SAME DEUTZ-FAHR DEUTSCHLAND GmbH

WORKSHOP MANUAL

AGROTRON 106 MK3

AGROTRON 110 MK3
AGROTRON 115 MK3
AGROTRON 120 MK3
AGROTRON 135 MK3
AGROTRON 150 MK3
AGROTRON 165 MK3
 INTRODUCTION

INTRODUCTION
The purpose of this workshop manual is to provide instruction for repair technicians and
a practical guide to improving the quality of repairs.
This manual enables repair technicians to acquire a thorough knowledge of the ma-
chine, indicating the correct methods for fault diagnosis, for working in safety and for
accurate dimensional checks and visual inspections. The instructions also indicate the
products to use, the tightening torques and the adjustment data.
The technical material contained in this manual is reserved to Authorised Dealers and
Service Centres who will be duly informed of any technical changes to the machines in
question through the issue of documents regarding modifications, updates and sup-
plements for optional equipment.
All technicians and their colleagues are expressly forbidden from reproducing any part
of this manual in any form or from communicating the contents to third parties without
the express written permission of the Manufacturer, who remains the sole owner of this
document with all rights reserved in accordance with applicable laws.

00-1
 GENERAL SAFETY RULES

SAFETY NOTES
To ensure that machines entrusted to Authorised Service Centres for repair or overhaul continue to function cor-
rectly, it is very important that all repair work is carried out in the prescribed manner.
The procedures for checks and repairs indicated in this manual are safe and effective.
Some of the operations described require the use of special tools and equipment: these tools have been designed for
a specific purpose and may ordered directly from the Manufacturers.
DO NOT USE MAKESHIFT TOOLS; not only is there is risk of personal injury, but such tools are rarely suited to the
purpose for which they are used.

To prevent injury to operators, the symbols and are used in this manual to indicate the safety precautions re-
quired. The warnings accompanying these symbols must always be adhered to carefully.
In potentially hazardous situations, always give priority to personal safety and take the necessary actions to eliminate
the danger.

GENERAL SAFETY RULES

1- Even if you have a thorough knowledge of the ma- 8 - Ensure that the area is well ventilated before starting
chine as regards its components, operation and the engine in order to avoid the formation of danger-
controls, always take particular care when carrying ous concentrations of toxic gases; always connect
out the following operations. Remember that the ma- suitable fume extraction equipment to the exhaust
chine you are working on is in need of repair or over- pipe.
haul and consequently may not always behave as
expected. 9 - Under no circumstances start the engine with the
safety guards removed; all repair and adjustment
2 - Before starting work, clean the machine thoroughly operations must be carried out with the engine
to remove all mud, dust and road dirt. stopped.
Also clean the cab to remove all traces of oil, snow
and ice from the access steps and grab rails. 10 - Do not top up fuel, oil or coolant levels when the en-
gine is running.
3 - When climbing up to or down from the cab, always
ensure you maintain three points of contact at a time 11 - Never smoke and ensure there are no naked flames
(foot or handholds) in order to keep your balance and nearby when topping up fuel or oil.
prevent accidental falls. Always remove the battery from the machine before
recharging.
4 - Always take special care when carrying out fault di-
agnosis operations; these operations often require 12 - Before checking or removing the battery, stop the
two persons, who must never stand in front of the engine and remove the key from the starter switch.
wheels when the engine is running. 13 - Remove the battery and recharge in a well-ventilated
5 - When carrying out checks and repairs, wear close- area where the temperature exceeds 0°C.
fitting clothing, safety goggles and protective gloves 14 - When checking or recharging the battery, do not
that are suitable for the task (cleaning, draining flu- smoke or allow naked flames in the vicinity as the hy-
ids, repairs). drogen gas given off by the battery is highly explo-
When working near moving parts, long hair should sive.
be gathered up and secured safely under a cap to
prevent the risk of entanglement and sever injury. 15 - The liquid (electrolyte) contained in the battery is very
harmful if it comes into contact with the skin and the
6 - Do not allow anyone who is not directly involved in eyes; for this reason, always wear gloves and safety
the work to come near the machine; ensure that they
goggles with side shields when checking or topping
remain at a safe distance.
up the battery.
7 - Keep well clear of moving parts; when the engine is Should any electrolyte accidentally come into con-
running, some moving parts are not easily visible and tact with your skin, wash the affected parts imme-
therefore present a risk of entanglement, even if pro- diately with copious amounts of water. If electrolyte
tected by safety guards. comes into contact with your clothing, this should be
removed as soon as possible.

00-3
 GENERAL SAFETY RULES

In case of accidental ingestion of electrolyte, drink 25 - Always use lifting equipment of suitable capacity for
copious amounts of water, milk or vegetable oil and the weight of the components to be removed. Ensure
take antacids such as magnesium, bicarbonate, lifting equipment is attached correctly.
etc.. and seek medical attention immediately.
26 - When lifting or supporting an assembly or compo-
16 - Before working on the electrical systems, always nent, manoeuvre the parts slowly and carefully to
disconnect the battery terminals. avoid oscillation or collision with other components.
IMPORTANT!
Always disconnect the negative terminal (--) first and 27 - Never work on components suspended from a hoist
then the positive terminal (+); when re-connecting or crane.
the battery on completion of the work, first connect 28 - When removing the retaining bolts of a component
the positive terminal (+) and then the negative (--). that could fall, always leave two opposing bolts in
17 - Before carrying out any arc welding, on the tractor, place for safety; before removing these last two bol-
always disconnect the battery terminals and unplug ts, attach the component to suitable lifting equip-
all the connectors of the electronic control units and ment or position support blocks.
the alternator. 29 - Any oil or fuel spilled during removal or dismantling
18 - When topping up lubricants, always wear suitable operations should be cleaned up as soon as possible
protective gloves. to prevent the risk of slipping and fire.

19 - Do not wear clothing contaminated by engine or hy- 30 - When refitting electrical cables and wires, ensure
draulic oil; prolonged contact with the skin can be that they are secured with their original retaining
harmful and may cause allergic reactions. straps or brackets to prevent the possibility of dam-
age caused by vibration.
20 - Used engine oil and hydraulic oil must be disposed
of in a proper manner; recover used lubricants and 31 - Never insert your fingers or hands to check the align-
dispose of them in accordance with the applicable ment between fixing holes in components; always
regulations. use a suitable dowel of soft material.

21 - Before carrying out any work on the hydraulic or 32 - When refitting assemblies or components, always
pneumatic systems, discharge all residual pressure use the specified tightening torques; the tightening
from the circuits. torques indicated in the paragraphs regarding as-
sembly/refitting operations have been determined
22 - Before carrying out any work on the hydraulic system through experimentation and must be scrupulously
or engine, allow the oil and engine coolant to cool adhered to.
down.
33 - When refitting parts that are subject to vibration or
23 - When removing and refitting certain assemblies, it that rotate at high speed, take particular care when
will be necessary to support the machine; use carrying final installation checks.
stands, jacks or blocks capable of supporting the
weight and arrange them in a triangular pattern to
prevent the machine from overturning.
24 - To lift heavy components, use a hoist or crane.
Check that wire ropes, chains or fibre slings are not
worn and that hooks are not damaged.

00-4
 HOW THE MANUAL IS STRUCTURED

HOW THE MANUAL IS STRUCTURED

Section 00 Contains the general safety rules, information on how to use and update
the manual, the symbols used, the products required, the standard tight-
ening torques and a conversion table for units of measurement.

Section 10 Contains technical descriptions and information regarding the mechan-

ical and hydraulic operation of machine components, the designations of
the various components, hydraulic diagrams and general technical data.

Section 20 Contains a guide to the use of the necessary software for machine and en-
gine configuration and for diagnostic.

Section 30 Contains the methods, checks and adjustments regarding the external
components; the operations dealt with in this section do not require re-
moval of the various assemblies that form the tractor frame and cab.

