. Remove the insulting tape after
assembly.
,03257$17 Fit the sleeve (item 102) so that the
sealing lips are facing towards the universal joint
shaft.
STEP 5 STEP 7
105
116
104
111
115 105
SD01M093
SD01M095
Fit the circlip (items 104 and 111). Attach a new
‘O’ ring (item 115) onto the sleeve. 127( The opening of the circlip must be at the
STEP 6 fixing screw (item 105).
STEP 8
100
102
106
SD01M096
380000398
Cover the thread of the fixing screw (item 105) with
Loctite 542. Screw in the fixing screw and tighten it.
127( The fixing screw secures the sleeve
SS01M124 (item 102) against turning in the protective sleeve.
STEP 10 STEP 13
114
115
SD01M097
SD01M101
Grease the ’O’ ring (item 115) at the centre pin Replace the screw plug (see arrow) in the protective
(item 114). Insert the drive shaft group with the centre sleeve by a lubricating nipple. Using a manually
pin into the axle housing up to the stop. operated grease gun, press in some grease
127( Facilitate fitting of the profile by slightly (POLYMER 400 or equivalent) until it is pressed out at
turning the shaft. the sealing rings at the ends of the protective sleeve.
Remove the lubricating nipple and screw in the screw
STEP 11 plug (covered with Loctite 542).
127( The screw plug must not be screwed in
deeper than the surface of the protective sleeve.
SD01M099
106
SD01M100
SENSORS
Removal
STEP 1 STEP 4
126
SD01M006 SD01M009
Tighten the securing screws (item 122) of the sensor Remove the sensor (item 126).
cover.
STEP 5
STEP 2
127
123
120
127
126
SD01M010
STEP 3 128
127
SD01M011
Fitting
STEP 1 STEP 4
129
128
126
SD01M150 SD01M153
If the holding ring (item 129) has been removed, cover Attach the sensor (item 126) to the holder. Push the
its circumference with LOCTITE 542 and insert it into sensor shaft into the rubber disk.
the bearing bolt.
STEP 5
127( The groove of the holding ring must be flush
with the fixing screw of the bearing bolt of the upper
swinging arm. 127
STEP 2
123
128
SD01M008
127
SD01M152
STEP 7 STEP 9
121
Adjusting the Sensors
127( The sensors can be set either with the axle
inserted or removed. To set the inserted axle, refer to 122
chapter 5002.
SSO2A053
SD01M154
SWINGING ARM
127( Before the swinging arm can be removed, the following work must be carried out:
• Remove the sensor (see page 58)
• Remove the torsion bar (see page 34)
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
• Remove the lower bolts of the hydraulic cylinder (see page 49)
• Remove the king pin housing (see page 41)
,03257$17 If only the upper swinging arm is removed, then from he work listed above, only the sensor has to be
removed! As preparatory work, steps 2 - 5 and step 9 have to be carried out as listed in the chapter on removing the
kingpin housing (see page 41).
153
SD01M076 SD01M077
Loosen the nut locks. Screw out the fixing screw of the Secure the swinging arm with a lifting device. Drive
bolt (item 176) of the upper swinging arm. Screw out out the bolts (item 132) using a soft mandrel.
the fixing screws of the cover (item 153).
STEP 4
STEP 2
131
132
133
SS01M027
66'
Remove the O-ring (item 131) and the thrust washer
Remove the cover (item 151) with the O-ring (item (item 133).
152) and the thrust washer (item 150).
127( &KHFN WKH EROW 2ULQJV DQGWKUXVW ZDVKHUV
UHSODFHDVUHTXLUHG
STEP 5 STEP 8
149
SS01M028 660
Pull out the sleeve (item 149) from its seating and Unscrew the lubrication nipple (item 142) from the
remove the swinging arm. centering bush (item 140). Remove the circlip (item
141).
STEP 6
STEP 9
134
148
135 137
SS01M029 140
SS01M031
Remove the sealing rings (item 135). Drive out the
sleeves (items 134 ad 138) using a suitable extractor. Pull out the centre pin (item 140) from the swinging
arm using a standard extractor (M8x1 thread).
127( Check the sealing rings and the sleeves;
replace if necessary. 127( Check the sealing ring (item 137) and the
bearing bush (item 138) in the centre pin and replace
STEP 7 them if necessary.
STEP 10
SD01M078
STEP 11 STEP 12
146
48
SD01M086 47
SD01M080 157
Unscrew the castellated nut (item 165) using nut key SS01M036
380000041 and then remove it. Relieve the swinging arm and drive out the shaft
127( When necessary, hold the opposite side of (item 157) using a soft mandrel.
the shaft using a suitable tool.
STEP 4
STEP 2
SS01M037
STEP 5 STEP 7
162
159
SS01M039
66'
Drive out the sleeves (items 159 and 162) using a
Remove the washer (item 167) with the O-ring (item suitable extractor.
156).
127( Check the sleeves; replace if necessary.
127( &KHFN WKH VHDOLQJ ULQJV DQG WKH ZDVKHUV
UHSODFHDVUHTXLUHG STEP 8
STEP 6 66
163
158
65
156 154
154
SS01M040
160
SS01M038 Loosen the hexagonal nut (item 66). Dismount the
universal joint (item 65) from the lower swinging arm.
Remove the sealing rings (items 156 and 160) and If necessary, dismount the stop (item 154).
the thrust washers (items 158 and 163).
127( Check the universal joint; replace if
127( Check the sealing rings and the thrust necessary.
washers; replace if necessary.
127( Secure the fixing screws (Item 155) with
Loctite 542.