Section 40 Contains information and diagrams regarding the machine's electrical

and electronic systems.

ATTENTION!
This manual does not contain the engine and transmision sections.
For these sections refer to the follow manuals:

Italian
English
Engine DEUTZ 1012 - 1013 0297 9771
French
German
0298 6837 German
0298 6838 English
Transmission ZF 7100L
0298 6839 French
0298 6840 Spanish
0298 6871 German
0298 6872 English
Transmission ZF 7100S
0298 6873 French
0298 6874 Spanish
0298 6877 German
0298 6878 English
Rear axle 7100
0298 9879 French
0298 9880 Spanish
0298 6831 German
0298 6832 English
Trasmission/rear axle 7200 L-S-H
0298 6833 French
0298 6834 Spanish
0298 6803 German
0298 6856 English
Front axle ZF 2025-2035-2045 AS
0298 6857 French
0298 6858 Spanish

00-5
 HOW TO CONSULT THE MANUAL

HOW TO CONSULT THE MANUAL

1. Removal and refitting of assembled units

(1) For the removal or refitting of assembled units, the sequence of operations and the methods to be applied are de-
scribed in the removal procedure; if the refitting sequence of operations is the exact reverse of the removal pro-
cedure, it is not described.
(2) All special techniques that apply only to the refitting procedure are indicated by the symbol 1 ; this same
symbol appears at the end of each major step in the removal procedure to indicate the parts for which special
techniques are to be applied during refitting.
E.g.: REMOVAL OF UNIT : ................................................ Operation heading
: ............................................................................. Safety rules to be observed when carrying out the pro-
cedure described
1 - Remove part (1):...................................................... Step of the procedure
★: ................................................................................. Technique or important information regarding the re-
moval operation.
2 - Disconnect (2) ......... 1 : ...................................Indicates the existence of special information regar-
ding refitting of the component in question.
..........
: .............................................................. Recover oil, liquid or fuel and the quantity to be recov-
ered
E.g.: REFITTING UNIT: ...................................................... Operation heading
• Refitting is the reverse of removal

1 :.......................................................................Technique to be applied during refitting

★: ................................................................................. Technique or important information regarding the refit-
ting operation
• ..........
: ........................................................... Filling with oil or liquid with quantity
2. During removal and refitting operations, in addition to the general safety rules, you must also apply the specific
«SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS».
Always adhere to these precautions.

3. List of special tools

(1) For details regarding the type, code numbers and quantity of all the tools (T1, T2, etc.) specified in the operating
procedures, see the heading «SPECIAL TOOLS».

4. Tightening torques
1 - In the operating procedures, the symbol denotes a specific tightening torque that has been determined ex-
perimentally and that must be adhered to.
2 - If the symbol does not appear, the torque values to be used are those indicated in the table in Section 00 of this
manual.

00-6
 HOW TO UPDATE THE MANUAL

HOW TO USE AND UPDATE THE MANUAL

1. UPDATING THE MANUAL

All additions, corrections or amendments to the manual will be sent to the Authorised Service Centres.
Before starting any repair or overhaul operations, check that you have the most recent updates as these may contain
supplementary data not present in previous issues.

2. INSERTING UPDATES
1- Check the number of the page and insert it in the appropriate section of the manual following the consecutive or-
der of the page numbers. Example:
20 5

Consecutive page number

Section number

2 - Supplementary pages: indicated with a hyphen (-) and consecutive number after the page number. Example:
20-5
20-5-1
Supplementary page
20-5-2
20-6
NOTE. The contents of supplementary pages are structured so that there is no overlap with existing pages.
3 - Updated pages: indicated by a consecutive number in a circle; this symbol appears below the page number.
Example:
20-5
20-5-1 Existing page
20-5-1 Update page

20-5-2 Existing page

NOTE. All supplementary and updated pages are indicated in the manual page list; a revised page list is
sent with each update and supersedes the previous list.

3. SYMBOLS USED IN THE MANUAL

For greater clarity, important information pertaining to operator safety and to critical stages in the working proce-
dures is highlighted by the symbols shown in the following table.

Symbol Meaning Notes Symbol Meaning Notes

Safety rules to be applied during Parts must be coated with adhesive,
Coating
operation. lubricant, etc.
Safety Points at which oil, water or fuel
Operation requiring special safety
Oil, water must be added and quantity requi-
measures due to internal pressure.
red.
Operations requiring special techni-
★ Warning cal or other precautionsto ensure
compliance with standard values.
Drain
Points from which oil, water or fuel
must be drained with quantity.

Weight of main assemblies.

Tightening Parts requiring special tightening
Weight Choose lifting ropes/slings careful-
torques torque during refitting or assembly.
ly; supports required, etc.

00-7
 SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS

SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS

★ When removing or refitting parts, always take the following safety precautions.

1. Precautions for removal operations

• Unless otherwise indicated, lower the working equipment until it rests on the ground.
• After disconnecting hydraulic and fuel system pipes, always fit plugs to the open ends of the pipes to prevent in-
gress of impurities.
• Before removing a cylinder, fully retract the piston and secure it in this position using a retaining strap.
• Use containers of sufficient capacity when draining oil, coolant or fuel.
• Before removing a part from the machine, check for alignment markings indicating the correct assembly po-
sition. If necessary, make new markings to ensure correct assembly.
• When unplugging electrical connectors, always grip the connectors firmly to avoid pulling on the wires.
• Where necessary, label wires and pipes before removal to avoid confusion when reconnecting.
• Check the number and thickness of any shims removed and keep them together in a safe place.
• To lift the machine or any of its main components, use lifting equipment of suitable capacity.
• When using bolts or eye bolts to remove parts, ensure they are screwed home fully.
• Before removing a part, clean the surrounding area and, after removing the part, cover it to prevent the ingress of
dirt and dust.

2. Precautions for refitting operations

• Tighten nuts and bolts to the specified tightening torques.
• When refitting flexible pipes and wires, take care not to twist or tangle them.
• Always fit new seals, O-rings, cotter pins and safety stop rings; ensure that cotter pins are bent over so that they
cannot work loose.
• Ensure that circlips are correctly installed in their seatings.
• When applying threadlocking compound, first clean the part removing all oil and grease, then cover the thread
evenly applying a few drops of the compound.
• When applying sealant, first clean the surface removing all traces of oil and grease and check for dirt or inden-
tations, then apply the sealant evenly making sure that it forms a continuous film around any fixing holes.
• Clean all parts, removing dirt, oxidisation, carbon deposits, burrs and indentations.
• Coat all moving parts with a thin film of engine oil.
• When reconnecting electrical connectors, first remove all traces of oil, dust and water from the inside of the con-
nector and then connect the two halves together firmly.
• When using eyebolts for lifting, check that they are not deformed, screw them fully home and align the eye with
the lifting hook.
• Bolt down flanged fittings evenly, tightening the bolts gradually in a crosswise pattern.

3. Precautions to be taken on completion of removal/refitting operations

• If coolant has been drained from the engine, refit the drain plug and add new coolant to the correct level. Start the
engine to circulate the coolant and then check the level again and top up.
• After removing hydraulic components, top up the hydraulic oil to the specified level. Start the engine to circulate
the oil in the hydraulic circuits and then recheck the level and top up as necessary.
• After having removed the variable displacement pump, before connecting the discharge pipe, fill the pump cas-
ing with oil.
• Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.

00-8
 LIFTING INSTRUCTIONS

LIFTING INSTRUCTIONS

Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equip-
ment with wire rope or polyester slings.
In the paragraphs regarding removal and refitting operations, the weight of the component or assembly to be lifted is

indicated with the symbol

WIRE ROPES - SLINGS

• Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:

WIRE ROPES POLYESTER SLINGS

(standard twisted «S» or «Z» type) (eye-and-eye - simple loop)
Capacity (kg) Capacity (kg)
Ø rope Width
mm 60° 90° (mm) 60° 90°

8 650 620 500 25 500 400 860 700

10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530

NOTE. Lifting capacities are calculated with a safety coefficient.

• The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the
rope/sling, this could cause the load to slip during lifting.
• Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope
strands to untwist or the load to slip; this could lead to serious injury.
• Never lift a heavy load when the two branches of the ropes form a wide angle.
The permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the
permitted load varies according to the angle of suspension for two Ø 10 mm ropes each with a load capacity of 1000 kg.

2000
1900
1700
2000
Load capacity: kg

1400

1000
1000
500

30° 60° 90° 120° 150°

Angle of suspension: ␣

00-9
 STANDARD TIGHTENING TORQUES FOR NUTS AND BOLTS

STANDARD TIGHTENING TORQUES FOR NUTS AND

BOLTS
The tightening torques for certain specific components and special tightening methods are indicated in the
relative assembly paragraphs.
★ The tightening torques indicated below refer to bolts and nuts assembled without lubrication and, where ap-
plicable, with anaerobic threadlocking compound.
The values apply to tightening on steel or cast iron components; for soft materials such as aluminium, copper,
plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.

BOLT CLASS

BOLT SIZE 8.8 10.9 12.9

Nm lb.ft. Nm lb.ft. Nm lb.ft.
M6x1 8.0 – 8.8 5.9 – 6.5 11.8 – 13.0 8.7 – 9.6 13.8 – 15.2 10.2 – 11.2
M8x1.25 19.4 – 21.4 14.3 – 15.8 28.5 – 31.5 21.0 – 23.2 33.3 – 36.9 24.5 – 27.2
M10x1.5 38.4 – 42.4 28.3 – 31.2 56.4 – 62.4 41.6 – 46.0 67.4 – 74.4 49.7 – 54.8
M12x1.75 66.5 – 73.5 49.0 – 54.2 96.9 – 107 71.4 – 78.9 115 – 128 84.8 – 94.3
COARSE THREAD

M14x2 106 – 117 78.1 – 86.2 156 – 172 115.0 – 126.8 184 – 204 135.6 – 150.3
M16x2 164 – 182 120.9 – 134.1 241 – 267 117.6 – 196.8 282 – 312 207.8 – 229.9
M18x2.5 228 – 252 168.0 – 185.7 334 – 370 246.2 – 272.7 391 – 432 288.2 – 318.4
M20x2.5 321 – 355 236.6 – 261.6 472 – 522 347.9 – 384.7 553 – 611 407.6 – 450.3
M22x2.5 441 – 487 325.0 – 358.9 647 – 715 476.8 – 527.0 751 – 830 553.5 – 611.7
M24x3 553 – 611 407.6 – 450.3 812 – 898 598.4 – 661.8 950 – 1050 700.2 – 773.9
M27x3 816 – 902 601.4 – 664.8 1198 – 1324 882.9 – 975.8 1419 – 1569 1045.8 – 1156.4

M8x1 20.8 – 23.0 15.3 – 17.0 30.6 – 33.8 22.6 – 24.9 35.8 – 39.6 26.4 – 29.2

M10x1.25 40.6 – 44.8 29.9 – 33.0 59.7 – 65.9 44.0 – 48.6 71.2 – 78.6 52.5 – 57.9

M12x1.25 72.2 – 79.8 53.2 – 58.8 106 – 118 78.1 – 87.0 126 – 140 92.9 – 103.2

M12x1.5 69.4 – 76.7 51.1 – 56.5 102 – 112 75.2 – 82.5 121 – 134 89.2 – 98.8
FINE THREAD

M14x1.5 114 – 126 84.0 – 92.9 168 – 186 123.8 – 137.1 199 – 220 146.7 – 162.1

M16x1.5 175 – 194 129 – 143 257 – 285 189.4 – 210.0 301 – 333 221.8 – 245.4

M18x1.5 256 – 282 188.7 – 207.8 375 – 415 276.4 – 305.9 439 – 485 323.5 – 357.4

M20x1.5 355 – 393 261.6 – 289.6 523 – 578 385.5 – 426.0 611 – 676 450.3 – 498.2

M22x1.5 482 – 532 355.2 – 392.1 708 – 782 521.8 – 576.3 821 – 908 605.1 – 669.2

M24x2 602 – 666 443.7 – 490.8 884 – 978 651.5 – 720.8 1035 – 1143 762.8 – 842.4

00-10
 THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS

THREADLOCKERS, ADHESIVES, SEALANTS AND

LUBRICANTS

FUNCTION DESIGNATION DESCRIPTION

Loctite 222
Anaerobic product suitable or low-strength locking of retaining, adjustment and precision
Colour:
fasteners.
opaque fluorescent All traces of lubricant must first be removed using the specific activator.
purple

Anaerobic product that prevents loosening of all types of nut and bolt; used in place of con-
THREADLOCKER

Loctite 242
ventional mechanical locking systems.
Colour:
Used for medium-strength locking.
fluorescent blue All traces of lubricant must first be removed using the specific activator.

Loctite 243
Alternative product to 242; oil tolerant and so can used on lightly lubricated surfaces without
Colour: opaque
prior use of activator.
fluorescent blue

Loctite 270 Anaerobic product for high-strength locking of bolts and studs that do not normally require
disassembly.
Colour:
Parts must be heated to approximately 80°C for removal.
fluorescent green All traces of lubricant must first be removed using the specific activator.
DEGREASERS AND

Product used for degreasing and cleaning parts prior to application of Loctite anaerobic prod-
Loctite 703
ACTIVATORS

ucts; after drying, promotes uniform curing of threadlockers.

Product used for specifically for treatment of passive metals prior to use of slow-cure anaer-
obic threadlockers(series 5 and 6).
Loctite 747
Can also be used to increase cure speed at low temperatures or in applications where there is
large gaps between the parts.

Super-rapid anaerobic sealant for sealing between rigid metal faces; can eliminate the need
Loctite 510 for conventional gaskets as it can fill gaps up to 0.4 mm.
Colour: red Does not shrink and therefore fasteners do not need re-tightening to specified torque values
after curing.

Loctite 542 Anaerobic product used a liquid sealant for threaded fittings up to 3/4” gas; rapid curing and
Colour: brown parts may be disassembled with ordinary tools.
(for faces and flanges)

Loctite 554 Anaerobic sealant and locking compound used for sealing cooling and industrial fluid circuits.
SEALANTS

Colour: red Slow curing, also suitable for use on non-ferrous alloys.

Anaerobic sealant and locking compound used for sealing pipes and threaded fittings up to 2"
Loctite 572
in diameter.
Colour: white Very slow curing on most metal surfaces.

Loctite 576 Anaerobic product used a liquid thread sealant for large diameter threaded fittings (up to 2").
Colour: brown Very slow curing; also suitable for non-ferrous alloys and parts requiring subsequent removal.

Thixotropic anaerobic product used for sealing joints between metal faces.
Loctite 576 Ensures total contact between surfaces with maximum tolerance of 0.10 mm, filling micro-
Colour: green voids caused by flatness errors.
Very slow curing on most metal surfaces and requires prior application of an activator.

00-11
 THREADLOCKERS, ADHESIVES, SEALANTS AND LUBRICANTS

FUNCTION DESIGNATION DESCRIPTION

Cyanoacrylate instant adhesive suitable for bonding a wide range of acidic and porous ma-
Loctite 401 terials including, ceramics, wood, rubber and plastic (excluding polyolefin).
ADHESIVES
INSTANT

Colour: colourless Curing takes place in a few seconds as an effect of the condensed humidity present on the
surfaces to be bonded, and is independent of environmental conditions.