SS03D063
51. UPPER SWINGING ARM 131. ’O’ RING 144. WASHER 157. SHAFT
64. LOWER SWINGING ARM 132. BEARING BOLTS 145. BEARING BUSHES 158. THRUST WASHER
120. COVER 133. THRUST WASHER 146. SEALING RING 159. SLEEVE
121. PLUG 134. SLEEVE 147. FORK HOLDER 160. SEALING RING
122. BOLT 135. SEALING RING 148. SLEEVE 161. SLEEVE
123. BOLT 136. BEARING BOLTS 149. SLEEVE 162. SLEEVE
124. WASHER 137. SEALING RING 150. THRUST WASHER 163. THRUST WASHER
125. NUT 138. BEARING BUSHES 151. COVER 164. ’O’ RING
126. SENSOR 139. WASHER 152. ’O’ RING 165. SLOTTED ROUND NUT
127. HOLDER 140. CENTRE PIN 153. CYLINDER SCREW 166. ’O’ RING
128. RUBBER DISK 141. CIRCLIP 154. STOP 167. WASHER
129. HOLDING RING 142. GREASE NIPPLE 155. BOLT
130. SENSOR LINE 143. CLAMPING SLEEVE 156. ’O’ RING
159
SS01M092 SS01M094
Drive the sleeves (items 159 and 162) flush into the Position the lower swinging arm at the axle housing in
swinging arm using insertion tool 380000447. such a way that the sleeves in the swinging arm are
flush with the hole in the axle housing.
STEP 2
STEP 4
66'
Grease the sealing rings (item 160) and the thrust wa- 66'
sher (item 158) sufficiently. Insert both sealing rings
(item 160) into the swinging arm using insertion tool Heat the washer (item 167) up to approx. 120 °C and
380001512. fit it on the shaft (item 157). Fit the O-ring (item 156)
on the washer.
127( 7KH VHDOLQJ ULQJV PXVW EH LQVHUWHG ZLWK WKH
VSULQJSRLQWLQJLQZDUGV 127( $OVRJOXHWKHZDVKHUXVLQJ/RFWLWH
Insert the thrust washer (item 158). 127( )LW WKH ZDVKHU ZLWK WKH JURRYH SRLQWLQJ
WRZDUGVWKHVZLQJLQJDUP
127( 7KH WKUXVW ZDVKHU PXVW EH LQVHUWHG ZLWK
´3,76´SRLQWLQJRXWZDUGV
66'
157
SS01M106
65
SS01M110
137
47
SS01M033 SS01M112
Grease the new sealing ring (item 47) and insert it into Grease the new sealing ring (item 137) and insert it
the fork holder using insertion tool 380000031 (with into the centre pin (item 140) using insertion
sealing lip pointing towards the insertion tool). tool 380000031 (with sealing lip pointing towards the
insertion tool).
STEP 2
STEP 5
SD01M086 SD01M087
Grease the new sealing ring (item 137) and insert it Grease the bearing bush in the centre pin sufficiently.
into the swinging arm using insertion tool 380000031 Insert the centre pin into the swinging arm.
(with sealing lip pointing towards the swinging arm).
STEP 6
STEP 3
136 147 66'
SS01M111
Insert the circlip (item 141). Screw in the lubrication
Position the fork holder (item 147) in the swinging nipple (item 142).
arm and insert the bearing bolt (item 136). (Grease
the bearing bolt)
127( Align the hole X in the bearing bolt to the hole
in the fork holder. The threaded hole in the bearing
bolt must point towards the centre pin.
STEP 7 STEP 9
SD01M088 SS01M115
Insert the clamping sleeve (item 143) into the fork Position the upper swinging arm at the axle housing
holder. using a lifting device.
STEP 8 STEP 10
134
133
148 135
150
SS01M114 SS01M116
132
66'
Insert the sleeves (items 134 and 148) into the upper
swinging arm using insertion tool 380000445. Grease
the new sealing rings (item 135) and insert them into
the swinging arm using insertion tool 380001488. (see
SD01M089
figure)
Fit the O-ring (item 131) on the bolt. Insert the bolt,
thereby aligning the groove to the threaded hole of the
fixing screw (item 176). Drive the bolt in until it comes
to rest using a soft hammer. Turn the fixing screw until
it comes to rest.
,03257$17 6XIILFLHQWO\JUHDVHWKHWKUXVWZDVKHUV
VOHHYHVEROWDQGWKH2ULQJ
STEP 12 STEP 14
176
149 SD01M090
/8%5,&$7(817,/*5($6(&20(6287
$77+(32,1766+2:1
66'
STEERING CYLINDER
Removal
STEP 1 STEP 4
171
172
SD01M012 SD01M015
Loosen the lock nut (item 172). Unscrew the (item 171) track rod.
STEP 2 STEP 5
170
SD01M013
SD01M016
Loosen the nut (item 170).
Dismount the screw-in fitting for the hydraulic line.
STEP 3
STEP 6
174
170
SD01M014
SD01M017
Align the nut (item 170) flush to the spigot of the
steering knuckle arm (track rod arm). Disconnect the Loosen the securing screws (items 174) of the
steering knuckle arm from the kingpin housing using steering cylinder.
a soft hammer.
STEP 7 STEP 10
SD01M018
SD01M021
Pull out the steering cylinder from the axle housing.
Disassemble the seals of the cylinder pipe. Check the
STEP 8 cylinder pipe and replace it as required.
STEP 11
SD01M019
SD01M020
Fitting
STEP 1 STEP 4
SD01M020 SD01M142
Grease the new sealing rings and insert them into the Push the pre-assembled piston rod into the steering
cover. cylinder and mount the steering cylinder head.
STEP 2 STEP 5
SD01M201
SD01M021
Push the steering cylinder into the bores (attachment
Grease the new sealing rings and insert them into the holes) of the axle housing.
cylinder pipe.
STEP 3 STEP 6
173
173
SD01M143
SD01M022
Screw the knuckle joints (item 173) of the track rods
Insert the new sealing rings on the piston rod. onto the ends of the piston rod.
127( Grease the sealing rings before mounting Tightening torque ........................................ 300 Nm
them.
STEP 7 STEP 9
174
170
SD01M144 SD01M146
Screw in the securing screws (items 174) of the Insert the knuckle joints of both track rods into their
steering cylinder. appropriate seatings in the kingpin housing and screw
Tightening torque ........................................120 Nm on the nuts (item 170).
171 STEP 10
172
SD01M145
If track rods have been removed (item 171) then screw SD01M147
them back onto the knuckle joints. While holding on to Tighten the nuts.
the track rod, tighten the lock nuts (item 172).
Tightening torque ........................................ 220 Nm
Tightening torque ........................................250 Nm
174
170
171
172
173
175
173
172
176 176 197
170
177
188
190
179
191
176
178
177
197
187
192 189
193
188 194 190
195 191 SS01M192
196
STEP 1 STEP 3
SD00B017 SD00B019
Remove the brackets for the hydraulic lines on the Loosen the lock nut of the adjusting screw (at the
outside of the support frame (left and right). Discon- support frames). Turn out the adjusting screws by two
nect the hydraulic hoses from the pipelines that run in turns.
the support frame.
Seal the hydraulic hoses. 127( :KHQ UHDVVHPEOLQJ SUHWLJKWHQ WKH DGMX
VWLQJVFUHZVWR1P7KHQWLJKWHQWKHPDOWHUQDWHO\
:$51,1* If the tractor is equipped with a free XSWRDWRUTXHRI1P6HFXUHWKHDGMXVWLQJVFUHZV
return to the front, then this line must be sealed. If the E\PHDQVRIORFNQXWV
line is not sealed, hydraulic oil will run out!
STEP 2 STEP 4
SD00B020
SD00B018
Place a hydraulic jack under the support frame and Loosen the front fixing screws on the support frame.
remove the securing bolts. Remove the supporting frames.
127( When reassembling, secure screws with
Loctite 242 sichern and tighten them to a torque of
200 Nm!
STEP 5 STEP 8
127( For tractors fitted with front hitch, the shaft Mark the position of the hydraulic hoses to the steering
protector for the 4-wheel drive shaft must first be cylinder, disconnect them and fit protective caps. Mark
removed. the hydraulic hoses to position of the axle cylinders,
disconnect them and fit protective caps. Disconnect
Place a hydraulic jack under the centre of the axle and
the hydraulic hose to the differential lock, the front
raise the tractor. Lower the front of the tractor onto
PTO shaft and the brakes (if fitted) and fit with
suitable support trestles and remove the front wheels.
protective caps.
127( When re-fitting, tighten the wheel nuts of the
,032 5 7$ 17 I n or d er to p re v en t the l os s of
front wheels.
hydraulic oil, the hydraulic hoses must be securely
Tightening torque – braked axle.................. 570 Nm tied with the open ends upwards (towards the cab).
Tightening torque – unbraked axle.............. 425 Nm STEP 9
STEP 6
120
122
SD02A028
Place a container, with a capacity of at least 5.5 litres 127( When assembling, seal the cover with
under the oil drain plug, screw the oil drain plug out Loctite 518. Tighten the securing screws (item 122) to
and drain the oil. a torque of 13 Nm.
STEP 7
SD01M154
STEP 11
Remove the 4-wheel drive shaft from the front flange.
SD00B021
127( When assembling, tighten the fixing screws
Remove the fixing screws of the console for the front of the 4-wheel drive shaft to 60 Nm.
wheel mudguard.
STEP 12 STEP 14
SD00B026 SD00B028
Place a hydraulic jack under the centre of the front Lower the front axle by means of the hydraulic jack
axle. Loosen the fixing screws on front bearing block. and remove the jack.
STEP 13
SD00B027
PIVOTED BEARING
127( To assemble and to disassemble the swing bearing, the axle must first be removed. (see page 76)
Removal
STEP 1 STEP 4
195
196
SD01M001
187
SD01M004
Remove the rear bearing block (item 196). Unscrewthe fixing screw (item 187) of the bearing
STEP 2 bush (item 195) at the rear bearing block. Remove the
‘O’ ring and the bearing bush. Check all components
and replace as required.
STEP 5
186
SD01M002
197
185 Check centre pin (item 197) of the front and rear
bearing block and replace if required.
187
SD01M003
Fitting
127( The differential carrier must already be mounted in the axle housing prior to inserting the swivel bearing.
STEP 1 STEP 4
187
185 SD01M159
SD01M157
Push the bearing bush (item 185) into the front If required, replace the centre pin (item 197) of the
bearing block. front and rear bearing block. Cover the centre pin with
LOCTITE 638 before inserting it.
127( Align the hole for the retaining screw to the
hole in the bearing block. STEP 5
STEP 2
6''
SD01M158 Attach a new ‘O’ ring (item 194) into the bearing bush
of the rear bearing block. Insert the bearing bush into
Screw in and tighten the retaining screw (item 187) of the rear bearing block.
the bearing bush.
Tightening torque ........................................ 200 Nm 127( Align the hole for the retaining screw to the
hole in the bearing block.
Check the lubricating nipple and replace if necessary.
Tightening torque ............................................ 8 Nm
STEP 6
STEP 3
SD01M161
STEP 7
SD01M001
DIFFERENTIAL
127( The axle must be removed before removing the differential carrier. (see page 76)
Removal
STEP 1 STEP 3
201
216
229
200
SS01M041 SS01M044
127( Secure the differential carrier (item 201) with Unscrew the lock nut on the left (item 229) using nut
a lifting device before removing it. key 380000406.
Unscrew the lock nut on the right (item 216) using nut
Loosen all fixing screws (item 200) and remove the
key 380000441.
differential carrier.
127( The lock nuts on the left and the right differ
STEP 2 from each other.
STEP 4
219
220A
220
230
217 221
SS01M042
STEP 5 STEP 6
225
227 228
SS01M046 SS01M047
Remove the outer sealing ring (item 227), the ring Remove the differential and the outer rings from the
(item 228) and the inner sealing ring (item 227) as well differential carrier. Remove the support ring (item 226)
the disk (item 224). and the ’O’ ring (item 225).
127( Check the sealing rings and replace as ,03257$17 Do not swap the two outer bearing
required. rings when they are re-installed.
208
207 210
209
SS01M048 SS01M050
Plug the differential carrier into a vice. Remove the Remove both castellated nuts (item 209) and the disk
drive flange (item 207) and the cartridge sealing (item 210).
ring (item 208).