Loctite 495 Cyanoacrylate instant adhesive suitable for bonding a rubber, plastics and metal in any com-
Colour: colourless bination.

Silastic 738 One-part silicone adhesive/sealant, ready for use.

(Dow Corning) Cures on exposure to air to form a rubbery solid and obviates the need for conventional seals
SEALANTS
SILICONE

Colour: milky white on flexible joints, filling gaps greater than 1 mm.

One-part silicone adhesive/sealant, shrinking, ready for use.

Dirko Transparent
Cures rapidly when exposed to humidity in the air to form a rubbery solid; resistant to high
Colour: transparent temperatures.
POLYURETHANE
SEALANTS

Betaseal HV3 Polyurethane prepolymer based adhesive/sealant, high viscosity, suitable for permanent,
high-strength flexible bonding.
(Gurit Essex)
Slow curing, used for bonding glass to frames, wire mesh, metal plates, etc. surfaces must be
Colour: black degreased with primer.

Loctite 601 Anaerobic, fast-curing, high-strength adhesive.

Colour: Suitable for sealing and retaining cylindrical assemblies with gap clearances of up to 0.10 mm;
fluorescent green used for retaining rotors, gears, bearings, pulleys, bushes etc. on shafts.
RETAINING COMPOUNDS

Loctite 638
Anaerobic structural adhesive, quick-curing, very high strength; suitable for bonding cylin-
Colour:
drical parts in non-ferrous alloys.
fluorescent green

Loctite 648 Anaerobic structural adhesive, quick-curing, high-strength; suitable for bonding cylindrical
parts, permanent retention of threaded parts, sealing of refrigeration systems, retention of
Colour:
bearings, etc.
fluorescent green Alternative to Loctite 601 in high-temperature applications.

Loctite 986/AVX Anaerobic sealant/retaining compound for metal cylindrical parts.

Colour: Slow-curing, high-strength, heat-resistant and resistant to chemical pressure.
fluorescent red Parts must be first treated with an activator.

Grease
Multi-purpose Lithium grease used for lubrication of seals, to prevent oxidization and to fa-
(NLGI 2 EP
cilitate assembly operations.
ASTM D217: 265/295)
LUBRICANTS

Molikote Anti-wear compound, contains Molybdenum bisulphate, use neat or diluted with engine oil
(Dow Corning) for assembly of main engine bearings.

Vaseline Neutral pH compound used to protect battery terminals against oxidization and corrosion.

Engine oil
Used to dilute Molikote anti-wear lubricant during assembly of main engine bearings.
10W - 30

00-12
 SPECIAL TOOLS

SPECIAL TOOLS

SYMBOL CODE DESCRIPTION NOTES

T1 00239496 Tool for removal of steering unit inner gasket

T2 00239497 Tool for removal of steering unit dust seal

T3 00239498 Tool for mounting of steering unit inner gasket

T4 00239499 Tool for mounting of steering unit dust seal

T5 5.9030.743.1 Test lead for checking sensors with multimeter

T6 5.9030.743.0 Test lead for checking sensors with multimeter

T7 5.9030.740.0 SERDIA installation disc

T8 5.9030.741.0 Adapter cable

T9 5.9030.740.2 Interface level III

T10 5.9030.742.0 EDS software pack

00-13
 CONVERSION FACTORS

CONVERSION FACTORS

CONVERSION FROM BRITISH TO METRIC UNITS CONVERSION FROM METRIC TO BRITISH UNITS
mm = inch x 25.40 inch = mm x 0.0394
foot x 0.305 foot = m x 3.281
m =
yard x 0.914 yard = m x 1.094
km = Eng.miles x 1.609 Eng.miles = km x 0.622
cm² = Sq.in. x 6.452 Sq.in. = cm² x 0.155
Sq.ft. x 0.093 Sq.ft. = m² x 10.77
m² =
Sq.yard x 0.835 Sq.yard = m² x 1.197
cm³ = Cu.in. x 16.39 Cu.in. = cm³ x 0.061
Cu.ft. x 28.36 Cu.ft = m³ x 0.035
m³ =
Cu.yard x 0.763 Cu.yard = m³ x 1.311
Imp.gall. x 4.547 Imp.gall. = litres x 0.220
US gall. x 3.785 US gall. = litres x 0.264
litres=
pint x 0.568 pint = litres x 1.762
quart x 1.137 quart = litres x 0.880

/min = US.gpm x 3.785 US.gpm =
/min x 0.2642
oz. x 0.028 oz. = kg x 35.25
kg =
lb. x 0.454 lb. = kg x 2.203
kgm = lb.ft. x 0.139 lb.ft. = kgm x 7.233
kg/m = lb.in. x 17.87 lb.in. = kg/m x 0.056
kg/cm² = psi x 0.070 psi = kg/cm² x 14.22
lb./Imp.gall x 0.100 lb./Imp.gal. = kg/
x 10.00
kg/
=
lb./US.gall x 0.120 lb./US.gal. = kg/
x 8.333
kg/m³ = lb./cu.ft. x 16.21 lb./cu.ft. = kg/m³ x 0.062
Nm = lb.ft. x 1.356 lb.ft. = Nm x 0.737
bar = psi x 0.07 psi = bar x 14.503

Example:
42 mm →???? inch
42x0.0394= 1.6548 inch
42 inch →???? mm
42x25.4=1066.8 mm

00-14
 CONTENTS

SECTION 10
CONTENTS

1. TRANSMISSION................................................................. 1 3. HYDRAULIC FRONT AXLE SUSPENSION..................... 48