STEP 2
209
SS01M049
STEP 4 STEP 7
202
211
212
211
209
212
SS01M051 SD01M081
Press the pinion shaft out of the housing using a Check the condition of all parts.
hydraulic press. Remove the disks (item 211), the
,03257$17 The pinion shaft and master gear may
spring collet (item 212) and the bearing (item 202).
only be replaced in pairs.
127( Catch the pinion shaft when dismounting it.
127( The castellated nut (item 209) and the spring
STEP 5 collet (item 212) must always be replaced.
SS01M052
214
SS01M053
229
218 227
228
227
230
224
223
219
220A
226 220
221
225 222
210
209 218
208
207
206 223
215
214 217
213
216
211
212
205 211
200
201
SS01M162
DIFFERENTIAL UNIT
Disassembling
STEP 1 STEP 4
243
SS01M059 SS01M055
Remove the inner bearing rings from the differential Remove all outer and inner disks, the disk (item 243)
housing and from the cover using a bearing puller. and the axle bevel wheel (item 244).
STEP 2 STEP 5
248
235 SS01M063
239
253
247
236 SS01M057
237
238 Remove the bearing bolts (items 247 and 253) from
240 the differential housing.
SS01M054
SS01M058
242
242
242
242 243
242 244
245
246
247
248
249
250
241 251
241 252
241
241
241 254
253
235
236 SS01M193
237
238
239
240
Assembly
STEP 1 STEP 4
244
243
SS01M061 SS01M064
Clean all parts of the differential unit thoroughly, check Insert the axle bevel wheel (item 244) and the disk
for wear or damage and then assemble as shown in (item 243) into the differential housing. Alternately
the diagram. insert an outer disk and an inner disk (as shown in the
diagram) into the differential housing. The outermost
STEP 2
disk is an outer disk.
STEP 5
247
239
253
247 236
SS01M062 237
238
Place the differential housing vertically (with its 240
SS01M065
opening upwards). Insert the long bearing bolt
(item 253) from the outside. When doing so, insert the Grease the new ’O’ rings (items 237, 238 and 240) and
thrust washer, the differential bevel gear and the cross insert them into the piston nuts (item 239) and the
piece. cover (item 236). Insert the piston and the cover into
Then insert the two short bearing bolts (item 247) with the differential housing.
thrust washers and differential bevel gear.
127( Observe the correct positioning of the piston
STEP 3 (item 239)!
248
SS01M063
STEP 6 STEP 7
235 SS01M060
SS01M066 SS01M069
Insert the outer rings of the new bearing using a Measure distance "X" between the differential bearing
suitable insertion tool. and the surface of the inner bearing ring using a depth
127( Make sure that the bearing rings seat gauge and note the result.
correctly against the shoulders. STEP 5
STEP 2
SS01M071
STEP 6 STEP 8
211
212
211
SS01M073 SS01M075
Push the packing ring that has been calculated "S" Tighten the castellated nut using nut key (380000021)
onto the pinion shaft. and dolly (380000020) until the pinion shaft is free of
play.
,03257$17 Fit the packing ring with the chamfer
pointing towards the pinion. 127( The adjustment is made by turning the
castellated nut in steps. Make sure that the
Heat up the new inner bearing to 80 °C and place it on
prescribed rolling resistance is not exceeded.
the pinion shaft.
127( Before checking the rolling resistance, lightly
127( Make sure that the inner bearing ring is in
tap on both ends of the pinion shaft with a soft
contact with the shim (packing ring) (S).
hammer to ensure that the bearings sit correctly.
Attach the disks (item 211) and a new clamping sleeve
(item 212). STEP 9
,03257$17 The clamping sleeve (item 212) must
be replaced after every disassembly.
STEP 7
210
209
SS01M076
SS01M074
Tie a piece of string to the pinion shaft and wind the
string, without overlapping it, around the pinion shaft.
Insert the pre-assembled pinion shaft into the Tie a spring balance to the end of the string and
differential carrier. Heat up the second inner bearing measure the rolling resistance.
ring to 80 °C and fit it. Attach the disk (item 210) and a Tighten the castellated nut until the rolling resistance
new castellated nut (item 209). of the pinion shaft is between 92 and138 N (Newton).
127( Oil the bearing. P = 92 - 138 N
P = pinion (pinion shaft)
Note the value displayed for the rolling resistance.
127( If the castellated nut is overtightened and the
rolling resistance is thereby out of tolerance, the
spring collet ([clamping bush] item 212) must be
replaced.
STEP 10
Secure the nut with a suitable mandrel when the
prescribed rolling moment has been reached.
220
SS01M077
220A
Insert the new ’O’ ring (item 225) and the support ring 221
(item 226) into the oil bore hole (bearing seating on
the master gear side) in the differential carrier. Place
on the outer ring.
STEP 2
228
224
SS01M079
Insert the four centre pins (item 221) into the bearing
covers. Attach both bearing covers (items 220
227 and 220 A) and screw them in manually using the
appropriate screws.
STEP 4
229
229
SS01M080
226
228 Screw the castellated nuts (items 229 and 216) into
225 differential carrier.
Tighten both castellated nuts until the differential
SS01M078
carriers are slightly pre-tensioned. Tap lightly with a
Place the disk (item 224) with its stepped side soft hammer to ensure the bearing sits correctly.
pointing towards the bearing onto the outer bearing 127( Make sure that there is always tooth flank
ring. Pre-assemble the sealing rings (item 227) in the play during this procedure
spacer ring (item 228).
127( Use new sealing rings (item 227)! Oil the
sealing rings thoroughly before mounting them.
SS01M081
T = (P + 92) to (P + 107) N
SS01M083 If the total rolling moment "T" is too small then screw
in both castellated nuts by the same amount (angle of
Set tooth flank play as follows: rotation: clockwise).
• If the measured play is smaller than the
indicated tolerance range then loosen the 127( The tooth flank play must not be altered.
castellated nut on the master gear side slightly If the total rolling moment "T" is too large then screw
and screw in the opposite castellated nut out both castellated nuts by the same amount (angle
correspondingly. of rotation: anti-clockwise).
• If the measured play is larger than the indicated Turn the pinion shaft with the differential and tap lightly
tolerance range then loosen the castellated nut with a soft hammer on the side of the differential
opposite the master gear slightly and screw in the housing.
castellated nut on the master gear side
Check the rolling moment and the tooth flank play.
accordingly.