• INTRODUCTION.................................................................. 1 • 3.1 FRONT SUSPENSION CONTROL VALVE ................. 49
• 1.1 TRANSMISSION (Power Shift version) ........................ 2
4. FRONT AXLE.................................................................... 53
• • 1.1.1 MAIN COMPONENTS.......................................2
• • 1.1.2 TRANSMISSION HYDRAULIC SYSTEM...........5 • 4.1 HUB CARRIER AND FINAL REDUCTION UNIT......... 54
• • 1.1.3 GEARBOX .........................................................6 • 4.2 DIFFERENTIAL ........................................................... 56
• • GEARBOX COMPONENTS ........................................7
• • 1.1.4 MAIN CLUTCH..................................................8 5. HYDRAULIC SYSTEM ..................................................... 58
• • 1.1.5 HYDRAULIC GEARBOX AND SHUTTLE • HYDRAULIC SYSTEM
DISTRIBUTION VALVE......................................9
(106-115 CV models) (CCLS version)................................ 59
• • 1.1.6 CLUTCH ENGAGEMENT AND SOLENOID
VALVE OPERATION SCHEMATIC ..................13 • HYDRAULIC SYSTEM
• • 1.1.7 TRANSMISSION ELECTRONIC (120-165 CV models) (CCLS version)................................ 60
SYSTEM SCHEMATIC ....................................14 • HYDRAULIC SYSTEM
• 1.2 TRANSMISSION (Power Shuttle version) .................. 15 (106-115 CV models) (LS version) ..................................... 61
• • 1.1.1 MAIN COMPONENTS.....................................15 • HYDRAULIC SYSTEM
• • 1.1.2 TRANSMISSION HYDRAULIC SYSTEM.........18
(120-165 CV models) (LS version) ..................................... 62
• • 1.2.3 GEARBOX .......................................................19
• • GEARBOX COMPONENTS ......................................20 • 5.1 VARIABLE DISPLACEMENT PUMP ............................ 63
• • 1.2.4 MAIN CLUTCH................................................21 • • 5.1.1 BOOST PUMP ................................................ 66
• • 1.2.5 HYDRAULIC GEARBOX AND • • 5.1.2 HYDRAULIC PUMP ........................................ 67
SHUTTLE DISTRIBUTION VALVE...................22 • • 5.1.3 LOAD SENSING VALVE, PRESSURE
• • 1.2.6 CLUTCH ENGAGEMENT AND SOLENOID CUT-OFF VALVE ............................................ 69
VALVE OPERATION SCHEMATIC ..................26 • 5.2 HYDRAULIC SERVICES GEAR PUMP
• • 1.2.7 TRANSMISSION ELECTRONIC SYSTEM (106-115 CV models) ................................................. 77
SCHEMATIC ...................................................27
• 5.3 STEERING GEAR PUMP
• 1.3 REAR AXLE ................................................................ 29 (106-115 CV models) ................................................. 78
• 1.4 REAR PTO.................................................................. 31 • 5.4 GEAR PUMP FOR HYDRAULIC SERVICES
AND STEERING (120-165 CV models) ...................... 79
2. BRAKING SYSTEM.......................................................... 33
• 5.5 PRIORITY VALVE ....................................................... 81
• 2.1 BRAKE MASTER CYLINDER ..................................... 34
• 5.6 AUXILIARY SERVICES CONTROL VALVE................. 82
• 2.2 BRAKE ....................................................................... 35
• • 5.6.1 TYPES OF CONTROL VALVE WITH FIXED
• 2.3 TRAILER BRAKING SYSTEM .................................... 36 DISPLACEMENT PUMP (CCLS) .................... 85
• • 2.3.1 HYDRAULIC TRAILER BRAKING • • 5.6.2 TYPES OF CONTROL VALVE WITH
(ITALY VERSION) ............................................36 VARIABLE DISPLACEMENT PUMP (LS) ....... 87
• • 2.3.2 HYDRAULIC TRAILER BRAKING • • 5.6.3 SERVICES CONTROL SECTION .................... 88
(EXPORT VERSION)........................................38 • • 5.6.4 DESCRIPTIONS OF COMPONENTS.............. 89
• • 2.3.3 AIR TRAILER BRAKING • • 5.6.5 INLET MANIFOLD (CC version) ...................... 91
(ITALY VERSION) ............................................41 • • 5.6.6 LIFT CONTROL VALVE SECTION .................. 94
• • 2.3.4 AIR TRAILER BRAKING
(EXPORT VERSION)........................................42
• • COMPRESSOR ........................................................43
• • PRESSURE LIMITING VALVE...................................44
• • CAB SUSPENSION FEED VALVE ............................45
• • TRAILER BRAKING VALVE (2-WAY) ........................46
• • TRAILER BRAKING VALVE (1-WAY) ........................47

10-i
TRANSMISSION INTRODUCTION

1. TRANSMISSION

INTRODUCTION
• The AGROTON MARK III series is supplied to the customer with two transmission configurations:
a. POWER SHIFT transmission
b. POWER SHUTTLE transmission
The main difference between these two configurations lies in the behaviour of the electronic control unit when
reversing the direction of travel.
In the POWER SHIFT version, when the operator operates the shuttle control to change the direction of travel, the
command is actually only implemented when the speed of the tractor falls below 10 km/h and when the operator
depresses the clutch pedal.
In the POWER SHUTTLE version, the reversal of the direction of travel is managed entirely by the electronic control
unit without the operator having to depress the clutch pedal.
This type of control is achieved by way of a proportional solenoid valve that directly controls the main clutch.

• The transmission can be divided into the following three sections:

A. Gearbox
B. Rear axle
C. Rear PTO

A B

D0004360

10-1
TRANSMISSION MAIN COMPONENTS (Power Shift version)

1.1 TRANSMISSION (Power Shift version)

1.1.1 MAIN COMPONENTS

1 2

3 4 5 6

17

16

15

14 13 12 11 10 9 8 7 D0004370

1. Rear PTO control solenoid valve 6. Pilot line fitting for main clutch 11. Transmission oil temperature sensor 16. Rear PTO speed selector lever
2. Rear PTO control valve 7. Main clutch control pump (Booster) 12. Four-wheel drive control solenoid valve 17. Rear PTO speed selector lever (Optional)
3. Engine speed sensor (nLse - nMot) 8. Transmission oil low pressure sensor 13. Transmission oil suction line filter
4. Hydraulic pump for transmission 9. Gearbox output shaft speed sensor (nLsa) 14. Speed sensor for odometer (nAb)
5. Hydraulic gearbox control distribution valve 10. Creeper engagement shaft 15. Rear power take-off

10-2
TRANSMISSION MAIN COMPONENTS (Power Shift version)

18

19

23

22 21 20

18. Left brake cylinder

19. 30 km/h speed limiting pin
20. Mechanical gearbox shift lever
21. Right brake cylinder
D0004380 22. Differential lock control valve
23. Differential lock control solenoid valve

10-3
TRANSMISSION MAIN COMPONENTS (Power Shift version)

25

24
26

29 28 27 D0004390

24. Left axle casing

25. Lift shaft
26. Right axle casing
27. Rear PTO speed sensor
28. Gearbox oil level indicator
29. Rear reduction unit oil level indicator

10-4
TRANSMISSION TRANSMISSION HYDRAULIC SYSTEM (Power Shift version)

1.1.2 TRANSMISSION HYDRAULIC SYSTEM

The transmission hydraulic system is supplied by a gear pump driven from a lateral power-take-off.
The gear pump supplies pressurised fluid for the following uses:
• hydraulic gearbox control valve
• forward/reverse shuttle control valve
• main clutch pump (Booster)
• 4WD control solenoid valve
• rear PTO control solenoid valve
• differential lock control solenoid valve
• lubrication of the gearbox, rear differential and rear PTO clutch control shaft.

Lubrication circuit
pressure relief valve

Lubrication of
rear differential
PTO control
solenoid valve

Lubrication
Gearbox of rear PTO
lubrication drive shaft

Cooler
(not part of the
transmission)
Four-wheel
drive control
solenoid valve Gearbox control
distribution valve

To main clutch

Pressure Temperature
sensor sensor

Booster Gear pump

Cold starting Suction filter

safety valve

D0004411

10-5
GEARBOX DESCRIPTION (Power Shift version)

1.1.3 GEARBOX

DESCRIPTION
• The POWER SHIFT transmission receives drive from the engine (1) and transmits drive through the hydraulically-con-
trolled gearbox (2), the creeper unit (3), the main clutch (4) and the 6-speed mechanical gearbox (5) to the pinion (6)
and the power take-off (7) that provides the drive to the front axle .
The POWER SHIFT transmission is equipped with a double-output power take-off (9) to drive the hydraulic system
pumps.

9 4
2
1
3 5
NO LL 4ª 3ª 6ª 5ª 2ª 1ª

8 7 D0004400

COMPONENTS
1. Engine
2. Hydraulically-controlled 8-speed gearbox (4 forward and 4 reverse)
3. Creeper unit
4. Main clutch
5. 6-speed mechanical gearbox
6. Pinion
7. 4WD engagement clutch
8. Power take-off for front axle drive
9. Power take-off for hydraulic pumps

10-6
GEARBOX COMPONENTS (Power Shift version)

GEARBOX COMPONENTS

1 2 3 4 7 10 15

5 6 8 9 11 12 13 14
NO LL 4ª 3ª 6ª 5ª

2ª 1ª

D0004480
23 21 22 20 19 18 17 16
1. Flywheel and damper 6. Clutch “A” 11. Hydraulic pumps PTO drive gear 16. 1st and 2nd speed synchronizer 21. Clutch “G”
2. Clutch housing 7. Creeper unit 12. 3rd and 4th speed synchronizer 17. Pinion 22. Clutch “B”
3. Input shaft 8. Creeper unit synchronizer 13. 5th and 6th speed synchronizer 18. 4WD control clutch 23. Clutch “D”
4. Hydraulically-controlled gearbox 9. Main clutch 14. 1st and 2nd speed drive shaft 19. Creeper unit driven shaft
5. Clutch “C” 10. Mechanical gearbox 15. Rear PTO drive shaft 20. Clutch “F”

10-7
GEARBOX MAIN CLUTCH (Power Shift version)

1.1.4 MAIN CLUTCH

The main clutch of the POWER SHIFT transmission is an oil-bath multiplate unit with servo-assisted engagement and
hydraulic pilot system.
Clutch operation is entirely manual by way of the clutch pedal.
The system is equipped with a clutch cylinder (Booster) that directs fluid under pressure to the main clutch in accordance
with the travel of the clutch pedal.