127( After setting the tooth flank play, you must
also make sure that the tapered roller bearings of the
differential bearing is slightly tensioned. Setting the
bearing is described in the next work step.
SS01M085 SS01M088
To check the teeth meshing, cover some of the teeth Tighten the securing bolts on both bearing covers.
on the master gear with red lead. Tightening torque ........................................266 Nm
127( The meshing must always be checked on 127( After tightening the screws, check the total
BOTH tooth flanks of the teeth of the master gear. rolling moment "T". (see page 93)
When turning the pinion shaft, simultaneously brake
the master gear. (gives a real meshing) STEP 11
STEP 9 230
217
SS01M089
SS01M086 After carrying out the settings and checks, mount the
left and the right securing pins (items 217 and 230)
OK: The position of the meshing is CORRECT. using the appropriate screws (item 218).
Z: Contact with the tooth is too much Tightening torque ..........................................13 Nm
OUTWARDS:
Decrease the distance of the pinion shaft to the
middle of the master gear.
X: Contact with the tooth is too much INWARDS:
Increase the distance of the pinion shaft to the
middle of the master gear.
127( This representation refers to the teeth of the
master gear.
STEP 12 STEP 14
Screw in and tighten the oil drain screw (item 203).
Tightening torque.......................................... 60 Nm
208
,03257$17 Fill the axle housing with oil.
207 Oiltype and filling level (see Technical Data, page 12)
127( You can fill the oil after fitting the inner drive
shafts (see page 51).
After filling the oil, screw in and tighten the oil filler plug
(item 182).
Tightening torque.......................................... 60 Nm
STEP 15
SS01M090
127( Check the vent of the axle housing (item 180)
Insert the cassette sealing ring (item 208) into the for blockages:
differential carrier using insertion tool 380000022.
• Clean the area around the vent.
127( Moisten the inner surface of the cartridge • Screw out the vent and blow through with
sealing ring with a mixture of white spirits and water. compressed air. When doing so, make sure that
Place the drive flange (item 207) on the pinion shaft there are no blockages.
and fix using the clamping bolt (item 205). • Screw in the vent and tighten it.
Tightening torque- clamping bolt................... 57 Nm Tightening torque.......................................... 10 Nm
STEP 13
204
204
SS01M091
TRACK ALIGNMENT
"A"
Driving direction
"B" SS02B101
127( Before aligning the track, check the tyre air pressure (see Operating Manual).
STEP 1 STEP 7
The front axle must be recalibrated before starting the
track alignment.
172
(see Chapter 5002)
STEP 2
Lower the front axle to the lower limit and then activate
the suspension. Once the axle is in the middle
position, switch 173
off the engine and apply the parking brake.
127( The front wheels must face straight ahead.
STEP 3
Make marks on the rear inside of the wheel rim (rim
flange), at the same height as the centre of the wheel SS00C121
hub.
Loosen the locking nuts (item 172). Extend or shorten
STEP 4 the track rods by turning the knuckle joints (item 173).
Measure the distance B between these marks and Repeat STEP 1 to STEP 5.
make a note of it. When the track has been aligned correctly, tighten the
locking nuts (item 172).
STEP 5
Tightening torque ........................................ 250 Nm
Drive the tractor forwards until the marks at the front
are level with the centre of the wheel hub.
STEP 6
Measure the distance (A) between these marks and
make a note of it. The track must be adjusted so that
value A is
0 to 4 mm smaller than value B.
6HWWLQJ
Axle in “mid-position“.................... 0 to +4 mm (toe-in)
127( If the value determined is outside the
prescribed setting, the track alignment must be
corrected in accordance with 67(3
7$%/(2)&217(176
Introduction ........................................................................................................................................................... 8
Description ............................................................................................................................................................ 9
Transmission layout ....................................................................................................................................... 11
Transmission plug-in unit (cartridge) .............................................................................................................. 12
Transmission schematic diagram .................................................................................................................. 13
Transmission unit layout ................................................................................................................................ 14
Maintenance ........................................................................................................................................................ 43
Oil filling .......................................................................................................................................................... 43
Oil filling in the case of a repair: ..................................................................................................................... 43
Technical Data
Oil quantity, transmission, rear axle ..................................................................................................... approx. 60 l
Oil quantity, planetary gear, 135 HP / 145 HP ................................................................................................... 10 l
Oil quantity, planetary gear, 155 HP / 170 HP / 190 HP / 195 HP ..................................................................... 12 l
Quality, transmission, rear axle ...............................................................................................see operator manual
Quality, planetary gear ............................................................................... G (GL 5) SAE 85W-140, SAE 80W-90
Oil change, transmission, rear axle ......................................... every 1000 operating hours (at least after 2 years)
Oil change, planetary gear ......................... at 250 and every further 1000 operating hours (at least after 2 years)
Oil filter change, suction filter .................................................. every 1000 operating hours (at least after 2 years)
Oil filter change, pressure filter ............................................... every 1000 operating hours (at least after 2 years)
Transmission
Ratio 1 ............................................................................................................................................................ 2.610
Ratio 2 .............................................................................................................................................. 2.610 to 1.428
Ratio 3 .............................................................................................................................................. 1.428 to 0.740
Ratio 4 .............................................................................................................................................. 0.740 to 0.384
Transmission hydraulics
Lubricating pressure pump (rotor pump) ......................................................... 35.2 cm³ 82 l/min 2100 rpm engine
System pressure variable pump (vane cell pump) ............................................. 30 cm³ 70 l/min 2100 rpm engine
Ratio of engine / system and lubricating pressure pumps ....................................... i = 1:1.121 engine / all pumps
Pressure limiting valve – oil cooler ............................................................................................................... 2.5 bar
Lubricating pressure limiting valve ............................................................................................................... 1.5 bar
Pressure limiting valve – brake cooling ........................................................................................................... 1 bar
Suction filter – by-pass sieve ......................................................................................................................... 125 µ
Suction filter ..................................................................................................................................................... 15 µ
Pressure filter ................................................................................................................................................... 10 µ
Pressure filter by-pass valve (pressure difference) ......................................................................................... 7 bar
Pressure filter test switch (pressure difference) .............................................................................................. 5 bar
Pressure reduction valve ............................................................................................................................... 20 bar
3/2 directional control valves K1, K2, K3, K4, KR, KF, 4WD
Nominal voltage ........................................................................................................................................ 7.1 VDC
Resistance (20 °C) ................................................................................................................................... 2.5 ohms
Tightening torque ......................................................................................................................................... 30 Nm
PTO-shaft
540 ................................................................................................................................ at 1870 rpm engine speed
540E .............................................................................................................................. at 1600 rpm engine speed
1000 .............................................................................................................................. at 1870 rpm engine speed
1000E ............................................................................................................................ at 1600 rpm engine speed
Piston diameter, PTO clutch 135/145 HP (up to DBD...)............................................................................. 120 mm
Piston diameter, PTO clutch 135/145 HP (from DBD...) ............................................................................. 130 mm
Piston diameter, PTO clutch 155/170/190/195 HP ..................................................................................... 130 mm
PTO shaft spline ................................................................................................... 1 3/8" DIN 96, Form 1 - 6 spline
.......................................................................................................................... 1 3/8" DIN 961, Form 2 - 21 spline
......................................................................................................................... 1 3/4" DIN 9611, Form 3 - 20 spline
Introduction
Ever increasing demands are made on tractors. Apart from performance and price, efficiency, environmental compa-
tibility and comfort are becoming increasingly important criteria in the selection of a product.
The complexity of the drive and transmission systems increased constantly in the past, due to high technical and
functional requirements. A high degree of driving ability and user knowledge became prerequisite to operating such
systems.
CNH Austria has set its aim at developing a drive train system, from the engine to the wheels, in which the optimum
operating status of the entire system is guaranteed in every driving situation without intervention by the driver.
The main element of this system is the continuously variable transmission. The basis of this is hydrostatic/mechanical
power splitting. The continuously variable transmission represents a completely new generation of transmissions,
which guarantees optimised customer usage through high functionality, very good overall efficiency and a modular
construction.
All gear levers have been dispensed with on vehicles with continuously variable transmission. Driving speed is con-
trolled by the accelerator pedal or the Cruise Control. The electronic control system regulates the engine and trans-
mission to achieve the desired driving speed.
The driver can concentrate on driving and operating the units and is not distracted by changing gears.
Description
The main components of this transmission are:
● Hydrostatic unit
● Summing planetary gear
● Planetary trains (4 shift stages)
● Planetary unit (forwards / reverse)
● Transmission electronics (SGR)
● Transmission hydraulics
● Vehicle electronics (FMGR)
● Rear axle
Hydrostatic unit in the form of a swivel plate variable displacement pump with a fixed displacement motor, arranged
back-to-back.
A summing planetary gear in which the hydrostatic and mechanical power components are unified.
Planetary trains connected to the summing planetary gear, through which four transmission ratios are realised.
Greater transmission spread can be achieved through these ratio ranges. Shifting between the individual ratios is
done by the overlapped closing of claw couplings at synchronous speeds.
A forwards / reverse planetary unit with direct transmission for forwards travel and change of direction – by locking
the planet carrier against the housing – for reverse travel.
Transmission electronics (SGR) including transmission sensor technology to control and regulate internal trans-
mission functions.
Transmission hydraulics with integrated pressure and lubrication oil supply, pressure control valves, shifting valves
and oil filtering.
Vehicle electronics (FMGR) for processing signals from the operating elements. In addition, the vehicle controller
co-ordinates between the engine and transmission control systems.
Rear axle with electro-hydraulic operated multi-disk lock. Wet multi-disk brakes (driving and parking brakes). The
working brake is operated hydraulically, the parking brake mechanically. The wet PTO shaft clutch is electro-
hydraulically operated. Final drive with simple planetary drive. The 3-point hitch is shown in exploded view.
SS00B088
17
14
16
13
15
9
12
11
7
10
6
5
14
1
8
3
4
Transmission layout
1 Hydraulic tank
2 Viewing glass hydraulic fluid
3 Input shaft (vibration damper)
4 Transmission plug-in unit (cartridge)
5 Summing planetary gears P1 and P2
6 Planetary train P3 and P4
7 Planetary train forwards / reverse F/R
8 Drive shaft for hydraulic pumps and PTO shaft
9 Rear axle
10 Multi-disk clutch 4-wheel drive
11 Parking interlock
12 Bevel gear compensation with 100 % multi-disk lock
13 Multi-disk clutch PTO shaft
14 Wheel brake cylinder
15 Rear axle lube-oil distributor, brake cooling oil distributor
16 Planetary gear with own oil supply
17 Lifting shaft with lifting arm
6 7
SS00M054
8 5 4 3 2 10 9 1 1
1 Input shaft (drive for internal geared wheel 1, hydrostat, lubrication and system pressure pump,
PFC pump and PTO shaft).
2 Transmission plug-in unit
3 Transmission electronics (SGR)
4 Hydrostat electronics (Linde electronics box)
5 Suction filter lubrication pump / system pump 30 bar
6 System pump pressure 30 bar (vane-cell variable pump)
7 Lubricating pump (rotor pump)
8 Pressure filter
9 4-wheel clutch
10 Bevel pinion (power take-off)
1
2
3 4 5 SS00B091
1 Drive motor
2 Hydrostat (variable pump and fixed displacement motor)
3 Summing planetary gear P1, P2
4 Planetary train P3, P4 and couplings K1, K2, K3, K4
5 Planetary train forwards / reverse KF / KR
6 Output shaft bevel pinion
8 6 7 5 3 4
2
20
17
19
18
15 SS00B089
11
14
16
12
9 13 10
List of components:
1 Drive, motor 11 Internal geared wheel 2 (H2),
output shaft stage 1
2 Mechanical power transmission,
internal geared wheel 1 (H1) 12 Planet carrier 1 (land 1)
3 Variable displacement pump drive 13 Planetary gear (short, engages in H1 and S1)
4 Drive for hydraulic pumps and PTO shaft 14 Planetary gear (long, engages in the short
planetary gear on P1 and in S2 and H2 on P2)
5 Hydrostat pump
15 Sun 2 (S2), output shaft stage 2 and 4
6 Hydrostat motor
16 Odometer wheel, land 1 (ST1)
7 Variable unit, hydrostat pump
17 Gear selector drum with P3 and P4
8 Driven gear wheel, hydraulic motor,
hydrostatic power transmission 18 Sun 3 (S3)
9 Drive gear wheel for sun 1 (S1) 19 Sun 4 (S4)
10 Internal geared wheel 1 (H1) 20 Output shaft for stage 3
(firmly connected to land 1)
Functional description
The driving torque on the input shaft (1) drives, on the one hand, the internal geared wheel (H1) on the summing pla-
netary train (P1) via a spur wheel train, thereby ensuring purely mechanical power transmission, and on the other
hand, a variable hydrostat pump (5) via a further spur gear train (3) seated at the rear of the input shaft.