ECU

D0004420

1. Clutch pedal
2. Clutch pilot cylinder
3. Transmission gear pump
4. Clutch control cylinder (Booster)
5. Main clutch

10-8
GEARBOX HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE (Power Shift version)

1.1.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE

The function of the hydraulic gearbox distribution valve is to pilot and control the engagement of the gears in the
hydraulically-controlled gearbox .
The distribution valve controls the operation of:
A. the hydraulic gearbox control valve (1) to select S, H, M and L ratios
B. the shuttle control valve (2) to select FORWARD and REVERSE gears.
This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox, the rear differential and
the rear PTO control shaft.

1 2

Y7
B

F
Y6

Y5

VR1 VR2

VR
Y1

G1
Y4

H1

B1 S2

W
S1
R1 U

P2

P1

H2

PILOT P4
PRESSURE
VALVE 10 bar
Y2 G2

PILOT PRESSURE
VALVE 18 bar
P4

Y3
1
D

D0004430
CONTROL AND
LUBRICATING PUMP

10-9
GEARBOX GEARBOX CONTROL VALVE (Power Shift version)

A. GEARBOX CONTROL VALVE

PRESSURE TEST POINTS

a b c d e f

g
h

n m D0004440

Pos. Function Thread size

a. A or F clutch pressure M10x1

b. B or G clutch pressure M10x1

c. Y3 or Y4 solenoid valve pressure M10x1

d. Pressure Pg to relief valve M10x1

e. Pressure Pr from relief valve (18 bar) M10x1

f. Engagement pressure of clutch C or D M10x1

g. General pressure (18 bar) M10x1

h. Engagement pressure of clutch A/B or F/G M10x1

l. Pilot pressure (10 bar) M10x1

m. D clutch pressure M10x1

n. C clutch pressure M10x1

p. Modulated pressure M10x1

10-10
GEARBOX GEARBOX CONTROL VALVE (Power Shift version)

MAIN COMPONENTS

G1 S1 H2 H1

B1 Y3

R1 Y4

P1 Y1

P2 Y5

U Y2

P4 G2 P3

D0005320

B1 Breather valve
G1 Clutch selection valve for A/B or F/G clutches
S1 Relief valve
H2 Clutch engagement valve for C/D clutches
H1 Clutch engagement valve for A/B or F/G clutches
Y3 Pilot solenoid valve for engagement valve H2
Y4 Pilot solenoid valve for engagement valve H1
Y1 Pilot solenoid valve for clutch selection valve G1
Y5 Pilot solenoid valve for road/field selection valve
Y2 Pilot solenoid valve for C or D clutch selection valve G2
P3 Pilot pressure regulating valve
G2 Clutch selection valve for C or D clutches
P4 General pressure regulating valve
U Road/field operating mode selection valve
P1 Pressure modulating valve
P2 2-stage valve
R1 Null shift valve

10-11
GEARBOX SHUTTLE CONTROL VALVE (Power Shift version)

B. SHUTTLE CONTROL VALVE

MAIN COMPONENTS

VR Y6 Y7 S2

1 1

D0005330

Y6 Pilot solenoid valve for FORWARD gear

Y7 Pilot solenoid valve for REVERSE gear
VR FORWARD/REVERSE control spool valve
S2 Relief valve
1 Neutral return device

10-12
GEARBOX CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC (Power Shift version)

1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC

Forward

C A C A C A C A

Input
shaft D B D B D B D B

C A

Output
shaft GF GF GF GF

L gear M gear H gear S gear

D B

Reverse

GF

C A C A C A C A
Neutral

D B D B D B D B

GF GF GF GF

L gear M gear H gear S gear

D0004501

Solenoid valve operation when shifting from L to S gear (L→M→H→S)

Forward Reverse
Solenoid valve
L M H S L M H S
Y6 ● ● ● ●
Y7 ● ● ● ● ● = Solenoid valve energised
Y1 ● ● ● ● ❍ = Solenoid valve briefly
Y2 ● ● ● ● energised
Y3 ❍ ❍ ❍ ❍ ❍ ❍ during gear change
Y4 ❍ ❍

Solenoid valve operation when shifting from S to L gear (S→H→M→L)

Forward Reverse
Solenoid valve
S H M L S H M L
Y6 ● ● ● ●
Y7 ● ● ● ● ● = Solenoid valve energised
Y1 ● ● ● ● ❍ = Solenoid valve briefly
Y2 ● ● ● energised
Y3 ❍ ❍ ❍ ❍ ❍ ❍ during gear change
Y4 ❍ ❍

10-13
GEARBOX TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC (Power Shift version)

1.1.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC

COMPONENTS
A1 Electronic transmission control unit
A1- E8G
A2 Shuttle control lever (FORWARD/REVERSE)
EDM1 18
ED1+ 10 67 SD2 A6
ED2-
ED3(V)
45
37
17
25, 27
AD1
AD2 A3 Gearbox control valve
ED4(R) 9 32, 49 AD3
ED6 6 2, 24 AD4
EAM3 7
30
33
AD5
AD6 A4 Shuttle control valve
EDM2 13 5 AD7 H4
EAM1 35 26 AD8
EAM2
EF1
22
42
29 AD9 A14 A5 Range selector lever (L M H S)
EF2 16, 19 51 SD1
EF3
PWM1
71, 47
39
50 SDD1
1V A7 A6 Provision for tachymeter connection
A8
A7 Display
A2
A8 Diagnostics connection
A10 Engine load sensor
A5 +
A11 -
A11 Clutch pedal position sensor
A13 Transmission oil temperature sensor
Starting
A13 S3 inhibitor
S4 switch A14 Transmission oil low pressure indicator
A10
S6
B2 Pinion speed sensor (nAb) (theoretical groundspeed)
B3 Hydraulic gearbox output speed sensor (nLsa)
B2
B3 B4 Transmission input speed sensor (nLse - nMot)
ENGINE
B4 A3 A4 F1 Fuse (1A)
F2 Fuse (8A)
H4 FORWARD/REVERSE indicator lamp
H5 Audible alarm
S3 Clutch pedal depressed sensor
S4 Mechanical gearbox neutral sensor
1 F1 2 KL.30 PERMANENT PLUS
(+)

(+)
1 F2 2 KL.15 IGNITION S6 Transmission oil low pressure sensor (18 bar)
A14 A5
H

A13 T

07 29 08 10 45 55 31 54 (+)
(+) 37 EAM3 AD9 ED6 ED1 ED2 VP2 VP1 VP1
AD1 ED3(V) (T+) (T-) 50
09 SDD1 ED1 A8
AD2 ED4(R)
11 17
A2 UREF(5V) AD1 Y1 (GV1) (-)
25/27
AD2 Y2 (GV2)
H
22 32/49
X EAM2 AD3 Y3 (HV1) A3
A11 02/24
21 VMA AD4 Y4 (HV2)
47 26
DIAG. AD8 Y5 (MVKL)
71 30
EF3 AD5
19
DIAG. 33
16 AD6 (+)
EF2
42 51
EF1 SD1 SD1
A10 VMG1 EAM1 PWM1 EDM2 EDM1 AD7 VPS VM1 VM2 SD2 (-) A7
28 35 39 13 18 05 03 52 06 34 67
H5
Y7 Y6
(MVR) (MVV)
B2 B3 B4
S4
S3 S6 A6
P H4 A4