A fixed displacement motor (6), which is charged by the oil flow from the pump (5), is arranged back-to-back on this
hydrostat pump (5). Both the speed and the direction of rotation of the hydrostat motor can be altered by electro-
hydraulically adjusting (7) the swivel plate in the hydrostat pump. By swivelling the variable unit (7) on the pump, a
variable speed, between maximum negative and maximum positive, can thus be achieved on the hydrostat motor.
The hydrostat motor torque is transferred to the sun gear (S1), on the summing planetary gear (P1), via a spur gear
train (8/9).
In addition, four mechanical ratios (P2, P3, P4) are realised in the CVT transmission, in order to achieve sufficient
transmission spread and to keep the hydrostatic power component as small as possible.
Four claw couplings (K1, K2, K3, K4) enable driving in four ranges – in both forward (KF) and reverse (KR) travel.
287387 287387
)520
2
3 3 3
SS03C019
1
The principle function of power overlay in the summing planetary gear P1, is shown in the diagram above, by three
distinctive points (stage 1).
The internal geared wheel (1) represents the mechanical part of the power transmission.
This internal geared wheel is driven by the engine and always rotates in the same direction according to the engine
speed.
The hydrostatic power component is transferred via the sun gear (2).
As this sun gear is driven by the hydrostat motor, the speed of the sun gear can be varied by adjusting the swivel plate
on the hydrostat pump from maximum opposing speed up to synchronisation with the internal geared wheel.
3
3
7
4
6
SS03C020
5
3
1
2
The summing planetary train (P1 / P2) is a 5-shaft planetary gear with two input shafts and three output shafts.
The internal geared wheel (1) is driven directly by the input shaft via a spur gear stage.
The sun gear (2) is driven by the hydrostat motor.
Two narrow planetary gears (3), which mesh with two wide planetary gears (4) and thus reverse the direction of rota-
tion, are arranged between the internal geared wheel and the sun gear.
The internal geared wheel (5) and the sun gear (7), via which power is taken off, engage in these wide planetary gears
on the output side.
Furthermore, power can be taken off via a shaft connected to the planet carrier (6). These three output options on the
summing planetary gear (internal geared wheel (5), sun gear (7) and land (6), allow four ratios to be realised, in con-
nection with the subsequent planetary trains (P3, P4). The required transmission spread for vehicles, with high draft
requirements and high top speed is achieved in this way.
SS03D054
DRIVING SPEED KM/H
The speed diagram displayed above shows the sequences in the four ratios of the continuously variable transmission
at a constant engine speed of 2100 rpm.
The speeds in both directions of rotation are shown on the ordinate, the driving speed is shown on the abscissa of
the diagram.
In the following descriptions of speeds in the individual ratios, it is assumed that the engine speed is kept constant
and the claw couplings for forward travel (KF) are closed.
Internal geared wheel P1 (1) on input stage P1 rotates constantly at a speed of minus 2830 rpm.
The sun gear (2) for input stage P1, driven by the hydrostat motor, rotates at the same speed but in the opposite
direction (+2830 rpm), due to the hydrostat pump plate being swivelled fully (to minus).
The following speeds result, at vehicle standstill, on the three drive shafts of the summing planetary gear P2:
Standstill control
1 3
4 7 8 6 SS00B096
Ratio 1
Output is by way of the internal geared wheel P2 of the summing planetary gear, via planet carrier P3, P4 for this ratio,
directly to KF and the pinion shaft.
2 3 7 6
5 4 SS00B095
To change the ratio, and thus accelerate the vehicle, the pump plate is swivelled and the speed of sun gear P1 (1) for
the summing planetary gear is continually reduced until the sun (1) comes to a standstill. In this state, with the angle
of swivel in the hydrostat pump at zero, the speed of the engine output is zero and therefore the speed of the sun
gear in the summing planetary gears is also zero. The drive power transfer initiated is purely mechanical at this ope-
rating point.
By turning the swivel plate in the hydrostat pump further, a change in the direction of rotation of the engine shaft takes
place and when swivelled fully, the speed of the sun gear (1) reaches that of the internal geared wheel (2) on P1.
This results in a continuous increase in the speed of internal geared wheel (3) P2, through which the power flow is
fed to the transmission output via planetary train P3 in the 1st range.
With internal geared wheel (2) P1 and sun gear (1) P2 at the same speed, the entire summing planetary train and
thus internal geared wheel (3) P2, sun gear (4) P2 and planet carrier (5) P1 all rotate at the same speed.
At this operating point, internal geared wheel (6) on planetary train P4 comes to a standstill, as a result of identical
planetary trains P3 and P4.
As the internal geared wheel (7) for planetary train P3 is also stationary, claw coupling K2 can be closed in addition
to the still engaged claw coupling K1, through which the internal geared wheel of planetary train P4 is also connected
to the transmission housing.
After engaging coupling K2, the torque on coupling K1 is transferred to coupling K2 by adjusting the swivel plate in
the hydrostat pump. Only then is coupling K1 disengaged.
This ensures that the power flow in the transmission is not interrupted at any time, during the shifting sequence.