(-)

D0004491

10-14
TRANSMISSION MAIN COMPONENTS (Power Shuttle version)

1.2 TRANSMISSION (Power Shuttle version)

1.1.1 MAIN COMPONENTS

1 2 3 4 5 6

17

16

15

14 13 12 11 10 9 8 7 D0005170

1. Rear PTO control solenoid valve 6. Hydraulic gearbox distribution valve 11. Four-wheel drive control solenoid valve 16. Rear PTO speed selector lever
2. Rear PTO control valve 7. Transmission oil low pressure sensor 12. Transmission oil suction line filter 17. Rear PTO speed selector lever (Optional)
3. Engine speed sensor (nLse - nMot) 8. Gearbox output shaft speed sensor (nLsa) 13. Speed sensor for odometer (nAb)
4. Clutch control solenoid valve 9. Creeper engagement shaft 14. Clutch speed sensor (nHk)
5. Hydraulic pump for transmission 10. Transmission oil temperature sensor 15. Rear power take-off

10-15
TRANSMISSION MAIN COMPONENTS (Power Shuttle version)

18

19

23

22 21 20

18. Left brake cylinder

19. 30 km/h speed limiting pin
20. Mechanical gearbox shift lever
21. Right brake cylinder
22. Differential lock control valve
23. Differential lock control solenoid valve

D0005230

10-16
TRANSMISSION MAIN COMPONENTS (Power Shuttle version)

25

24
26

29 28 27 D0004390

24. Left axle casing

25. Lift shaft
26. Right axle casing
27. Rear PTO speed sensor
28. Gearbox oil level indicator
29. Rear reduction unit oil level indicator

10-17
TRANSMISSION TRANSMISSION HYDRAULIC SYSTEM (Power Shuttle version)

1.1.2 TRANSMISSION HYDRAULIC SYSTEM

The transmission hydraulic system is supplied by a gear pump driven from a lateral power take-off.
The gear pump supplies pressurised fluid for the following uses:
• hydraulic gearbox control valve
• forward/reverse shuttle control valve
• proportional solenoid control valve for main clutch
• 4WD control solenoid valve
• rear PTO control solenoid valve
• differential lock control solenoid valve
• lubrication of the gearbox, rear differential and rear PTO clutch control shaft.

Lubrication circuit
pressure relief valve

Lubrication of
rear differential
PTO control
solenoid valve

Lubrication
Gearbox of rear PTO
lubrication drive shaft

Gearbox control
distribution valve
Cooler
(not part of the
Main clutch transmission)
Four-wheel
drive control
solenoid valve

Proportional
solenoid valve

Pressure Temperature
sensor sensor

Gear pump

Cold starting Suction filter

safety valve

D0005181

10-18
GEARBOX DESCRIPTION (Power Shuttle version)

1.2.3 GEARBOX

DESCRIPTION
• The POWER SHUTTLE transmission receives drive from the engine (1) and transmits drive through the hydraulically-
controlled gearbox (2), the creeper unit (3), the main clutch (4) and the 6-speed mechanical gearbox (5) to the pinion
(6) and the power take-off (7) that provides the drive to the front axle .
The POWER SHUTTLE transmission is also equipped with a double-output power take-off (9) to drive the hydraulic
system pumps.

9 4
2
1
3 5
NO LL 4ª 3ª 6ª 5ª 2ª 1ª

8 7 D0004400

COMPONENTS
1. Engine
2. Hydraulically-controlled 8-speed gearbox (4 forward and 4 reverse)
3. Creeper unit
4. Main clutch
5. 6-speed mechanical gearbox
6. Pinion
7. 4WD engagement clutch
8. Power take-off for front axle drive
9. Power take-off for hydraulic pumps

10-19
GEARBOX COMPONENTS (Power Shuttle version)

GEARBOX COMPONENTS

1 2 3 4 7 10 15

5 6 8 9 11 12 13 14
NO LL 4ª 3ª 6ª 5ª

2ª 1ª

D0005190
23 21 22 20 19 18 17 16
1. Flywheel and damper 6. Clutch “A” 11. Hydraulic pumps PTO drive gear 16. 1st and 2nd speed synchronizer 21. Clutch “G”
2. Clutch housing 7. Creeper unit 12. 3rd and 4th speed synchronizer 17. Pinion 22. Clutch “B”
3. Input shaft 8. Creeper unit synchronizer 13. 5th and 6th speed synchronizer 18. 4WD control clutch 23. Clutch “D”
4. Hydraulically-controlled gearbox 9. Main clutch 14. 1st and 2nd speed drive shaft 19. Creeper unit driven shaft
5. Clutch “C” 10. Mechanical gearbox 15. Rear PTO drive shaft 20. Clutch “F”

10-20
GEARBOX MAIN CLUTCH (Power Shuttle version)

1.2.4 MAIN CLUTCH

The main clutch of the POWER SHUTTLE transmission is an oil-bath multiplate unit with hydraulic control.
Clutch operation is entirely automatic and is controlled by an electronic control unit which receives signals from the clutch
pedal position sensor.
The system has a clutch control solenoid valve that directs pressurised fluid to the clutch in accordance with the pedal
position.

4
2
3
1

ECU

D0005200

1. Clutch pedal
2. Clutch pedal position sensor
3. Electronic transmission control unit
4. Transmission gear pump
5. Clutch control proportional solenoid valve
6. Main clutch

10-21
GEARBOX HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE (Power Shuttle version)

1.2.5 HYDRAULIC GEARBOX AND SHUTTLE DISTRIBUTION VALVE

The function of the hydraulic gearbox distribution valve is to pilot and control the engagement of the gears in the
hydraulically-controlled gearbox .
The distribution valve controls the operation of:
A. the hydraulic gearbox control valve (1) to select S, H, M and L ratios
B. the shuttle control valve (2) to select FORWARD and REVERSE gears.
This distribution valve also supplies hydraulic fluid for the lubrication of the mechanical gearbox, the rear differential and
the rear PTO control shaft.

1
A

Y7
B

F
Y6

Y5

VR1 VR2

VR
Y1

G1
Y4

H1

B1 S2

W
S1
R1 U

P2

P1

H2

PILOT P4
PRESSURE
VALVE 10 bar
Y2 G2

PILOT PRESSURE P4
VALVE 18 bar

1
Y3
D

Y8

CONTROL AND
LUBRICATING PUMP D0005210

10-22
GEARBOX GEARBOX CONTROL VALVE (Power Shuttle version)

A. GEARBOX CONTROL VALVE

PRESSURE TEST POINTS

a b c d e f

g
h

n m D0004440

Pos. Function Thread size

a. A or F clutch pressure M10x1

b. B or G clutch pressure M10x1

c. Y3 or Y4 solenoid valve pressure M10x1

d. Pressure Pg to relief valve M10x1

e. Pressure Pr from relief valve (18 bar) M10x1

f. Engagement pressure of clutch C or D M10x1

g. General pressure (18 bar) M10x1

h. Engagement pressure of clutch A/B or F/G M10x1

l. Pilot pressure (10 bar) M10x1

m. D clutch pressure M10x1

n. C clutch pressure M10x1

p. Modulated pressure M10x1

10-23
GEARBOX GEARBOX CONTROL VALVE (Power Shuttle version)

MAIN COMPONENTS

G1 S1 H2 H1

B1 Y3

R1 Y4

P1 Y1

P2 Y5

U Y2

P4 G2 P3

D0005320

B1 Breather valve
G1 Clutch selection valve for A/B or F/G clutches
S1 Relief valve
H2 Clutch engagement valve for C/D clutches
H1 Clutch engagement valve for A/B or F/G clutches
Y3 Pilot solenoid valve for engagement valve H2
Y4 Pilot solenoid valve for engagement valve H1
Y1 Pilot solenoid valve for clutch selection valve G1
Y5 Pilot solenoid valve for road/field selection valve
Y2 Pilot solenoid valve for C or D clutch selection valve G2
P3 Pilot pressure regulating valve
G2 Clutch selection valve forC or D clutches
P4 General pressure regulating valve
U Road/field operating mode selection valve
P1 Pressure modulating valve
P2 2-stage valve
R1 Null shift valve

10-24
GEARBOX SHUTTLE CONTROL VALVE (Power Shuttle version)

B. SHUTTLE CONTROL VALVE

MAIN COMPONENTS

VR Y6 Y7 S2

1 1

D0005330

Y6 Pilot solenoid valve for FORWARD gear

Y7 Pilot solenoid valve for REVERSE gear
VR FORWARD/REVERSE control spool valve
S2 Relief valve
1 Neutral return device

10-25
GEARBOX CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC (Power Shuttle)

1.2.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC

Forward

C A C A C A C A

Input
shaft D B D B D B D B

C A

Output
shaft GF GF GF GF

L gear M gear H gear S gear

D B

Reverse

GF

C A C A C A C A
Neutral

D B D B D B D B

GF GF GF GF

L gear M gear H gear S gear

D0004501

Solenoid valve operation when shifting from L to S gear (L→M→H→S)

Forward Reverse
Solenoid valve
L M H S L M H S
Y6 ● ● ● ●
Y7 ● ● ● ● ● = Solenoid valve energised
Y1 ● ● ● ● ❍ = Solenoid valve briefly
Y2 ● ● ● ● energised
Y3 ❍ ❍ ❍ ❍ ❍ ❍ during gear change
Y4 ❍ ❍

Solenoid valve operation when shifting from S to L gear (S→H→M→L)

Forward Reverse
Solenoid valve
S H M L S H M L
Y6 ● ● ● ●
Y7 ● ● ● ● ● = Solenoid valve energised
Y1 ● ● ● ● ❍ = Solenoid valve briefly
Y2 ● ● ● energised
Y3 ❍ ❍ ❍ ❍ ❍ ❍ during gear change
Y4 ❍ ❍

10-26
GEARBOX TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC (Power Shuttle version)

1.2.7 TRANSMISSION ELECTRONIC SYSTEM SCHEMATIC

COMPONENTS
A1 Electronic transmission control unit(EST45)
EST-45
SD 2 59 36 SD 4 A9
A2.1 Range selector lever (L M H S)
ED 11 29
ED 8 44 57 ADM 5
EU 1
ED 6
38
67
11
34
ADM 6
ADM 7
A2.2 Shuttle control lever (FORWARD/REVERSE)
ED 7 22 33 ADM 8
ED 1 63 50 AIP 7
ED 2
ED 3
65
20 A1
32
55
AIP 3
AIP 4
A3 Gearbox control valve
ED 12 30
EDM 1
ER 1
31
39
56 AIP 1 H3 A5 Diagnostics
EF 7 17 5 ADM 4 A12
EF 6 40
EF 5 16 A6 Display
EF 4 62 14 SD 1 A6
15 SDDK
H5
A9 Tachymeter

S7 A5 A10 Engine load sensor

A11 Proportional solenoid valve for main clutch control
B10 +
-
A2.1 A12 INFOCENTER
A2.2

B1 Engine speed sensor (nLse - nMot)

B11 B13
B3 Hydraulic gearbox output speed sensor (nAb)
A11 S4

A10 S6 PEDAL
CLUTCH
K1 B4 Transmission input speed sensor (nLsa)
B9 Clutch speed sensor (nHk)

B3 B9 6-SPEED
TRANSMISSION B4
B10 Clutch pedal position sensor
ENGINE CLUTCH
B11 Temperature sensor
A3 A4
B1 B13 Clutch proximity sensor
F1 Fuse (8A)
F2 Fuse (8A)
H3 Low oil pressure indicator lamp
H5 Audible alarm
1 F1 2 KL.30
(+)

(+)
1 F2 2 KL.15
K1 Interlock starter relay 70A
1
S7
1
P
1
S6
S4 Mechanical gearbox neutral sensor
B13 H3
B9 3 B4 3 B3 3 B1 3 2 2 2
A5 1
2 2 2 2 44 45 23 68 5 21 30 29 S6 Transmission oil low pressure sensor (18 bar)
ED8 VP1 VPE1 VPE2 ADM4 ED10 ED12 ED11
4 15 2
1 1 1 1 VMG2 SDDK
17
3
EF7
36 A6 X2:D H5 S7 Interlock button
40
VMG1 SD4 A9
EF6
62 3 X2:A
EF4 14 X1:B
16 SD1
EF5 57 B
38 ADM5 Y1(GV1)
EU1 11 C
37 ADM6 Y2(GV2)
2 AU 34 D
ADM7 Y3(HV1) X2:C
A1 33 E A3
B10 H
3
ADM8
50 A
Y4(HV2) A12
T AIP7
24 Y5(MVR)
1 VMGA1 8 F
VPS2 (+) OPTION
H
T
B11 32 1
39 AIP3 Y6(MVV)
ER1 55 2
VP 67
ED6
AIP4 Y7(MVR) A4
A2.1 TIPP + 22 VPS1
12 3
(+)
TIPP - ED7
56 1
63 AIP1 FK
V - AUTOM. ED1 13 2 A11
65 VPS1 (+)
VP N - AUTOM. ED2
20
R - AUTOM. ED3
EDM1 VM1 VM2 SD2
A2.2
KL.30 31 01 02 59
87 85
1
K1 S4 OPTION
30 86 A10
2

KL.50a KL.50
Mot. avv. Blocco. avv.

D0005221

10-27
PAGE INTENTIONALLY
LEFT BLANK
REAR AXLE DESCRIPTION

1.3 REAR AXLE

DESCRIPTION
The rear axle receives drive from the pinion (4) and transmits drive through the differential (5) and epicyclic reduction units
(2) to the rear wheels (1).
The rear axle is equipped with an electro-hydraulically controlled differential lock (6) and two hydraulically operated brakes
(3).

4
2 2
3 3
1 1

6 5

D0004450

COMPONENTS
1. Wheels
2. Epicyclic reduction unit
3. Brake
4. Pinion
5. Differential
6. Differential lock

10-29
REAR AXLE COMPONENTS

COMPONENTS

1 2 3 4 5 6 7 8

D0004470

12 11 10 9

1. Differential lock 7. Hub

2. Central axle housing 8. Axle casing
3. Differential 9. Planet carrier
4. Brake control device 10. Ring gear
5. Brake 11. Planet pinion
6. Half-shaft 12. Crown wheel

10-30
REAR AXLE DESCRIPTION

1.4 REAR PTO

DESCRIPTION
The rear PTO provides drive for external implements at a preselected rotation speed.
The rotary drive is taken directly from the engine and then reduced through a 2 -or 4-speed gearbox with manual speed
selection.
The PTO is engaged by way of an electro-hydraulically controlled clutch .

a b

3 3
1 1

4 4

6 5 6 5

562 1046 c d
D0004460

1. Clutch Speed of PTO output shaft - 4-speed version

2. Synchronizer 1 Synchronizer 2
3. Intermediate shaft Synchronizer 1
c d
4. Intermediate shaft
5. PTO shaft a 562 1046
6. Synchronizer 2 b 772 1437

10-31
REAR PTO COMPONENTS

COMPONENTS

2 SPEED VERSION 4 SPEED VERSION

a b
1 2 1 2

3 3

4 4
8

5 5

6 6

7 7

D0005340
c d c d

1. PTO engagement clutch 5. Synchronizer (speeds a/b)

2. PTO input shaft 6. PTO end shaft
3. Intermediate shaft 7 PTO output shaft
4. Intermediate shaft 8. Synchronizer (speeds c/d)

10-32