Ratio 2
4 2
3 1
6 SS00B097
The power flow in the above diagram is given after shifting from the 1st ratio to the 2nd ratio.
For tractors, this shifting point takes place at approx. 8 km/h.
In the 2nd ratio, the torque is transferred, from summing planetary train P1, via sun gear (1) P2 and the planet
carrier (2) of planetary train P4, to the drive shaft.
In reducing the speed of sun gear (3) P1 for the summing planetary gear, by swivelling the swivel plate in the hydrostat
variable displacement pump back, the speed of the sun gear (1) on the power output side of summing planetary train
P2 is constantly increased.
The increase in speed of the sun gear (1) on the power output side results from the sum of the differential speed added
to the speed of internal geared wheel P1, which comes about by reducing the input speed of sun (3) P1 against that
of internal geared wheel (4) P1. Transferred to the power output side of the sun gear (1) P2 , through the short pla-
netary gear (5) onto the long planetary gear (6) to sun (1) P2.
By swivelling the hydrostat pump back to zero, the speed of the sun (3) P1 is also zero. The synchronous speed on
claw coupling K3 is achieved by adjusting the angle of the swivel plate in the hydrostat pump to maximum, in the op-
posite direction.
Coupling K3 engages, a specific hydrostat swivel transfers the load from coupling K2 to coupling K3, whereupon cou-
pling K2 is disengaged.
For tractors, this shifting point takes place at approx. 14 km/h.
Ratio 3
2
1
SS00B098
4
In the 3rd ratio, power is output via planet carrier (1) P1 of the summing planetary gear.
Again, the continual ratio change in the transmission is made by varying the output speed of the hydrostat motor (sun
gear P1) (2) by adjusting the swivel plate in the hydrostat pump.
The speed of sun gear P1 (2) is changed from the maximum counter rotation speed of internal geared wheel P1
(+2830 rpm) to the speed of internal geared wheel (3) P1 (-2830 rpm). In this way, block rotation in the summing pla-
netary train P1/P2 is achieved analogous to the shifting point from ratio 1 to ratio 2. In this operating status, synchro-
nous speed between planet carrier (1) P1 and sun gear (4) P2 is also achieved.
In this way, claw coupling K4 can be engaged and, analogous to the preceding shifts, claw coupling K3 can be dis-
engaged after successful load transfer.
For tractors, this shifting point takes place at approx. 28 km/h.
Ratio 4
SS00B099
The following power flow is given after shifting into the 4th ratio:
Power is output via sun gear (1) P2 in the 4th ratio.
To achieve the maximum output speed, the direction of rotation and the speed of sun gear (2) P1 is changed, so that
the highest possible speed is finally achieved.
Forward / reverse
SS00B100
A forward/reverse planetary train follows the continuously variable range in the transmission.
For forward motion, the power flow, between the output shaft of the continuously variable part and the transmission
output shaft, is transferred directly via claw coupling KF.
For reverse motion, the planet carrier (1) is connected to the housing by closing claw coupling KR, through which the
direction of rotation is reversed.
By shifting claw coupling KF (forwards) and claw coupling KR (reverse) in an overlapping manner, it is possible to
ensure that there are no interruptions in torque in the drive train during shifting from forward to reverse travel. In this
way, the drive train remains engaged at all times.
Claw couplings
All couplings in the continuously variable transmission are claw couplings, which are engaged and held by means of
oil pressure, via ring pistons and are disengaged by the transferred torque and disk springs. Power flow is given
across the entire range of the transmission, through the overlapping shifting from one ratio to the next, as described
previously.
The use of disk springs is required to achieve short shifting times, when changing between ratios and when changing
over from forward to reverse travel. It is possible to keep the times for shifting from one ratio to the next to under
150 milliseconds by using a suitable control system. As a result of these short shifting times, ratio changes, during
vehicle acceleration, are no longer noticed by the driver .
Claw couplings are used in the CVT / CVX transmission instead of multi-disk clutches in order to keep frictional loss,
within the transmission, as low as possible. Practically no losses, resulting from high differential speeds, occur in the
disengaged state, which would not be the case if multi-disk clutches were used.
SD03C010
Transmission hydraulics
19
3 15
2 16
14
12 10 9 5
11 7 8 6 13
17
23
SS00M051
22
21 20
1 Suction filter 11 4/3 directional control valve, parking interlock
2 Pressure filter 12 3/2 directional control valve, 4-wheel drive
3 Valve block 13 Pressure reduction valve, 20 bar
4 Pressure reservoir N 20 bar/20 °C 14 3/2 directional control valve, front PTO shaft
5 3/2 directional control valve, 15 Temperature sensor
coupling 1 16 System pressure sensor
6 3/2 directional control valve, 17 Lubricating pressure sensor
coupling 2
19 Differential pressure switch, 5 bar
7 3/2 directional control valve,
coupling 3 20 Measuring wheel – cartridge input speed sensor (B24)
8 3/2 directional control valve, 21 Measuring wheel – speed sensor P1/P2 (B35)
coupling 4 22 Measuring wheel – speed sensor P3/P4 (B25)
9 3/2 directional control valve, 23 Measuring wheel – output speed 1 / 2 (B26)
forwards coupling
10 3/2 directional control valve,
reverse coupling
The system pressure is raised by a vane-cell variable displacement pump. This hydraulic pump is located on the
transmission housing cover. It is driven by spur gearing on the drive shaft.
The 30 bar system pressure is fed to the valve plate (3) (for claw couplings, 4-wheel drive and parking interlock) and
20 bar is fed to consumers, like PTOs and the front / rear differential locks, through a pressure reduction valve. The
shifting valves (directional control valves), the claw couplings and the safety interlock (parking interlock) are located
in the valve plate, amongst others.
Drops in pressure, during coupling shifts, are kept within limits by a pressure reservoir (4).
Cooling is done by the lubricating circuit, the lubricating oil pump supplies a feed pressure of max. 5 bar.
There is transmission fluid in both circuits (system, lubrication).
Sva 6-51700 EN Edition 07-2006
Test connections
6 5 4 1 3 14 9 10 2
Sva 6-51700 EN